Molex 63825-9900 User manual

IDT Hand Tool

Doc No: ATS-638259900 Release Date: 05-24-13 UNCONTROLLED COPY Page 1 o 6

Revision: A Revision Date: 05-24-13

RAST R5

IDT

Hand Tool

Application Tooling

Specification Sheet

Order No 6

3825

FEATURES

% Terminates wire directly into the direct and indirect R5 connectors

% Accommodates 2 to 11 circuit connectors

% A ull cycle ratchet ensures complete terminations

% This tool is designed or prototype or low volume work only and is not intended or production

SCOPE

Products: 5.0mm RAST R5 IDT Female Connectors, Direct and Indirect, Series 93055, 93065, 93244, and 93395.

Product List

The ollowing is a partial list o the product order numbers that this tool is designed to run. Updates to this list are

available on www.molex.com.

Connector

Series No

Connector Order No

93055

0101

93055

0102

93055

0103

93055

0104

93055

0105

93055

0106

93055

0107

93055

0108

93055

0109

93055

0110

93055

0111

93055

0112

93055

0113

93055

0114

93055

0116

93055

0117

93055

0118

93055

0119

93055

0120

93055

0121

93055

0122

93055

0123

93055

0124

93055

0125

93055

0126

93055

0128

93055

0129

93055

0130

93055

0131

93055

0132

93055

0133

93055

0134

93055

0135

93055

0136

93055

0137

93055

0138

93055

0139

93055

0140

93055

0142

93055

0143

93055

146

93055

0144

93055

0145

93055

0147

93055

0148

93055

0149

93055

0150

93055

0151

93055

0152

93055

0153

93055

0154

93055

0155

93055

0159

93055

0160

93055

0161

93055

0162

93055

0163

93055

0164

93055

0201

93055

0202

93055

0203

93055

0204

93055

0205

93055

0206

93055

0207

93055

0208

93055

0209

93055

0210

93055

0211

93055

0212

93055

0213

93055

0214

93055

0215

93055

0216

93055

0217

93055

0218

93055

0219

93055

0220

93055

0221

93055

0222

93055

0223

93055

0224

93055

0225

93055

0226

93055

0227

93055

0228

930

0229

93055

0230

93055

0231

93055

0232

93055

0233

93055

0235

93055

0236

93055

0237

93055

0238

93055

0239

93055

0241

93055

0301

93055

0302

93055

0303

93055

0304

93055

0305

93055

0306

93055

0307

93055

0308

93055

0309

93055

0310

93055

0311

93055

0312

93055

0313

93055

0314

93055

0315

93055

0316

93055

0317

93055

0318

93055

0319

93055

0320

93055

0321

93055

0324

93055

0325

93055

0326

93055

0401

93055

0402

93055

0403

93055

0404

93055

0405

93055

0406

93055

0407

93055

0408

93055

0409

93055

0410

93055

0412

93055

0413

93055

0414

93055

0415

93055

0416

93055

0417

93055

0418

93055

0419

93055

0420

93055

0421

93055

0422

93055

0423

93055

0501

93055

0502

93055

0503

93055

0504

93055

0505

93055

0506

93055

0507

93055

0508

93055

0509

93055

0510

93055

0511

93055

0601

93055

0602

93055

0603

93055

0604

93055

0605

93055

0606

93055

0607

93055

0608

93055

0609

93055

0610

93055

0611

93055

0612

93055

0613

93055

0614

93055

0615

93055

0616

93055

0617

93055

0618

93055

0701

93055

0702

93055

0703

93055

0704

055

0705

93055

0706

93055

0707

93055

0708

93055

0709

93055

0710

93055

0711

93055

0712

93055

0713

93055

0801

93055

0802

93055

0803

93055

0804

93055

0805

93055

0806

93055

0807

93055

0808

93055

0809

93055

0901

93055

0902

93055

0903

93055

0904

93055

0905

93055

0906

93055

0907

93055

0908

93055

0909

93055

0910

93055

0911

93055

0912

93055

0913

IDT Hand Tool

Doc No: ATS-638259900 Release Date: 05-24-13 UNCONTROLLED COPY Page 2 o 6

Revision: A Revision Date: 05-24-13

93065

1001

93065

1101

93065

1102

93065

2001

93065

2002

93065

2003

93065

2004

93065

2005

93065

2006

93065

2007

93065

3001

93065

3002

93065

3003

93065

3004

9306

3005

93065

3006

93065

3007

93065

3008

93065

3009

93065

3010

93065

4001

93065

4002

93065

5001

93065

5002

93065

5003

93065

5004

93065

6001

93065

6002

93065

7001

93065

7002

93065

7003

93065

8001

93065

8002

93065

8003

93065

8004

93065

8005

93065

8006

3065

8007

93065

9001

93065

9002

93065

9003

93065

9004

93065

9005

93065

9006

93244

0101

93244

0103

93244

0104

93244

0106

93244

0107

93244

0108

93244

0109

93244

0110

93244

0111

93244

0112

93244

0113

93244

0114

93244

0115

93244

0116

93244

0117

93244

0118

93244

0119

93244

0120

93244

0121

93244

0122

93244

0123

93244

0124

93244

0125

93244

0127

93244

0128

93244

0130

93244

0131

93244

0136

93244

0137

93244

0138

93244

0139

93244

0201

93244

0202

93244

0204

93244

0205

93244

0206

93244

0207

93244

0209

93244

0210

93244

0211

93244

0212

93244

0213

93244

0214

93244

0215

93244

0216

93244

0217

93244

0219

93244

0220

93244

0221

93244

0222

93244

0223

93244

0225

93244

0226

93244

0228

93244

0301

93244

0302

93244

0303

93244

0304

93244

0305

93244

0306

93244

0307

93244

0308

93244

0309

93244

0310

93244

0311

93244

0312

93244

0315

93395

0101

93395

0102

93395

0105

93395

0126

93395

0133

93395

0134

93395

0135

93395

0136

93395

0201

93395

0202

93395

0203

93395

0218

93395

0227

93395

0228

9339

0229

93395

0230

93395

0231

93395

0232

93395

0233

93395

0301

93395

0313

Applicable Wires

Connector Series No

Conductor Size

Insulation Diameter Maximum

93055

93065

0.5mm²

2.10mm

0.75mm²

2.44mm

1.0mm²

2.55mm

93244

93395 1.5mm² 2.90mm

Tool Set-Up

The tool is adjusted or connector circuit size as ollows:

1. Slide the connector nest out o the tool rame.

2. Loosen the adjustable post by turning the knurled top

counterclockwise (CCW) one-hal turn.

3. Slide the adjustable post to the end o its slot, the arthest away rom

the stop block. See Figure 1.

4. Place the connector in the connector nest and slide it up against the

stop block as shown in Figure 2.

5. Move the adjustable post against the side o the connector and tighten it by turning the knurled top clockwise

(CW). See Figure 3. Do not use tools to tighten the adjustable post; inger-tight is su icient.

Figure 2

ADJUSTABLE POST

CONNECTOR

Figure 1

CONNECTOR

NEST

Figure

ADJUSTABLE POST

CONNECTOR

IDT Hand Tool

Doc No: ATS-638259900 Release Date: 05-24-13 UNCONTROLLED COPY Page 3 o 6

Revision: A Revision Date: 05-24-13

Figure

TOOL

FRAME

REFERENCE MARK

CONNE

CTOR

NEST

OPERATION

Open the hand tool by squeezing the handles together. At the end o the closing stroke, the ratchet mechanism

will release and the handles will spring open.

1. Slide the connector nest out o the tool rame.

2. Place the proper connector into the nest as shown in Figure 4. The mating side o the connector should be

against the top o the nest and the wire holes toward the bottom.

3. Slide the connector nest into the tool rame until the irst termination position is aligned with the re erence mark

on the rame ace. See Figure 5. The connector nest is detented and will “click” into place.

NOTE: I the connector nest is di icult to slide into the tool rame, slide it out and make sure the connector is ully

seated in the nest.

4. Insert the appropriate wire into the connector hole until it stops.

5. Make sure the inserted wire is in alignment with the re erence mark on the rame ace, then squeeze the tool

handles together until the ratchet releases.

NOTE: I the wire is not in alignment with the re erence mark, connector and/or tool damage will occur i

termination is attempted.

NOTE: The ull cycle ratchet action will not release the tool until it has been ully closed.

NOTE: I something jams, the ratchet mechanism can be released by pushing upward on the ratchet pawl

located between the tool handles. See Figure 9.

6. Release the tool handles and allow them to spring open.

7. Move the connector nest to the next termination position. The nest is detented and will “click” into place.

8. Repeat steps 4 through 7 until all terminations are complete.

9. Slide the connector nest out o the tool rame and remove the terminated connector.

Figure 4

ADJUSTABLE POST

CONNECTOR POSITION

IDT Hand Tool

Doc No: ATS-638259900 Release Date: 05-24-13 UNCONTROLLED COPY Page 4 o 6

Revision: A Revision Date: 05-24-13

Assembly Inspection

A ter termination, the contacts must be seated to the dimension shown below:

Maintenance

It is recommended that each operator o the tool be made aware o , and responsible or, the ollowing maintenance

steps:

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

2. Make certain all pins; pivot points and bearing sur aces are protected with a thin coat o high quality machine

oil. Do not oil excessively. The tool was engineered or durability, it needs cleaning and lubrication or

maximum service li e. Light oil used at the pivot points every 5,000 terminations or 3 months, will signi icantly

enhance the tool li e.

3. Wipe excess oil rom hand tool, particularly rom the terminating area.

4. When tool is not in use, keep the handles closed to prevent objects rom becoming lodged in the termination

punch 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 orce the handles open or

closed. The tool will open easily by pressing the ratchet release lever up. See Figure 9.

Tool Frame Preload

Tool rame preload is not available on this type o rame. The tool should be replaced when it ails to meet

assembly dimensions.

Warranty

This tool is or terminating individual wires into insulation displacement connectors only. All tools are warranted to

be ree o manu acturing de ects or a period o 30 days. Should such a de ect occur, we will repair or exchange

the tool, ree o charge. This repair or exchange will not be applicable to altered, misused, or damaged tools. This

tool is designed or hand use only. Any clamping, ixturing, or use o handle extensions voids this warranty.

CAUTION: Molex speci ications are valid only when used with Molex connectors and tooling.

Series:

93055, 93244, 93395

19 3 +/

0 2

19 3 +/

0 2

Series:

93065

IDT Hand Tool

Doc No: ATS-638259900 Release Date: 05-24-13 UNCONTROLLED COPY Page 5 o 6

Revision: A Revision Date: 05-24-13

CAUTIONS:

1. Manually powered hand tools are intended or low volume, prototyping, or ield repair. This tool is NOT

intended or production use. Repetitive use o this tool should be avoided.

2. Insulated handles are not protection against electrical shock.

3. Wear eye protection at all times.

4. Use only the Molex connectors and wires speci ied or this tool.

Applications for the Modular Crimp Head

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

without irst reading and understanding the instructions in the proper Manual or Speci ication Sheet. See Chart

below or the correct Manual or Speci ication Sheet.

WARNING: NEVER install tooling or service a powered tool while it is connected to any power source.

Disconnect the power source (electric or pneumatic) rom the actuator

CAUTION: Keep ingers away rom the crimping area when operating a powered tool. It can cause severe

injury.

CAUTION: Wear sa ety glasses when operating or servicing this tool.

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

Modular Crimp Head

Order No

Tool

Order no Tool Description

Adapter

Order No

Adapter

Description Figure No

63825-9970

63816

0000

Hand Crim

p 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 Power Crimp Adapter

63816

0100

Air Powe

r Tool

63816

0700

Air Power Crimp Adapter

Applications for the Modular Crimp Head

Hand Crimp Tool

Battery Powered Tool

Air Powered Tool

Figure 6

Figure 7

Figure 8

MODULAR

CRIMP

HEAD

LOCKING

PINS

HAND

CRIMP

FRAME

LONG

OR SHORT

AIR

POWER

TOOL

MODULAR

CRIMP HEAD

LOCKING

PINS

LOCKING

PINS

AIR

POWER

CRIMP

ADAPTER

MODULAR

CRIMP

HEAD

BATTERY

POWER

CRIMP

ADAPTER

LOCKING

PINS

LOCKING PINS

BATTERY

POWERED

TOOL

IDT Hand Tool

Doc No: ATS-638259900 Release Date: 05-24-13 UNCONTROLLED COPY Page 6 o 6

Revision: A Revision Date: 05-24-13

RATCHET

RELEASE LEVER

HANDLE

SPRING

Figure 9

PARTS LIST

IDT Hand Tool 63825

9900

Item

Order No

Description

Quantity

63825-9970 Modular Crimp Head 1

63816-0000 Hand Crimp Frame (Short) 1

63816-0001 Locking Pin 2

63600-0525 Handle Spring 1

Visit our Web site at http://www.molex.com

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