Molex 63825-9670 Bedienungsanleitung

Hand Crimp Tool for 4.0mm Pitch Motor Crimp Terminals

Doc No: ATS-6 82596HM Release Date: 05-21-12 UNCONTROLLED COPY Page 1 of 6

Revision: A Revision Date: 05-21-12

►

INSULATION

CRIMP HEIGHT

BRUSH

STRIP LENGTH

BELL MOUTH

BEND DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP HEIGHT

TWISTING

CUT OFF

TAB

SEAM

WIRE

Application Tooling

Sp cification Sh t

Modular Crimp H ad

Ord r No. 63825-9670

Hand Crimp Tool

Ord r No. 63825-9600

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

% Modular Crimp Head is removable and can be use in the Air Powered Tool Order No.6 816-0100,

accompanied by Air Powered Crimp Adapter (Order No. 6 816-0700).

% Can also be used in the Battery Powered Tool Order No.6 816-0200 (110 V) or 6 816-0250 (220 V)

accompanied by Battery Powered Crimp Adapter (Order No. 6 816-0600).

SCOPE

Products: 4.0mm Pitch Motor Crimp Terminal, 22 AWG.

T rminal

S ri s No.

T rminal Ord r No. Wir Siz and Typ (1)

Insulation Diam t r

Strip L ngth

IPC/WHMA-A620m (2)

T rminal (

)

Maximum

R l

(

)

Loos

mm²

Typ

In.

59 59 -8100

59 -8000

0. 2

0. 4

UL1007

1.15

1.50

.045

059

1.75

.069

1.60

2.10

.06

.08

0. 2

0. 4

UL1061

1. 0

1.50

.051

.059

1.75

.069

1.60

2.10

.06

.08

(1)

This hand tool will crimp other wire types of

equivalent gauge size. (The hand tool frame is labeled for convenience.)

(2) To achieve optimum IPC-A620 insulation crimps, use this insulation OD range.

( ) Overall insulation OD specification for terminal.

(4) Customer to cut off terminal from reel: 0.15m (.006”) maximum Cut-off Tab.

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 4.0mm Pitch Motor Crimp Terminals

Doc No: ATS-6 82596HM Release Date: 05-21-12 UNCONTROLLED COPY Page 2 of 6

Revision: A Revision Date: 05-21-12

▲Insulation Crimp Not :

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).

CONDITIONS:

After crimping, the crimp profiles should measure the

following.

T rminal S ri s No

Wir Siz and Typ

Conductor Crimp (R f

Profil

H ight

Width

(R f)

AWG

Typ

In.

UL1007

UL 1061

0. 2

0. 4

UL1007

0.70

0.75

.028

.0 0

.04

0. 2

0. 4

UL1061

0.70

0.75

.028

.0 0

.04

T rminal S ri s No

Wir Siz and Typ

Insulation Crimp

(R f.)

Pull Forc Minimum

H ight

Width

(R f)

AWG

Typ

In.

Lb.

0. 2

0. 4

UL1007

1.55

.061

.06

9.2

8.8

0. 2

0. 4

UL10

1.55

.061

.06

9.2

8.8

Tool Qualification Not s:

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.

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. Make sure the wire stop

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

. 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. Maintain 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 .

OVERLAP

INSULATION

CRIMP

OVERLAP FORM GEOMETRY

ANVIL

PUNCH

WIRE

TERMINAL

SEATED IN

LOCATOR

SWING

LOCATOR

OPEN

Figur 1

HAND TOOL

OPEN

WIRE

STOP

BLADE

Hand Crimp Tool for 4.0mm Pitch Motor Crimp Terminals

Doc No: ATS-6 82596HM Release Date: 05-21-12 UNCONTROLLED COPY Page of 6

Revision: A Revision Date: 05-21-12

LOCATOR

WIRE

CONDUCTOR PUNCH

WIRE STOP

BLADE

INSULATION

PUNCH

CONDUCTOR

ANVIL

INSULATION

ANVIL

TERMINAL

Figur 3

WIRE

TERMINAL

WIRE STOP

BLADE

Figur 2

M4 BHCS

PIVOT

LOCATOR

Figur 4

6. Close the tool until the ratchet releases.

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

7. Lift the wire stop blade up.

8. Carefully remove the crimped terminal.

Not : To maintain good brush control and a consistent bell mouth the

crimping instructions must be followed.

T rminal Locator R plac m nt

R moval

1. With the tool in the open position, pivot the terminal locator outward.

2. Remove the M4 BHCS. See Figure 4.

Installation

1. Place the new locator, (See Chart on page 2), on the hand tool. Install the M4 BHCS. See Figure 4.

2. Tighten the screw enough to hold the locator. Make sure the

locator can still float freely with hand pressure.

. 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 M4 BHCS.

Maint nanc

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.

INCORRECT

Figur 5

CORRECT INCORRECT

Hand Crimp Tool for 4.0mm Pitch Motor Crimp Terminals

Doc No: ATS-6 82596HM Release Date: 05-21-12 UNCONTROLLED COPY Page 4 of 6

Revision: A Revision Date: 05-21-12

. 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 lifting the ratchet release lever. See Figure 6.

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: Repetitive use of this tool should be avoided.

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.

Not s:

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.

. This tool is intended for standard conductor sizes. It may not give a good insulation crimp support for all

insulation sizes.

4. Molex 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.

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 Molex Quality Crimping

Handbook 6 800-0029 for additional information on crimping and crimp testing.

6. Molex does not certify crimp hand tools.

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

Hand Crimp Tool for 4.0mm Pitch Motor Crimp Terminals

Doc No: ATS-6 82596HM Release Date: 05-21-12 UNCONTROLLED COPY Page 5 of 6

Revision: A Revision Date: 05-21-12

MODULAR

CRIMP

HEAD

BATTERY

POWER

LOCKING

PINS

LOCKING PINS

BATTERY

POWERED

TOOL

AIR

POWER

TOOL

MODULAR

CRIMP HEAD

LOCKING

PINS

LOCKING

PINS

AIR

POWER

CRIMP

ADAPTER

Applications for th Modular Crimp H ad

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

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

See Chart below for the correct Manual 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 Modular Crimp Head.

Modular Crimp H ad

Ord r No.

Tool

Ord r no.

Tool

D scription

Adapt r

Ord r No.

Adapt r

D scription

Figur

No.

6 825-9670

6 816

0000

Hand Crimp Frame (Short)

N/A

6 816

0050

Hand Crimp Frame (Long)

N/A

6 816

0200

Battery Power

Tool (110 V)

6 816

0600

Battery Power Crimp Adapter

6 816

Battery Power

Tool (220 V)

6 816

0600

Battery Power Crimp Adapter

6 816

0100

Air

Tool

6 816

0700

Air Power Crimp Adapter

Applications for th Modular Crimp H ad

Hand Crimp Tool

Batt ry Pow r d Tool

Air Pow r d Tool

Figur 3

Figur 4

Figur 5

MODULAR

CRIMP

HEAD

LOCKING

PINS

HAND CRIMP

FRAME LONG

OR SHORT

Hand Crimp Tool for 4.0mm Pitch Motor Crimp Terminals

Doc No: ATS-6 82596HM Release Date: 05-21-12 UNCONTROLLED COPY Page 6 of 6

Revision: A Revision Date: 05-21-12

RATCHET

RELEASE LEVER

HANDLE

SPRING

CRIMPING

SPRING (2)

Figur 9

M4 X 6mm

LONG BHCS

PARTS LIST

Hand Crimp Tool

63825

It m

Ord r Numb r

D scription

Quantity

6 825

Modular

Crimp

Head

1 (

ef)

6 816

Hand Crimp

Frame

(

short

)

(

ef)

6 825

Locator

6 816

0001

Locking

6 600

0525

Handle Spring

6 600

0520

Crimping Spring

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

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