Molex 63825-5000 Manuale utente

2.50mm Pitch Floating Wire-to-Board Plug Crimp Terminal

Doc No: AT -638255000 Release Date: 04-11-13 UNCONTROLLED COPY Page 1 of 7

Revision: A Revision Date: 04-11-13

▲INSULATION CRIMP HEIGHT

BRUSH

STRIP LENGTH

BELL MOUTH

CONDUCTOR CRIMP HEIGHT

BEND DOWN

BEND UP

ROLLING

TWISTING

SEAM

CUT

OFF TAB

HAND CRIMP

TOOL

Application Toolin

Specification Sheet Order No. 63825-5000

FEATURES

 A full cycle ratcheting hand tool ensures complete crimps

 Ergonomic soft grip handles for comfortable crimping

 A precision user-friendly terminal locator wire stop holds terminals in the proper crimping position

 Right and Left handed applications

 This tool is IPC/WHMA A-620 Class 2 compliant as indicated.

 This tool is RoH compliant, however RoH compliant is not required

SCOPE

Products: 2.50mm Pitch Floating Wire-to-Board Plug Crimp Terminal, 22-24 AWG.

Terminal Series No.

Terminal Order No.

Wire Size



Insulation Diameter

trip Len th

Loose Piece



Reel

AWG

mm²

In.

503371 ---- 503371-0000

22-24

.178-0.34

1.15-1.70 .045-.067 2.40-2.80

.094-.110



Customer to cut off terminal from reel: 0.

mm (.00

”) maximum Cut

off Tab.

See Conditions on pa e 2.

DEFINITION OF TERMS

TYPE 4D

2.50mm Pitch Floating Wire-to-Board Plug Crimp Terminal

Doc No: AT -638255000 Release Date: 04-11-13 UNCONTROLLED COPY Page 2 of 7

Revision: A Revision Date: 04-11-13

▲Insulation Crimp Note:

Due to the terminal’s insulation grip design and/or

insulation diameter range, this tool uses “overlap” form

geometry in the insulation punch. This produces an

overlap insulation crimp (A620 – compliant). While the

insulation punch profile may appear “lopsided”, this is

a normal condition for this tool. ee figure to the right.

( ome tools with multiple crimp pockets may not have

the “overlap” profile on all pockets).

CONDITIONS:

After crimping, the conductor profiles should measure the following.

Terminal Series No Wire Size

Conductor Crimp





Profile

Hei ht

Width (Ref.)

503371

AWG

In.

0.3

0.34

880

.930

.035

.037

1.32

.051

.052

0.178

0.2

.820

.870

.032

.034

1.32

.051

.052



To Achieve IPC

620 Class 2 Crimps, the following over

all wire insulation diameter ranges are recommended:

Profile 22: 1.40 – 1.65mm (.055-.065 inch)

Profile 24: 1.30 – 1.60mm (.051-.063 inch)

Terminal Series No

Wire Size

Insulatio

n Crimp

Pull Force Minimum

Hei ht (Ref.)

Width (Ref.)

503371

AWG

In.

Lb.

0.31

0.34

2.20

.087

1.70

1.90

.067

.075

34.3

7.71

0.178

0.22

2.07

.081

1.70

1.90

.067

.075

24.5

5.51

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.

Note:

A crimp height chart is provided with this manual as Reference Only. Due to the wide range of wires, strands,

insulation diameters, and durometers available,

actual crimp height measurements may very

slightly. An occasional, destructive, pull force test

should be performed to check hand tool crimp.

Pull Force value Must exceed the Minimum pull

force specifications listed.

OPERATION

CAUTION: Install only Molex terminals

listed above with this tool. Do not crimp

hardened objects as damage can occur to

the tool or die.

SQUEEZE

HANDLES

TOGETHER

HANDLE WILL

SPRING OPEN

Fi ure 1

LOCATOR

IN DOWN

POSTION

PUSH ON THE

LOCATOR BUTTON

Fi ure 2

OVERLAP

INSULATION

CRIMP

OVERLAP FORM GEOMETRY

ANVIL

PUNCH

WIRE

2.50mm Pitch Floating Wire-to-Board Plug Crimp Terminal

Doc No: AT -638255000 Release Date: 04-11-13 UNCONTROLLED COPY Page 3 of 7

Revision: A Revision Date: 04-11-13

RELEASE

LOCATOR BUTTON

TERMINAL Fi ure 3

LOCATOR

PUSHED THRU

TOOLING

TERMINAL

LOCATOR

BUTTON

PUSHED IN

LOCATOR

TERMINAL

WIRE AGAINST

THE WIRE STOP

WIRE

WIRE STOP IS PART

OF THE LOCATOR

Fi ure 5

PRE

STRIPPED

WIRE

TERMINAL

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. ee Figure 1.

Crimpin Terminals

1. elect the desired terminal listed in the preceding charts.

2. Make sure the center of the locator is in the down position. With the locator attached, push the locator button

on the back of the hand tool to bring the locator forward through the tooling. ee Figure 2.

3. While holding the locator button in, load the terminal into the proper nest opening in the locator based on the

wire gauge or terminal type markings on the hand tooling. ee Figure 3.

4. Release the locator button, allowing the locator to return to the crimping

position.

5. Close the tool handle until the first ratchet position engages. ee Figure

6. Insert the properly stripped wire through the terminal and against the wire

stop. ee Figure 5.

7. Crimp the terminal by squeezing the tool handles until the ratchet

mechanism cycle has been completed. Release the handles to open the

jaws.

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

PARTIALLY

CLOSE HANDLE

TOOLING

PARTIALLY

CLOSED

Fi ure 4

FIRST RATCHET

POSITION

OPEN

POSITION

2.50mm Pitch Floating Wire-to-Board Plug Crimp Terminal

Doc No: AT -638255000 Release Date: 04-11-13 UNCONTROLLED COPY Page 4 of 7

Revision: A Revision Date: 04-11-13

Fi ure 8

PUSH ON

HANDLE

JAWS OPEN

PULL OPEN

TOOLING

M3 BHCS

8. Remove the crimped terminal from the terminal

locator by pulling on the wire.

9. Visually inspect the crimped terminal for proper

crimp location.

10. On some large O.D. wires, it may not be possible

to insert the wire with the tool partially closed.

Those wires should be inserted with the hand tool

in the open position. Insert the wire above the

terminal in the punch and against the wire stop

then close the tool. ee Figure 6.

Locator Replacement

ee the parts list on the last page of this document for the proper locator order number. Follow the steps below to

replace the locator.

1. Open the crimp hand tool.

2. queeze gently on the lower area shown in

Figure 7A with your thumb and index finger.

The lower tabs of the locator should

disengage from the hand tool.

3. Lift and pull away from the hand tool. The

top locator hooks should slip out of the top

slots easily. ee Figure 7A.

4. To reinstall the new locator, make sure the

hand tool is in the open position.

5. Press the red insert down as far as it will go

as shown in Figure 7B.

6. Holding onto the lower part of the locator

with your thumb and index finger, insert the

locators top hooks (2) into the hand tool top

slots.

7. Rotate the locator down and press the lower

tabs into the two bottom slots of the hand

tool. To secure the locator into place, the lower

tabs must snap into place on the hand tool frame.

Ri ht or Left Hand Operation

This hand tool has an added feature that can be

converted from a right handed application to a left

handed application. It is necessary to reverse the

tooling if using the left handed application along with the

locator. Follow the steps below:

1. The locator must be removed before reversing the

tooling.

TERMINAL

Fi ure 6

WIRE

WIRE STOP

MAKE SURE

CENTER OF LOCATOR

IS IN THE

DOWN POSITION

Fi ure 7B

SQUEEZE

HERE

SQUEEZE

HERE

LOCATOR

Fi ure 7A

TOP HOOKS

TOP SLOTS OF

HANDTOOL

LOWER TABS

2.50mm Pitch Floating Wire-to-Board Plug Crimp Terminal

Doc No: AT -638255000 Release Date: 04-11-13 UNCONTROLLED COPY Page 5 of 7

Revision: A Revision Date: 04-11-13

MATCH

UP MARKS

FRONT

BACK

Fi ure 9

2. Remove the M3 BHC which is holding the upper

tooling.

3. Flip the upper tooling to the opposite side and replace

the M3 BHC . Make sure the small markings on the

front and back of the hand tool frame, match up and

are on the outside of the hand tool frame. ee Figure

8 and 9.

4. Do the same thing with the lower tooling and tighten

the M3 screws. Be sure the small markings line up.

5. Reinstall the locator by following the Instructions in

the locator replacement section.

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

hould 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

pressing up on the ratchet release lever in the movable handle. ee Figure

11.

How to Adjust Tool Preload (See Fi ure 12)

This hand tool is factory preset to 25-45 LB . preload. It may be necessary over the life of the tool to adjust tool

handle preload force. Listed below are the steps required to adjust the crimping force of the hand tool to obtain

proper crimp conditions:

1. Hold the hand tool in the palm of your hand as shown in Figure 10. Using the index finger squeeze the link

towards the top of the hand tool frame. This will release the preload adjustment wheel.

LUBRIC

ATION POINTS

(BOTH SIDES) LIGHT OIL

(EVERY 3 MONTHS OR

5,000 CRIMPS)

Fi ure 10

RATCHET RELEASE

LEVER

Fi ure 11

2.50mm Pitch Floating Wire-to-Board Plug Crimp Terminal

Doc No: AT -638255000 Release Date: 04-11-13 UNCONTROLLED COPY Page 6 of 7

Revision: A Revision Date: 04-11-13

Fi ure 12

SQUEEZE

THE LINK IN

THE HANDLE

HOLD THE HAND

TOOL IN POSITION

SETTING

WHEEL

RATCHET

RELEASE LEVER

2. Rotate the setting wheel counter-

clockwise (CCW) to increase handle

force. The numbers will display

higher. To decrease handle force

rotate the setting wheel clockwise

(CW).

3. Release the link to lock the setting

wheel in place.

4. Check the crimp specifications or

conduct a pull test after tool handle

preload force is adjusted.

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

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.

Certification

Molex does not certify or re-certify hand tools but rather supplies the following guidelines for customers to re-certify

hand tools.

% This tool is qualified to pull force only. To re-certify, crimp a terminal to a wire, which has been stripped

12.7mm (1/2”) long, so there is no crimping of the insulation. Pull the terminal and wire at a rate no faster than

25mm (1.00”) per minute. ee the Molex web site for the Quality Crimp Handbook for more information on pull

testing.

% If the tool does not meet minimum pull force values, handle preload should be increased and the pull test

rerun, ( ee How to Adjust Preload).

% When the hand tool is no longer capable of achieving minimum pull force, it should be taken out of service and

replaced.

2.50mm Pitch Floating Wire-to-Board Plug Crimp Terminal

Doc No: AT -638255000 Release Date: 04-11-13 UNCONTROLLED COPY Page 7 of 7

Revision: A Revision Date: 04-11-13

RATCHET

RELEASE LEVER

Fi ure 13

PARTS LIST

tem Number

Order Number

Description

Quantity

REF

63825

Hand Crimp Tool

Figure 13

63825

Locator Assembly

63810

0104

pring, Return

63810

0105

pring, Ratchet

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

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