Molex 63825-9700 Bedienungsanleitung

Hand Crimp Tool for 1.50mm (.059") Pico-SPOX Crimp Terminals

Doc. No: ATS-6382597HM Release Date: 05-06-13 UNCONTROLLED COPY Page 1 of 6

Revision: B Revision Date: 04-26-18

INSULATION

CRIMP

▲SEE NOTE

BRUSH

STRIP

LENGTH

BELL MOUTH

CONDUCTOR CRIMP

HEIGHT

BEND

DOWN

BEND UP

ROLL

CONDUCTOR

CRIMP

TWIST

CUT-OFF TAB

SEAM

Application Tooling Specification

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

IPC/WHMA-A-620 Class 2 compliant as indicated on page 2

Modular Crimp Head is removable and can be used 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 63816-0250

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

This tool is RoHS compliant

SCOPE

Products: 1.50mm (.059") Pico-SPOX Crimp Terminal, Female, 24-26 AWG.

Terminal Series No.

Terminal Order No.

Wire Size

(2) Insulation Diameter

Maximum

Strip Length

(1) Available in Reel

form only

AWG

mm²

In.

87421

87421-0000

87421-0002

0.20

1.15

.045

1.05-1.54

.041-.061

0.12

1.00

.039

(1) Customer to cut off terminal from reel: 0.15mm (.006”) maximum cut-off tab.

(2) See Conditions on page 2.

DEFINITION OF TERMS

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

in the scope.

Order No. 63825-9700

Type 4A

Hand Crimp Tool for 1.50mm (.059") Pico-SPOX Crimp Terminals

Doc. No: ATS-6382597HM Release Date: 05-06-13 UNCONTROLLED COPY Page 2 of 6

Revision: B Revision Date: 04-26-18

▲Insulation Crimp Note

Due to the terminal’s insulation grip design and

insulation diameter range, this tool uses the

overlap form geometry in the insulation punch.

This produces an overlap insulation crimp (A-620-

compliant). Although 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

Terminal Series

No.

Bell Mouth

Conductor Brush

Bend Up

Bend Down

Twist

Roll

In.

Degree

87421

0.05-0.40

.002-.016

0.00-0.50

.000-.020

After crimping, the crimp profiles should measure the following:

Terminal

Series No.

Wire Size

Conductor Crimp

Insulation Crimp

Pull Force

Minimum

Profile

Height (Ref.)

Width (Ref.)

Height (Ref.)

Width (Ref.)

AWG

mm2

In.

Lb.

26-30

87421

0.20

0.56-0.60

.022-.024

1.00

.039

1.40

.055

1.10

.043

29.4

6.60

0.12

0.52-0.58

.020-.023

1.00

.039

1.24

.049

1.10

.043

19.6

4.40

28†

30†

To achieve IPC/WHMA-A-620 class 2 crimps, the following overall wire insulation diameter ranges are recommended:

Profile 24: 0.90-1.15mm (.035-.045”)

Profile 26-30:0.80-1.00mm (.032-.040”)

†Scope Change: As of 06-15-2017, Molex Product Engineering does not recommend the use of 28 AWG and 30 AWG

wires in 87421-000* terminals. Terminal 87421-010* should be used for 28 AWG and 30 AWG wires. See the Molex website

for appropriate application tooling.

Tool Qualification Notes

1. (Ref) means the dimension provided is approximate due to the wide range of wires, conductor

stranding, insulation diameters and insulation hardness.

2. An occasional pull force test should be performed. It must exceed the minimum pull force

specification.

3. Pull force should be measured with no influence from the insulation crimp. To ensure this, strip

the wire long enough so the terminal insulation grips do not contact the wire insulation.

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 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.

3. Gently pivot the locator closed.

4. Bring down the wire stop blade. Make sure the wire

stop blade is fully seated on the terminal behind the

conductor grip section.

TERMINAL

SEATED IN

LOCATOR

SWING

LOCATOR

OPEN

Figure 1

HAND TOOL

OPEN

WIRE

STOP BLADE

OVERLAP

INSULATION

CRIMP

OVERLAP FORM GEOMETRY

ANVIL

PUNCH

WIRE

Hand Crimp Tool for 1.50mm (.059") Pico-SPOX Crimp Terminals

Doc. No: ATS-6382597HM Release Date: 05-06-13 UNCONTROLLED COPY Page 3 of 6

Revision: B Revision Date: 04-26-18

WIRE

CONDUCTOR

PUNCH

WIRE STOP

BLADE

INSULATION

PUNCH

LOCATOR

CONDUCTOR

ANVIL

INSULATION

ANVIL

TERMINAL

Figure 3

WIRE

INSULATION

ANVIL

TERMINAL

WIRE STOP

BLADE

Figure 2

5. Slide the pre-stripped wire into the terminal. Make sure to aim the wire brush toward 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 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.

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.

TERMINAL LOCATOR REPLACEMENT

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 M4 BHCS. See Figure 4.

Installation

1. Place the proper locator 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.

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 M4 BHCS.

INCORRECT

Figure 5

CORRECT

INCORRECT

M4 BHCS

PIVOT

LOCATOR

Figure 4

Hand Crimp Tool for 1.50mm (.059") Pico-SPOX Crimp Terminals

Doc. No: ATS-6382597HM Release Date: 05-06-13 UNCONTROLLED COPY Page 4 of 6

Revision: B Revision Date: 04-26-18

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 a 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 the hand tool, particularly from the crimping area. Oil transferred from

the crimping area onto certain terminations may affect the electrical characteristics of an

application.

5. When the 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 9.

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. Should such a defect occur, Molex 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 use 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.

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. 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 are damaged or worn, a new tool

must be purchased.

Hand Crimp Tool for 1.50mm (.059") Pico-SPOX Crimp Terminals

Doc. No: ATS-6382597HM Release Date: 05-06-13 UNCONTROLLED COPY Page 5 of 6

Revision: B Revision Date: 04-26-18

5. Pull force should be used as the final criterion for an acceptable crimp. Pull force is

measured with no influence from the insulation crimp. The insulation should be stripped

long (1/2”) so the insulation grips on the terminal do not grip the wire insulation or the

conductor. Refer to Molex Quality Crimping Handbook 63800-0029 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.

APPLICATIONS FOR THE MODULAR CRIMP HEAD

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 plugged 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 servicing this tool.

The chart below shows all applications for the modular crimp head:

Tool

Order No.

Tool

Description

Adapter

Order No.

Adapter

Description

Figure

No.

63816-0000

Hand Crimp Frame (Short)

—

63816-0050

Hand Crimp Frame (Long)

—

63816-0200

Battery Powered Tool (110 V)

63816-0600

Battery Power Crimp Adapter

63816-0250

Battery Powered Tool (220 V)

63816-0600

Battery Power Crimp Adapter

63816-0100

Air Powered Tool

63816-0700

Air Power Crimp Adapter

Applications for the Modular Crimp Head

Hand Crimp Tool

Battery Powered Tool

Air Powered Tool

Figure 6

Figure 7

Figure 8

MODULAR

CRIMP

HEAD

LOCKING

PINS

HAND CRIMP

FRAME LONG

OR SHORT

MODULAR

CRIMP

HEAD

BATTERY

POWER

CRIMP

ADAPTER

LOCKING

PINS

LOCKING PINS

BATTERY

POWERED

TOOL

AIR

POWERED

TOOL

MODULAR

CRIMP HEAD

LOCKING

PINS

LOCKING

PINS

AIR POWER

CRIMP

ADAPTER

Hand Crimp Tool for 1.50mm (.059") Pico-SPOX Crimp Terminals

Doc. No: ATS-6382597HM Release Date: 05-06-13 UNCONTROLLED COPY Page 6 of 6

Revision: B Revision Date: 04-26-18

PARTS LIST

Hand Crimp Tool 63825-9700

Item

Order Number

Description

Quantity

63816-0000

Hand Crimp Frame (Short)

63825-9775

Locator

63816-0001

Locking Pin

63600-0525

Handle Spring

63600-0520

Crimping Spring

Application Tooling Support

Phone: (402) 458-TOOL (8665)

E-Mail: [email protected]

Website: www.molex.com/applicationtooling

Molex is a registered trademark of Molex, LLC in the United States of America and may be registered in other countries; all other

trademarks listed herein belong to their respective owners.

HANDLE

SPRING

RATCHET

RELEASE LEVER

LOCATOR

M4 X 8mm

LONG BHCS

Figure 9

CRIMPING

SPRING (2)

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