Molex 63825-2600 Manual de usuario

Hand Crimp Tool For 3.18mm (.125”) Lighting Terminals

Doc o: ATS-638252600 Release Date: 03-21-12 UNCONTROLLED COPY Page 1 of 7

Revision: A Revision Date: 03-21-12

TYPE 4D

CONDUCTOR

BRUSH

STRIP LENGTH

CONDUCTOR

CRIMP

CUT-OFF

TAB

BELL

MOUTH

BEND UP

TWISTING

ROLLING

BEND

DOWN

WIRE

SEAM

INSULATION CRIMP

▲SEE NOTE

HAND CRIMP

TOOL

Applicatio Tooli g

Specificatio Sheet Order No. 63825-2600

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 or left handed operation

 IPC/WHMA A-620 Class 2 compliant as indicated

 RoHS compliant, however RoHS compliant is not required

 For 12AWG crimps use hand tool 63825-2700

SCOPE

Products: 3.18mm (.125”) Lighting Terminal for 16AWG and 18AWG wires.

Termi al

Series No.

Termi al Order No.

Reel Form o ly

Co ductor Size I sulatio Outside Diameter (1)

Strip Le gth

AWG mm² mm I . mm I .

42824 42824-4001 16 - 18

1.3 – 0.8

1.90 – 3.10 0.075 – 0.122

3.8 – 4.3

0.15 – 0.17

42824-4004

42825 42825-4001 16 - 18

1.3 – 0.8

1.90 – 3.10 0.075 – 0.122

42825-4004

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

 Customer to cut off terminal from reel: 0.40mm (.016”) maximum cut-off tab.

DEFINITION OF TERMS

Hand Crimp Tool For 3.18mm (.125”) Lighting Terminals

Doc o: ATS-638252600 Release Date: 03-21-12 UNCONTROLLED COPY Page 2 of 7

Revision: A Revision Date: 03-21-12

▲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.

CRIMP SPECIFICATIONS

After crimping, the crimped terminals should

measure as follows:

Termi al Series No. Bell mouth Co ductor Brush

mm I . mm I .

42824 and 42825 0.20 - 0.60 0.008 - 0.024 1.00 -1.50 0.039 - 0.059

Termi al Series No.

Be d up

Be d dow Twist

Roll Seam

Seam shall not be open and no wire

Allowed out of the crimping area

Degrees Degrees

42824 and 42825 3 3 4 8

Termi al

Series No.

Wire Size Co ductor Crimp I sulatio Crimp Pull Force

Mi imum

Height Width (Ref)

Height Maximum

Width Maximum

AWG

mm2

mm I . mm

I . mm I . mm I . N Lb.

42824 and 42825 18 0.8 1.52 – 1.60

0.060 – 0.063

2.30

0.090

3.9 0.15 4.0 0.16 116 26

42824 and 42825 16 1.3 1.58 – 1.66

0.062 – 0.065

2.30

0.090

4.2 0.17 4.2 0.17 178 40

CAUTION: Crimp only the Molex terminals listed in the scope for this tool. Do not crimp hardened objects as

damage can occur to the tool frame and/or crimp dies.





 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.

Note:

A crimp height chart is provided with this manual as Reference Only. Due to the

wide range of wires, strands, insulation diameters, and durometer 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 specification.

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.

OVERLAP

INSULATION

CRIMP

OVERLAP FORM GEOMETRY

ANVIL

PUNCH

WIRE

SQUEEZE HANDLES

TOGETHER

HANDLE WILL

SPRING OPEN

Figure 1

Hand Crimp Tool For 3.18mm (.125”) Lighting Terminals

Doc o: ATS-638252600 Release Date: 03-21-12 UNCONTROLLED COPY Page 3 of 7

Revision: A Revision Date: 03-21-12

PRE-STRIPPED WIRE

TERMINAL

Figure 5 TERMINAL

WIRE AGAINST

THE WIRE

STOP

WIRE

WIRE STOP IS

PART OF

THE LOCATOR

Crimpi g Termi als

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

2. Make sure the locator is attached behind the lower tooling and is above all the

anvils surfaces.

3. The spring loaded wire stop should be clear of the locator’s cavity, if not push up

on the red tab to move the wire stop out of the way while inserting the terminal.

See Figure 3.

4. 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 3.

5. Partially close the tool handle until the first ratchet position engages, and

holds the terminal in place. 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.

ote: 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

IN DOWN

POSTION

RED

TAB

Figure 2

TERMINAL

Figure 3 TERMINAL

PUSH UP

ON THE

RED TAB

PARTIALLY

CLOSE HANDLE

TOOLING

PARTIALLY

CLOSED

Figure 4

FIRST

RATCHET

POSITION

OPEN

POSITION

Hand Crimp Tool For 3.18mm (.125”) Lighting Terminals

Doc o: ATS-638252600 Release Date: 03-21-12 UNCONTROLLED COPY Page 4 of 7

Revision: A Revision Date: 03-21-12

SQUEEZE

HERE

SQUEEZE

HERE

LOCATOR

Figure 7

TOP HOOKS

TOP SLOTS OF

HANDTOOL

LOWER TABS

Figure 9

PUSH ON

HANDLE

JAWS OPEN

PULL OPEN

TOOLING TOOLING

M3 BHCS

Locator Replaceme t

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.

1. Open the crimp hand tool.

2. Squeeze gently on the lower area shown in Figure 7 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.

See Figure 7.

4. To reinstall the new locator, make sure the hand tool is in the open

position.

5. 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.

6. 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.

Right or Left Ha d Operatio

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

Figure 6

WIRE

STOP

WIRE

MATCH

UP MARKS

FRONT BACK

Figure 9

Hand Crimp Tool For 3.18mm (.125”) Lighting Terminals

Doc o: ATS-638252600 Release Date: 03-21-12 UNCONTROLLED COPY Page 5 of 7

Revision: A Revision Date: 03-21-12

Figure 12

SQUEEZE

THE LINK IN

THE HANDLE

HOLD THE HAND

TOOL IN POSITION

SETTING

WHEEL

RATCHET

RELEASE LEVER

2. Remove the M3 BHCS which is holding the upper tooling. Flip the upper

tooling to the opposite side and replace the M3 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.

3. Do the same thing with the lower tooling and tighten the M3 screws. Be

sure the small markings line up.

4. Reinstall the locator by following the Instructions in the locator

replacement section.

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.

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

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 11.

How to Adjust Tool Preload

(See Figure 12)

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:

RATCHET RELEASE

LEVER

Figure 11

LUBRICATION POINTS

(BOTH SIDES) LIGHT OIL

(EVERY 3 MONTHS OR

5,000 CRIMPS)

Figure 10

Hand Crimp Tool For 3.18mm (.125”) Lighting Terminals

Doc o: ATS-638252600 Release Date: 03-21-12 UNCONTROLLED COPY Page 6 of 7

Revision: A Revision Date: 03-21-12

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.

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.

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: 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 OT 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.

Certificatio

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 3.18mm (.125”) Lighting Terminals

Doc o: ATS-638252600 Release Date: 03-21-12 UNCONTROLLED COPY Page 7 of 7

Revision: A Revision Date: 03-21-12

RATCHET

RELEASE LEVER

Figure 13

PARTS LIST

Item Number Order Number Descriptio Qua tity

REF 63825-2600 Hand Crimp Tool Figure 13

1 63825-2675 Locator Assembly 1

2 63810-0104 Spring, Return 1

3 63810-0105 Spring, Ratchet 1

http://www.molex.com

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