Molex 63825-8000 Manuale utente

Hand Crimp Tool for MX120G™Crimp Terminals

Doc No. ATS-6 8258000 Release Date: 0 -22-1 UNCONTROLLED COPY Page 1 of 7

Revision: A Revision Date: 0 -22-1

INSUL CRIMP

HEIGHT

BRUSH

STRIP

LENGTH

BELL

MOUTH

COND. CRIMP

HEIGHT

BEND

DOWN

BEND UP

ROLLING

CRIMP

HEIGHT

TWISTING

CUT

OFF

TAB

SEAM

HAND CRIMP

TOOL

Application Toolin

Specification Sheet Order No. 63825-8000

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

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

SCOPE

Products: 1.2mm MX120G™ Mat Seal Receptacle Terminals, 0.75mm2, 1.00mm2 wires.

Terminal

Series No.

Terminal Order No.

Wire Size

Insulation Diameter

Strip Len th

Loose Piece





Reel

Wire Type

mm² mm In. mm In.

6799 6799-0001

FLRY

5 mm2

1.60-2.20

.06 -.087

4.50-5.50

.177-.217

FLRY

1.00

mm2



Customer to cut off terminal from reel: 0.

0mm (.0

”) maximum Cut

off Tab.

DEFINITION OF TERMS

The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the

scope.

TYPE 4D

Hand Crimp Tool for MX120G™Crimp Terminals

Doc No. ATS-6 8258000 Release Date: 0 -22-1 UNCONTROLLED COPY Page 2 of 7

Revision: A Revision Date: 0 -22-1

RELEASE

LOCATOR BUTTON

TERMINAL

Fi ure 3

LOCATO

PUSHED THRU

TOOLING

TERMINAL

LOCATOR

BUTTON

PUSHED IN

LOCATOR

CONDITIONS:

After crimping, the conductor profiles should measure the following.

Terminal

Series No

Wire Size

Conductor Crimp

nsulation Crimp

Pull Force

Minimum Profile

Hei ht

Width (Ref.)

Hei ht

Max.

Width

Max.

Wire Type

In.

Lb.

.75

1.0

6799

FLRY

0.75

1.10

1.20

.04

.047

1.60

.06

2. 5

.09

2. 0

.091

115

25.9

FLRY

1.00

1.05

1.15

.045

2.05

.081

2.55

.100

2. 0

.091

120

27.0

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.

CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects as damage can

occur to the tool or die.

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

vary 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

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. See Figure 1.

Crimpin Terminals

SQUEEZE

HANDLES

TOGETHER

HANDLE WILL

SPRING OPEN

Fi ure 1

LOCATOR

IN DOWN

POSTION

PUSH ON THE

LOCATOR BUTTON

Fi ure 2

Hand Crimp Tool for MX120G™Crimp Terminals

Doc No. ATS-6 8258000 Release Date: 0 -22-1 UNCONTROLLED COPY Page of 7

Revision: A Revision Date: 0 -22-1

PRE

STRIPPED

WIRE

TERMINAL

Fi ure 5

TERMINAL

WIRE AGAINST

THE WIRE

STOP

WIRE

WIRE STOP IS PART

OF THE LOCATOR

1. Select 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. See Figure 2.

. 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. See Figure .

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. See

Figure 4.

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

wire stop. See 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.

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. See Figure 6.

Locator Replacement

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

replace the locator.

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 MX120G™Crimp Terminals

Doc No. ATS-6 8258000 Release Date: 0 -22-1 UNCONTROLLED COPY Page 4 of 7

Revision: A Revision Date: 0 -22-1

Fi ure 8

PUSH ON

HANDLE

JAWS OPEN

PULL OPEN

TOOLING

M3 BHCS

MATCH

UP MARKS

FRONT

BACK

Fi ure 9

1. Open the crimp hand tool.

2. Squeeze 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.

. Lift and pull away from the hand tool. The

top locator hooks should slip out of the top

slots easily. See 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.

2. Remove the M BHCS which is holding the upper tooling.

. Flip the upper tooling to the opposite side and replace the M BHCS. 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. See Figure 8

and 9.

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

Hand Crimp Tool for MX120G™Crimp Terminals

Doc No. ATS-6 8258000 Release Date: 0 -22-1 UNCONTROLLED COPY Page 5 of 7

Revision: A Revision Date: 0 -22-1

Fi ure 12

SQUEEZE

THE LINK IN

THE HANDLE

HOLD THE HAND

TOOL IN POSITION

SETTING

WHEEL

RATCHET

RELEASE LEVER

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

. 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 0 weight automotive oil) used

at the oil points, every 5,000 crimps or 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

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

How to Adjust Tool Preload (See Fi ure 11)

This hand tool is factory preset to 25-45

LBS. 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 12. Using

the index finger squeeze the link

towards the top of the hand tool

frame. This will release the preload

adjustment wheel.

LUBRICATION POINTS

(BOTH SIDES) LIGHT OIL

(EVERY 3 MONTHS OR

5,000 CRIMPS)

Fi ure 10

RATCHET RELEASE

LEVER

Fi ure 11

Hand Crimp Tool for MX120G™Crimp Terminals

Doc No. ATS-6 8258000 Release Date: 0 -22-1 UNCONTROLLED COPY Page 6 of 7

Revision: A Revision Date: 0 -22-1

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).

. 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 0

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: 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.

. 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. See 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, (See 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.

Hand Crimp Tool for MX120G™Crimp Terminals

Doc No. ATS-6 8258000 Release Date: 0 -22-1 UNCONTROLLED COPY Page 7 of 7

Revision: A Revision Date: 0 -22-1

RATCHET

RELEASE LEVER

Fi ure 13

PARTS LIST

Item Number

Order Number

Description

Quantity

REF

6 8

Hand Crimp Tool

Figure

6 8

Locator Assembly

6 810

0104

Spring, R

eturn

6 810

0105

Spring, Ratchet

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

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