Molex 63825-6900 Benutzerhandbuch

Hand Crimp Tool for Board-In Crimp Terminals

Doc No: ATS-6382569H Release Date: 07-25-12 UNCONTROLLED COPY Page 1 of 6

Revision: A Revision Date: 07-25-12

INSULATION

CRIMP

▲SEE NOTE

BRUSH

STRIP

LENGTH

BELL MOUTH

COND.CRIMP

HEIGHT

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP

TWISTING

CUT

OFF TAB

SEAM

Applicatio Tooli g

Specificatio Sheet

Modular Crimp Head

Order No. 63825-6970

Ha d Crimp Tool

Order No. 63825-6900

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

% odular 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 63813-0250 (220 V),

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

SCOPE

Products: 2.50mm Pitch Board-In Crimp Terminal, ale, 20-24 AWG.

Termi al

Series

Termi al Order No.

Wire Size



I sulatio Diameter

Wire Strip Le gth



Reel

Loose

AWG

mm²

I .

50097

8000

500

8100

0.50

0.20

1.40

1.90

.055

.075

2.50

3.00

.098

.118



Customer to cut off terminal from reel: 0.

mm (.0

”) maximum Cut

off Tab

 See crimp specification for the individual Insulation Diameter.

DEFINITION OF TERMS

This illustration is a generic terminal representation and not an exact image of any terminal listed in the scope.

TYPE 4A

Hand Crimp Tool for Board-In Crimp Terminals

Doc No: ATS-6382569H Release Date: 07-25-12 UNCONTROLLED COPY Page 2 of 6

Revision: A Revision Date: 07-25-12

▲I sulatio 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. See figure to

the right. (Some tools with multiple crimp pockets may

not have the “overlap” profile on all pockets).

CRIMP SPECIFICATIONS:

After crimping, the crimp profiles should measure the following.

Termi al Series No.

Wire Size

Co ductor Crimp

Profile

Height

Width

(Ref.)

AWG

mm²

I .

A (24)

B (22)

C (20)

50097

0.50

0.92

1.02

.036

.040

1.30

1.40

.051

.055

0.35

0.84

0.89

.033

.035

1.30

1.40

.051

.055

0.20

0.77

0.82

.030

.032

1.30

1.40

.051

.055

Termi al Series No. Wire Size I sulatio Diameter 

I sulatio Crimp

Maximum

Pull Force

Mi imum

Height

(Ref.)

Width

(Ref.)

AWG

mm²

I .

Lb.

50097

0.50

1.40

1.90

.055

1.90

.075

1.90

.075

58.

13.21

0.35

1.40

1.90

.055

.075

1.90

.075

1.90

.075

39.

8.81

0.20

1.40

1.90

.055

.075

1.90

.075

1.90

.075

29.4

6.61



To Achieve IPC

620 Class 2 Crimps, the following over

all wire insulation diameter ranges are reco

mmended:

Profile A (24): 1.40-1.90mm (.055-.075 in.)

Profile B (22): 1.40-1.60mm (.055-.063 in.)

Profile C (20): 1.60-1.90mm (.063-.075 in.)

Tool Qualificatio Notes:

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

insulation crimp.

2. The above specifications are guidelines to an optimum

crimp.

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.

Crimpi g Termi als

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

locator open by pulling up 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. ake sure the wire

stop blade is fully seated on the terminal behind the conductor grip section.

OVERLAP

INSULATION

CRIMP

OVERLAP FORM GEOMET

ANVIL

PUNCH

WIRE

TERMINAL

SEATED IN

LOCATOR

OPEN

Figure 1

HAND TOOL

OPEN

Hand Crimp Tool for Board-In Crimp Terminals

Doc No: ATS-6382569H Release Date: 07-25-12 UNCONTROLLED COPY Page 3 of 6

Revision: A Revision Date: 07-25-12

WIRE

CONDUCTOR

PUNCH

TERMINAL

WIRE STOP

BLADE

Figure 2

WIRE

CONDUCTOR

PUNCH

WIRE STOP

BLADE

INSULATION

PUNCH

LOCATOR

CONDUCTOR

ANVIL

INSULATION

ANVIL

TERMINAL

Figure 3

3. Gently pivot the locator closed.

4. Bring down the wire stop blade.

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.

aintain 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 and terminal in place until the terminal is fully

crimped. See Figure 3.

6. Close the tool until the ratchet releases.

7. Lift the wire stop blade up.

8. Carefully remove the crimped terminal.

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.

Termi al Locator Replaceme t/Cha ge 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 4 BHCS. See Figure 4.

I stallatio

1. Place the proper locator, on the hand tool. Install the 4 BHCS. See

Figure 4.

2. Tighten the screw enough to hold the locator. ake sure the locator can still float freely with hand pressure.

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 4 BHCS.

Mai te a ce

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.

M4 BHCS

PIVOT LOCATOR

Figure 4

Hand Crimp Tool for Board-In Crimp Terminals

Doc No: ATS-6382569H Release Date: 07-25-12 UNCONTROLLED COPY Page 4 of 6

Revision: A Revision Date: 07-25-12

INCORRECT

Figure 5

CORRECT

INCORRECT

3. ake 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 6.

Warra ty

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. anually 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 olex terminals specified for crimping with this tool.

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, however crimp force is adjustable (See instructions above).

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. olex 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.

Hand Crimp Tool for Board-In Crimp Terminals

Doc No: ATS-6382569H Release Date: 07-25-12 UNCONTROLLED COPY Page 5 of 6

Revision: A Revision Date: 07-25-12

MODULAR

CRIMP

HEAD

BAT

TERY

POWER

CRIMP

ADAPTER

LOCKING

PINS

LOCKING PINS

BATTERY

POWERED

TOOL

AIR

POWER

TOOL

MODULAR

CRIMP HEAD

LOCKING

PINS

LOCKING

PINS

AIR

POWER

CRIMP

ADAPTER

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 olex Quality Crimping

Handbook 63800-0029 for additional information on crimping and crimp testing.

6. olex does not certify crimp hand tools.

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

Applicatio s for the Modular Crimp Head

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

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

See Chart below for the correct anual 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 odular Crimp Head.

Modular Crimp Head

Order No.

Tool

Order o.

Tool

Descriptio

Adapter

Order No.

Adapter

Descriptio Figure No.

63825-6970

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

attery Power

Tool (220 V)

63816

0600

Battery Power Crimp Adapter

63816

0100

Air

Tool

63816

0700

Air Power Crimp Adapter

Applicatio s for the Modular Crimp Head

Ha d Crimp Tool

Battery Powered Tool

Air Powered Tool

Figure

MODULAR

CRIMP

HEAD

LOCKING

PINS

HAND CRIMP

FRAME LONG

OR SHORT

Hand Crimp Tool for Board-In Crimp Terminals

Doc No: ATS-6382569H Release Date: 07-25-12 UNCONTROLLED COPY Page 6 of 6

Revision: A Revision Date: 07-25-12

RATCHET

RELEASE LEVER

HANDLE

SPRING

CRIMPING

SPRING (2)

LOCATOR

Figure 9

M4 X 6mm

LONG BHCS

PARTS LIST

Ha d Crimp Tool

63825

Item

Order Number

Descriptio

Qua tity

63825

odular

Crimp

Head

1 (

ef)

63816

Hand Crimp

Frame

(

Short

)

(

ef)

63825

Locator

63816

0001

Locking

63600

0525

Handle Spring

63600

0520

Crimping Spring

http://www.molex.com

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