Molex 63825-8100 Manual de usuario

Hand Crimp Tool For C-Grid III™ Female Crimp Terminals

Doc No: ATS-638258 00 Release Date: -27- 2 UNCONTROLLED COPY Page of 7

Revision: B Revision Date: - - 6

INSULATION

CRIMP

BRUSH

STRIP

LENGTH

BELL MOUTH

CRIMP HEIGHT

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP

TWISTING

HAND CRIMP

TOOL

Application Tooling

Specification S eet Order No. 63825-8100

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

 Dies and Locator from this tool can be used in the Battery Powered Tool Order No.638 6-0200 ( 0 V) or

638 6-0250 (220 V), with the use of the 638 6-0800 Crimp Head

 Many different tool kits can be used with a single Battery Powered Crimp Tool

 This tool is IPC/WHMA A-620 Class 2 compliant

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

SCOPE

Products: C-Grid III™ Female Crimp Terminals, 22-24 AWG

Terminal Series No.

Terminal Order No.

Wire Size



Insulation Diameter

Strip Lengt

Loose Piece



Reel

AWG

mm²

In.

90 9

90 9-2 09

90 9-2 0

90 9-2

90 9-0 09

90 9-0 0

90 9-0

22-24

0.35-0.20

.02- .47 .040-.058 2.80-3.30

. 0-. 30



Customer to cut off terminal from reel: 0. 5mm (.006”) maximum Cut

off Tab.

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.

TYPE 4D

Hand Crimp Tool For C-Grid III™ Female Crimp Terminals

Doc No: ATS-638258 00 Release Date: -27- 2 UNCONTROLLED COPY Page 2 of 7

Revision: B Revision Date: - - 6

RELEASE

LOCATOR BUTTON

TERMINAL Figure 3

LOCATOR

PUSHED THRU

TOOLING

TERMINAL

LOCATOR

BUTTON

PUSHED IN

LOCATOR

CONDITIONS:

After crimping, the conductor profiles should measure the following.

Terminal

Series No

Wire Size

Condu

ctor Crimp

Insulation Crimp

Pull Force

Minimum Profile

Heig t

Widt (Ref.)

Heig t (Ref.)

Widt (Ref.)

90 9

AWG

In.

Lb.

0.35

0.7

0.8

.032

.60

.063

.60

.063

39.2

8.82

0.20

.02

.06

29.4

6.6



To Achieve IPC

620 Class 2 Crimps, the following over

all wire insulation diameter ranges are recommended:

Profile 22: . 5 – .30mm (.045-.05 inch) (UL 06 - .25mm Dia.)

Profile 24: .25 – .40mm (.049-.055 inch) (UL 007 – .40mm Dia.)

Tool Qualification Notes:

. 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 document as Reference Only. Due to the wide range of wires, strands,

insulation diameters, and durometers available, actual crimp height measurements may very slightly. An

occasional, destructive, pull force test should be preformed to check hand tool crimp. Pull Force value Must exceed

the Minimum pull force specifications listed.

OPERATION

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.

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 .

Crimping Terminals

LOCATOR

IN DOWN

POSTION

PUSH ON THE

LOCATOR BUTTON

Figure 2

SQUEEZE

HANDLES

TOGETHER

HANDLE WILL

SPRING OPEN

Figure 1

Hand Crimp Tool For C-Grid III™ Female Crimp Terminals

Doc No: ATS-638258 00 Release Date: -27- 2 UNCONTROLLED COPY Page 3 of 7

Revision: B Revision Date: - - 6

Figure 5 TERMINAL

WIRE AGAINST THE

WIRE STOP

WIRE

WIRE STOP IS PART

OF THE LOCATOR

PRE

STRIPPED

WIRE

TERMINAL

. 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.

3. 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 3.

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

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.

0. 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.

PARTIALLY

CLOSE HANDLE

TOOLING

PARTIALLY

CLOSED

Figu

re 4

FIRST RATCHET

POSITION

OPEN

POSITION

TERMINAL

Figure 6

WIRE

STOP

Hand Crimp Tool For C-Grid III™ Female Crimp Terminals

Doc No: ATS-638258 00 Release Date: -27- 2 UNCONTROLLED COPY Page 4 of 7

Revision: B Revision Date: - - 6

Figure

PUSH ON

HANDLE

JAWS OPEN

PULL OPEN

TOOLING

M3 BHCS

MATCH

UP MARKS

FRONT

BACK

Figure 9

. 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.

3. 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.

Rig t 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:

. The locator must be removed before reversing

the tooling.

2. Remove the M3 BHCS which is holding the upper

tooling.

3. 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.

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

the M3 screws. Be sure the small markings line up.

5. Reinstall the locator by following the Instructions in

the locator replacement section.

MAKE SURE

CENTER OF LOCATOR

IS IN THE

DOWN POSITION

Figure 7B

SQUEEZE

HERE

SQUEEZE

HERE

LOCATOR

Figure 7A

TOP HOOKS

TOP SLOTS OF

HANDTOOL

LOWER TABS

Hand Crimp Tool For C-Grid III™ Female Crimp Terminals

Doc No: ATS-638258 00 Release Date: -27- 2 UNCONTROLLED COPY Page 5 of 7

Revision: B Revision Date: - - 6

Figure 12

SQUEEZE

THE LINK IN

THE HANDLE

HOLD THE HAND

TOOL IN POSITION

SETTING

WHEEL

RATCHET

RELEASE LEVER

Maintenance

It is recommended that each operator of the tool be made aware of, and

responsible for, the following maintenance steps:

. 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 .

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:

. Hold the hand tool in the palm of your

hand as shown in Figure 0. 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).

LUBRICATION POINTS

(BOTH SIDES) LIGHT OIL

(EVERY 3 MONTHS OR

5,000 CRIMPS)

Figure 10

RATCHET RELEASE

LEVER

Figure 11

Hand Crimp Tool For C-Grid III™ Female Crimp Terminals

Doc No: ATS-638258 00 Release Date: -27- 2 UNCONTROLLED COPY Page 6 of 7

Revision: B Revision Date: - - 6

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.

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, 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:

. 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.

3. 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

2.7mm ( /2”) long, so there is no crimping of the insulation. Pull the terminal and wire at a rate no faster than

25mm ( .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 C-Grid III™ Female Crimp Terminals

Doc No: ATS-638258 00 Release Date: -27- 2 UNCONTROLLED COPY Page 7 of 7

Revision: B Revision Date: - - 6

RATCHET

RELEASE LEVER

Figure 13

PARTS LIST

Item Number

Order Number

Description

Quantity

REF

63825

8100

Hand Crimp Tool

Figure 13

638

Locator Assembly

638 0

0 04

Spring, Return

638 0

0 05

Spring, Ratchet

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

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