Molex 63825-0500 Manuale utente

Hand Crimp Tool for Commoning Crimp Terminals

Doc No: ATS-638250500 Release Da e: 02-14-11 UNCONTROLLED COPY Page 1 of 7

Revision: A Revision Da e: 02-14-11

BRUSH

STRIP

LENGTH

BELL MOUTH

CONDUCTOR

CRIMP HEIGHT

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP

TWISTING

CUT-OFF TAB

SEAM

INSULATION

CRIMP

TYPE 4D

HAND CRIMP

TOOL

Application Toolin

Specification Sheet Order No. 63825-0500

FEATURES

 A full cycle ra che ing hand ool ensures comple e crimps

 Ergonomic sof grip handles for comfor able crimping

 A precision user-friendly erminal loca or wire s op holds erminals in he proper crimping posi ion

 Righ and Lef handed applica ions

 This ool is WHMA-IPCA620 Class 2 complian as indica ed

 This ool is RoHS complian , however RoHS complian is no required

SCOPE

Produc s: Commoning Terminals, 28-30 AWG.

Terminal

Series No.

Terminal Order No.  Wire Size

Insulation Diameter Strip Len th

Loose Piece

Reel

AWG

mm²

In.

1457

.055

0.90

5.54

218

Cus omer o cu off erminal from reel: 0.18mm (.007”) maximum Cu

off Tab.

To Achieve IPC-A-620 Class 2 Crimps, the followin wire insulation diameter limits are recommended:

1. 28 AWG 0.89mm (.035 inch) UL1061.

2. 30 AWG 0.81mm (.032 inch) UL1061.

 For Crimping 24-26 AWG Wire- Use 63823-1200 Hand Crimp Tool.

DEFINITION OF TERMS

Hand Crimp Tool for Commoning Crimp Terminals

Doc No: ATS-638250500 Release Da e: 02-14-11 UNCONTROLLED COPY Page 2 of 7

Revision: A Revision Da e: 02-14-11

LOCATOR IN

DOWN POSTION

PUSH

ON THE

LOCATOR BUTTON

Fi ure 2

▲Insulation Crimp Note:

Due o he erminal’s insula ion grip design

and/or insula ion diame er range, his ool

uses “overlap” form geome ry in he

insula ion punch. This produces an overlap

insula ion crimp (A620 – complian ). While

he insula ion punch profile may appear

“lopsided”, his is a normal condi ion for his

ool. See figure o he righ . (Some ools

wi h mul iple crimp pocke s may no have

he “overlap” profile on all pocke s).

CONDITIONS:

Af er crimping, he conduc or profiles should measure he following.

Terminal Series No

Wire Size

Conductor Cri

Insulation Crimp

AWG

Hei ht (Ref.)

Width (Ref.)

Hei ht (Ref.)

Width (Ref.)

1457-6

0.09

0.89

0.91

.035

.036

1.65 Max

065 Max.

1.55

.061

055

0.89

.034

.035

1.65 Max

065 Max.

1.35

.053

Terminal Series No Wire Size

Pull Force

Minimum Profile

AWG

Lb.

1457-6

11.2

055

4.4

Tool Qualifica ion No es:

1. Pull Force should be measured wi h no influence from he insula ion crimp.

2. The above specifica ions are guidelines o an op imum crimp.

OPERATION

CAUTION: Ins all only Molex erminals lis ed above wi h his ool. Do no crimp

hardened objec s as damage can occur o he ool or die.

Open he ool by squeezing he handles oge her. A he

end of he closing s roke, he ra che mechanism will

release he handles and he hand ool will spring open.

See Figure 1.

Crimpin Terminals

1. Selec he desired erminal, lis ed in he preceding

char s. Ins all he proper loca or (See char above

and see Loca or Ins alla ion on page 5).

2. Make sure he cen er of he loca or is in he down

posi ion. Wi h he loca or a ached, push he loca or bu on on he back of he

hand ool o bring he loca or forward hrough he ooling. See Figure 2.

SQUEEZE

HANDLES

TOGETHER

HANDLE WILL

SPRING OPEN

Fi ure 1

OVERLAP

INSULATION

CRIMP

OVERLAP

FORM GEOMETRY

ANVIL

PUNCH

WIRE

Hand Crimp Tool for Commoning Crimp Terminals

Doc No: ATS-638250500 Release Da e: 02-14-11 UNCONTROLLED COPY Page 3 of 7

Revision: A Revision Da e: 02-14-11

TERMINAL

Fi ure 3

LOCATOR

PUSHED THRU

TOOLING

TERMINAL

RELEASE

LOCATOR

BUTTON

LOCATOR

BUTTON

PUSHED IN

PRE

STRIPPED

WIRE

TERMINAL

Fi ure 5

TERMINAL

WIRE AGAINST

THE WIRE

STOP

WIRE

WIRE STOP

IS PART OF

THE LOCATOR

3. While holding in he loca or bu on, load he erminal in o he proper nes

opening in he loca or based on he wire gauge or erminal ype

markings on he hand ooling. See Figure 3.

4. Release he loca or bu on, allowing he loca or o re urn o he crimping

posi ion.

5. Close he ool handle un il he firs ra che posi ion engages. See Figure

6. Inser he properly s ripped wire hrough he erminal and agains he

wire s op. See Figure 5.

7. Crimp he erminal by squeezing he ool handles un il he ra che

mechanism cycle has been comple ed. Release he handles o open

he jaws.

No e: The amper proof ra che ac ion will no release he ool un il i has been fully closed.

8. Remove he crimped erminal from he erminal

loca or by pulling on he wire.

9. Visually inspec he crimped erminal for proper

crimp loca ion.

10. On some large O.D. wires, i may no be possible o

inser he wire wi h he ool par ially closed. Those

wires should be inser ed wi h he hand ool in he

open posi ion. Inser he wire above he erminal in

he punch and agains he wire s op hen close he

ool. See Figure 6.

TERMINAL

Fi ure 6

WIRE

WIRE STOP

PARTIALLY

CLOSE HANDLE

TOOLING

PARTIALLY

CLOSED

Fi ure 4

FIRST RATCHET

POSITION

OPEN

POSITION

Hand Crimp Tool for Commoning Crimp Terminals

Doc No: ATS-638250500 Release Da e: 02-14-11 UNCONTROLLED COPY Page 4 of 7

Revision: A Revision Da e: 02-14-11

Fi ure 8

PUSH ON

HANDLE

JAWS OPEN

PULL OPEN

TOOLING TOOLING

M3 BHCS

SQUEEZE

HERE

LOCATOR

Fi ure 7A

SQUEE

HERE

TOP HOOKS

TOP SLOTS OF

HANDTOOL

LOWER TABS

MAKE SURE

CENTER OF LOCATOR

IS IN THE

DOWN POSITION

Fi ure 7B

Note:

A crimp heigh char is provided wi h his manual as Reference Only. Due o he wide range of wires, s rands,

insula ion diame ers, and durome ers available, ac ual crimp heigh measuremen s may very sligh ly. An

occasional, des ruc ive, pull force es should be preformed o check hand ool crimp. Pull Force value Mus exceed

he Minimum pull force specifica ions lis ed.

Locator Installation

See he par s lis on he las page of his documen for he proper loca or order number. Follow he s eps below o

replace he loca or.

1. Open he crimp hand ool.

2. Squeeze gen ly on he lower area shown in Figure 7A wi h your humb and index finger. The lower abs of he

loca or should disengage from he hand ool.

3. Lif and pull away from he hand ool. The op

loca or hooks should slip ou of he op slo s easily.

See Figure 7A.

4. To reins all he new loca or, make sure he hand

ool is in he open posi ion.

5. Press he red inser down as far as i will go as

shown in Figure 7B.

6. Holding on o he lower par of he loca or wi h your

humb and index finger, inser he loca or op hooks

(2) in o he hand ool op slo s.

7. Ro a e he loca or down and press he lower abs in o he wo bo om slo s of he hand ool. To secure he

loca or in o place, he lower abs mus snap in o place on he hand ool frame.

MATCH

UP MARKS

FRONT

BACK

Fi ure 9

Hand Crimp Tool for Commoning Crimp Terminals

Doc No: ATS-638250500 Release Da e: 02-14-11 UNCONTROLLED COPY Page 5 of 7

Revision: A Revision Da e: 02-14-11

Ri ht or Left Hand Operation

This hand ool has an added fea ure ha can be conver ed from a righ handed

applica ion o a lef handed applica ion. I is necessary o reverse he ooling

along wi h he loca or if using he lef handed applica ion. Follow he s eps

below:

1. The loca or mus be removed before reversing he ooling.

2. Remove he M3 BHCS which is holding he upper ooling.

3. Flip he upper ooling o he opposi e side and replace he M3 BHCS Make

sure he small markings on he fron and back of he hand ool frame ma ch

up and are on he ou side of he hand ool frame. See Figure 8 and 9.

4. Do he same hing wi h he lower ooling and igh en he M3 screws. Be sure

he small markings line up.

5. Reins all he loca or by following he Ins ruc ions in he loca or replacemen sec ion.

Maintenance

I is recommended ha each opera or of he ool be made aware of, and responsible for, he following main enance

s eps:

1. Remove dus , mois ure, and o her con aminan s wi h a clean brush, or sof , lin free clo h.

2. Do no use any abrasive ma erials ha could damage he ool.

3. Make cer ain all pins; pivo poin s and bearing surfaces are pro ec ed wi h a hin coa of high quali y machine

oil. Do no oil excessively. The ool was engineered for durabili y bu like any o her equipmen i needs

cleaning and lubrica ion for a maximum service life of rouble free crimping. Ligh oil (such as 30 weigh

au omo ive oil) used a he oil poin s, every 5,000 crimps or 3 mon hs, will

significan ly enhance he ool life.

4. Wipe excess oil from hand ool, par icularly from crimping area. Oil

ransferred from he crimping area on o cer ain ermina ions may affec

he elec rical charac eris ics of an applica ion.

5. When ool is no in use, keep he handles closed o preven objec s from

becoming lodged in he crimping dies, and s ore he ool in a clean, dry

area.

Miscrimps or Jams

Should his ool ever become s uck or jammed in a par ially closed posi ion, Do Not force he handles open or

closed. The ool will open easily by pressing up on he ra che release lever in he movable handle. See Figure 11

How to Adjust Tool Preload

(See Fi ure 10)

This hand ool is fac ory prese o 25-45 LBS. preload. I may be necessary over he life of he ool o adjus ool

handle preload force. Lis ed below are he s eps required o adjus he crimping force of he hand ool o ob ain

proper crimp condi ions:

RATCHET RELEASE

LEVER

Fi ure 11

LUBRICATION POINTS

(BOTH SIDES) LIGHT OIL

(EVERY 3 MONTHS OR

5,000 CRIMPS)

Fi ure 10

Hand Crimp Tool for Commoning Crimp Terminals

Doc No: ATS-638250500 Release Da e: 02-14-11 UNCONTROLLED COPY Page 6 of 7

Revision: A Revision Da e: 02-14-11

Fi ure 12

SQUEEZE

THE LINK IN

THE HANDLE

HOLD THE HAND

TOOL IN POSITION

SETTING

WHEEL

RATCHET

RELEASE LEVER

1. Hold he hand ool in he palm of your

hand as shown in Figure 12. Using

he index finger squeeze he link

owards he op of he hand ool frame.

This will release he preload

adjus men wheel.

2. Ro a e he se ing wheel coun er-

clockwise (CCW) o increase handle

force. The numbers will display

higher. To decrease handle force,

ro a e he se ing wheel clockwise

(CW).

3. Release he link o lock he se ing

wheel in place.

4. Check he crimp specifica ions or

conduc a pull es af er ool handle

preload force is adjus ed.

Warranty

This ool is for elec rical erminal crimping purposes only. This ool is made of he bes quali y ma erials. All vi al

componen s are long life es ed. All ools are warran ed o be free of manufac uring defec s for a period of 30

days. Should such a defec occur, we will repair or exchange he ool free of charge. This repair or exchange will

no be applicable o al ered, misused, or damaged ools. This ool is designed for hand use only. Any clamping,

fix uring, or use of handle ex ensions voids his warran y.

CAUTION: Molex crimp specifica ions are valid only when used wi h Molex erminals and ooling.

CAUTIONS:

1. Manually powered hand ools are in ended for low volume or field repair. This ool is NOT in ended for

produc ion use. Repe i ive use of his ool should be avoided.

2. Insula ed rubber handles are no pro ec ion agains elec rical shock.

3. Wear eye pro ec ion a all imes.

4. Use only he Molex erminals specified for crimping wi h his ool.

Certification

Molex does no cer ify or re-cer ify hand ools bu ra her supplies he following guidelines for cus omers o re-cer ify

hand ools.

% This ool is qualified o pull force only. To re-cer ify, crimp a erminal o a wire, which has been s ripped

12.7mm (1/2”) long, so here is no crimping of he insula ion. Pull he erminal and wire a a ra e no fas er han

25mm (1.00”) per minu e. See he Molex web si e for he Quali y Crimp Handbook for more informa ion on pull

es ing.

% If he ool does no mee minimum pull force values, handle preload should be increased and he pull es

rerun, (See How o Adjus Preload).

% When he hand ool is no longer capable of achieving minimum pull force, i should be aken ou of service and

replaced.

Hand Crimp Tool for Commoning Crimp Terminals

Doc No: ATS-638250500 Release Da e: 02-14-11 UNCONTROLLED COPY Page 7 of 7

Revision: A Revision Da e: 02-14-11

RATCHET

RELEASE LEVER

Fi ure 13

PARTS LIST

Ite

m Number

Order Number

Description

Quantity

REF

63825

0500

Hand Crimp Tool

Figure 13

638

Loca or Assembly

63810

0104

Spring, Re urn

63810

0105

Spring, Ra che

h p://www.molex.com

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