Molex 63825-9400 User guide

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638259400 - HAND CRIMP TOOL

Excellent Integrated System Limited

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Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638259400 - HAND CRIMP TOOL

Hand Crimp Tool For Wire to Motor Crimp Terminals

Doc No: ATS-63825 4HM Release Date: 0 -04-13 UNCONTROLLED COPY Page 1 of 6

Revision: A Revision Date: 0 -04-13

INSULATION

CRIMP

BRUSH

STRIP LENGTH

BELL MOUTH

COND.CRIMP

HEIGHT

BEND

DOWN

BEND UP

ROLLING

TWISTING CUT-OFF TAB

SEAM

Application Toolin

Specification Sheet

Modular Crimp Head

Order No. 63825-9470

Hand Crimp Tool

Order No. 63825-9400

FEATURES

% A full cycle ratcheting hand tool ensures complete crimps

% Ergonomically designed soft handles

% Precisely designed crimping profiles with simple contact positioning

% Easy handling due to outstanding force ratio

% A-620 Class 2 compliant as indicated and RoHS compliant

% Modular Crimp Head is removable and can be use in the Air Powered Tool Order No.63816-0100,

accompanied by Air Powered Crimp Adapter (Order No. 63816-0700).

% Can also be used in the Battery Powered Tool Order No.63816-0200 (110 V) or 63816-0250 (220 V),

accompanied by Battery Powered Crimp Adapter (Order No. 63816-0600).

SCOPE

Products: Wire to Motor Crimp Terminals, .30-.50mm².

Terminal Series No.

Terminal Order No.

Wire Size

Insulation Diameter

Strip Len th

Loose Piece

(1)

Reel

Wire Type

mm²

In.

505 2 505 2-8100 505 2-8000

AVSS 0.30 1.40-1.50

.055-.05

2.00-2.60

.07 -.102

AVS 0.30 1.80-1. 0

.071-.075

CAVS 0.50 1.60-1.70

.063-.067

(1)

Customer to cut off terminal from reel: 0.20mm (.008”) maximum Cut

ff Tab.

DEFINITION OF TERMS

TYPE 4A

2 / 7

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638259400 - HAND CRIMP TOOL

Hand Crimp Tool For Wire to Motor Crimp Terminals

Doc No: ATS-63825 4HM Release Date: 0 -04-13 UNCONTROLLED COPY Page 2 of 6

Revision: A Revision Date: 0 -04-13

TERMINAL

SEATED IN

LOCATOR

SWING

LOCATOR OPEN

Fi ure 1

HAND

TOOL

OPEN

WIRE

STOP

BLADE

CRIMP SPECIFICATIONS:

Terminal

Series No.

Bell mouth Conductor Brush Bend up Bend Down Twist Roll

In.

De ree

505 2

0.00

0.30

.000

.012

0.00

1.00

.000

.03

After crimping, the crimp profiles should measure the following.

Terminal

Series No

Wire Size

Conductor Crimp

Insulation Crimp

Pull Force

Minimum 



Profile

Hei ht

Width (Ref.)

Hei ht (Ref.)

Width (Ref.)

505 2

Wire Type

In.

Lb.

0.30

0.50

AVSS

0.30

0. 4

.037

.03

2.15

2.05

.081

4 .0

11.0

AVS

0.30

0. 4

.037

.03

2.15

.085

2.05

4 .0

11.0

CAVS

0.50

1.0

.03

.043

2.20

2.05

4 .0

11.0

To Achieve IPC

620 Class 2 Cri

mps, the following over

all wire insulation diameter ranges are recommended:

Profile 0.30: 1.50 – 1. 0mm (.05 -.075 inch)

Profile 0.50: 1.60 - 1.70mm (.063-.067 inch)

Tool Qualification Notes:

1. Pull Force should be measured with no influence from the insulation crimp.

2. The above specifications are guidelines to an optimum crimp.

Notes:

1. This tool should only be used for the terminals and wire gauges specified on this sheet.

2. This tool is not adjustable for crimp height. Variations in tools, terminals, wire stranding, and insulation types

may affect crimp height.

3. This tool is intended for standard conductor sizes. It may not give a good insulation crimp support for all

insulation sizes.

4. Molex does not repair hand tools (see warranty above). The replacement parts listed are the only parts

available for repair. If the handles or crimp tooling is damaged or worn, a new tool must be purchased.

5. Pull force should be used as the final criteria for an acceptable crimp. Pull force is measured with no

influence from the insulation crimp. The insulation should be stripped long (1/2 in.) so the insulation grips

on the terminal do not grip the wire insulation or the conductor. Refer to Molex Quality Crimping

Handbook 63800-002 for additional information on crimping and crimp testing.

6. Molex does not certify crimp hand tools.

OPERATION

Open the tool by squeezing the handles together, at the

end of the closing stroke, the ratchet mechanism will

release the handles, and the hand tool will spring open.

1. With the hand tool in the open position, pivot the

terminal locator open by pulling on the locator knob

and lift the wire stop blade up. See Figure 1.

2. Insert the terminal into the correct profile until the

terminal is fully seated and stops.

3. Gently pivot the locator closed.

4. Push down on the wire stop blade.

3 / 7

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638259400 - HAND CRIMP TOOL

Hand Crimp Tool For Wire to Motor Crimp Terminals

Doc No: ATS-63825 4HM Release Date: 0 -04-13 UNCONTROLLED COPY Page 3 of 6

Revision: A Revision Date: 0 -04-13

WIRE

INSULATION

PUNCH

TERMINAL

WIRE STOP BLADE

Fi ure 3

Fi ure 2

WIRE

TERMI

NAL

LOCATOR

INSULATI

PUNCH

INSULATION

ANVIL

WIRE STOP

BLADE

CONDUCTOR ANVIL

CONDUCTOR

PUNCH

5. Slide the pre-stripped wire into the terminal; make sure to aim the wire brush towards the tip point on the

wire stop blade. See Figure 2. Align the wire so that it is parallel and sitting into the terminal. Maintain a

light and constant pressure on the wire that is seated in the terminal at all times. (Do not let go of the

wire.) Be sure to hold the wire in place until the terminal is fully crimped. See Figure 3.

6. Close the tool until the ratchet releases.

7. Carefully remove the crimped terminal.

Note: To maintain good brush control and a consistent bell mouth the crimping instructions must be followed.

Note: The tamper proof ratchet action will not release the tool until it has been fully closed.

Note: To maintain good brush control and a consistent bell mouth the crimping instructions must be followed.

Terminal Locator Replacement/Chan e Over

This section describes the procedure for changing locators.

Removal

1. With the tool in the open position, pivot the terminal locator

outward.

2. Remove the M4 BHCS. See Figure 4.

Installation

1. Place the proper locator, (See Chart on page 2), on the hand tool.

Install the M4 BHCS. See Figure 4.

2. Tighten the screw enough to hold the locator. Make sure the

locator can still float freely with hand pressure.

M4 BHCS

PIVOT LOCATOR

Fi ure 4

4 / 7

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638259400 - HAND CRIMP TOOL

Hand Crimp Tool For Wire to Motor Crimp Terminals

Doc No: ATS-63825 4HM Release Date: 0 -04-13 UNCONTROLLED COPY Page 4 of 6

Revision: A Revision Date: 0 -04-13

INCORRECT

Fi ure 5

CORRECT

INCORRECT

3. Insert the proper terminal fully into the correct profile slot

until the terminal is fully seated and stops. Then gently

pivot the locator closed.

4. With hand pressure, slowly slide the locator to the correct

position. See Figure 5.

5. Gently pivot the locator open without disturbing the

location.

6. Hold the locator firmly in place and slowly tighten the M4

BHCS.

Maintenance

It is recommended that each operator of the tool be made aware of, and responsible for, the following

maintenance steps:

1. Remove dust, moisture, and other contaminants with a clean brush, or soft, lint free cloth.

2. Do not use any abrasive materials that could damage the tool.

3. Make certain all pins; pivot points and bearing surfaces are protected with a thin coat of high quality machine

oil. Do not oil excessively. The tool was engineered for durability but like any other equipment it needs

cleaning and lubrication for a maximum service life of trouble free crimping. Light oil (such as 30 weight

automotive oil) used at the oil points, every 5,000 crimps or 3 months, will significantly enhance the tool life.

4. Wipe excess oil from hand tool, particularly from crimping area. Oil transferred from the crimping area onto

certain terminations may affect the electrical characteristics of an application.

5. When tool is not in use, keep the handles closed to prevent objects from becoming lodged in the crimping dies,

and store the tool in a clean, dry area.

Miscrimps or Jams

Should this tool ever become stuck or jammed in a partially closed position, Do Not force the handles open or

closed. The tool will open easily by lifting the ratchet release lever. See Figure .

Warranty

This tool is for electrical terminal crimping purposes only. This tool is made of the best quality materials. All vital

components are long life tested. All tools are warranted to be free of manufacturing defects for a period of 30

days. Should such a defect occur, we will repair or exchange the tool free of charge. This repair or exchange will

not be applicable to altered, misused, or damaged tools. This tool is designed for hand use only. Any clamping,

fixturing, or use of handle extensions voids this warranty.

CAUTION: Repetitive use of this tool should be avoided.

CAUTIONS:

1. Manually powered hand tools are intended for low volume or field repair. This tool is NOT intended for

production use. Repetitive use of this tool should be avoided.

2. Insulated rubber handles are not protection against electrical shock.

3. Wear eye protection at all times.

4. Use only the Molex terminals specified for crimping with this tool.

5 / 7

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638259400 - HAND CRIMP TOOL

Hand Crimp Tool For Wire to Motor Crimp Terminals

Doc No: ATS-63825 4HM Release Date: 0 -04-13 UNCONTROLLED COPY Page 5 of 6

Revision: A Revision Date: 0 -04-13

MODULAR

CRIMP

HEAD

BATTERY

POWER

CRIMP

ADAPTER

LOCKING

PINS

LOCKING PINS

BATTERY

POWERED

TOOL

AIR

POWER

TOOL

MODULAR

CRIMP HEAD

LOCKING

PINS

LOCKING

PINS

AIR

POWER

CRIMP

ADAPTER

CAUTION: Molex crimp specifications are valid only when used with Molex terminals and tooling.

Applications for the Modular Crimp Head

WARNING: NEVER operate, service, install, or adjust this Modular Crimp Head without proper instruction

and without first reading and understanding the instructions in the proper Manual or Specification Sheet.

See Chart below for the correct Manual or Specification Sheet.

WARNING: NEVER install tooling or service this tool while it is into any power source. Disconnect the

power by unplugging or turn off the Actuator from its power source.

CAUTION: Keep fingers away from the crimping area when operating this tool. It may cause severe injury.

CAUTION: Wear safety glasses when operating or serving this tool.

The chart below shows all applications for this Modular Crimp Head.

Modular Crimp Head

Order No.

Tool

Order no.

Tool

Description

Adapter

Order No.

Adapter

Description

ure

No.

63825- 470

63816

0000

Hand Crimp Frame (Short)

N/A

63816

0050

Hand Crimp Frame (Long)

N/A

63816

0200

Battery Power

Tool (110 V)

63816

0600

Battery Power Crimp Adapter

63816

0250

Battery Power

Tool (220 V)

63816

0600

Battery Po

wer Crimp Adapter

63816

0100

Air

Tool

63816

0700

Air Power Crimp Adapter

Applications for the Modular Crimp Head

Hand Crimp Tool

Battery Powered Tool

Air Powered Tool

Fi ure

MODULAR

CRIMP

HEAD

LOCKING

PINS

HAND CRIMP

FRAME LONG

OR SHORT

6 / 7

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638259400 - HAND CRIMP TOOL

Hand Crimp Tool For Wire to Motor Crimp Terminals

Doc No: ATS-63825 4HM Release Date: 0 -04-13 UNCONTROLLED COPY Page 6 of 6

Revision: A Revision Date: 0 -04-13

RATCHET

RELEASE LEVER

HANDLE

SPRING

CRIMPING

SPRING (2)

LOCATOR

Fi ure 9

M4 X 8mm

LONG BHCS

PARTS LIST

Item

Order Number

Description

Quantity

63825

Modular

Crimp

Head

63816

Hand Crimp

Frame

(

Long

)

63825

Locator

63816

0001

Locking Pin

63600

0525

Handle Spring

63600

0520

Crimping Spring

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