0638255275 - Molex Inc. - Datasheet.Live

Hand Crimp Tool for Board-In Crimp Terminals

Doc No: ATS-6382552HM Release Date: 06-01-12 UNCONTROLLED COPY Page 1 of 5

Revision: C Revision Date: 04-01-14

INSULATION

CRIMP

Figure 1

1.80 +0.10/0.00mm (.071 +.004/.000”)

Diameter PC Board Hole

WIRE

CONDUCTOR

CRIMP

1.57 ±

±±

± 0.18 mm (.062 ±

±±

±-.007”)

Thick PC Board

Section E-E

E-E

Application Tooling

Specification Sheet

Modular Crimp Head

Order No. 63825-5270

Hand Crimp Tool

Order No. 63825-5200

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.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).

SCOPE

Products: Board-In Crimp Terminals, 18 - 22 AWG.

Terminal Series No. Terminal Order No.

Wire Size

Insulation Diameter

Strip Length

AWG

mm²

In.

5298

0106

0276

18-22 0.80-0.35 1.70-3.05 .067-.120 4.50-4.70 .177-.185

0230

0277

DEFINITION OF TERMS

TYPE 4A

Hand Crimp Tool for Board-In Crimp Terminals

Doc No: ATS-6382552HM Release Date: 06-01-12 UNCONTROLLED COPY Page 2 of 5

Revision: C Revision Date: 04-01-14

Crimp Specification

After crimping, the conductor profiles should measure the following (See Figure 1).

Terminal Series No. Wire Size

Dimensions (Figure

♦Pull Force

Minimum

F (Ref.)

AWG

In.

Lb.

5298

0.80

1.05 - 1.15 0.041 - 0.045 1.70 - 1.78 0.067 - 0.070 1.40 0.055 13.3 3

0.50

0.35

♦The crimp on this terminal is not an electrical crimp; the final soldering operation is the electrical connection.

This minimum pull force is what should be expected when pulling the terminal with both insulation and

conductor crimped.

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. Variations in tools, terminals, wire stranding, and insulation types

may affect crimp height.

3. This tool is intended for AWG conductors with UL1015 insulation. It may not give a good insulation crimp

support for other insulation styles.

4. Molex does not repair hand tools (see Warranty on page 3). 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. Refer to Molex Quality Crimping

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

6. Molex does not certify crimp hand tools.

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.

Preparing Terminals for Crimping

The terminals must be cut from the reel as shown. See Figure 2. The

carrier strip hole is used to assist in loading the terminal in position over

the crimp anvils. The carrier strip will help maintain terminal position

during crimping and can be broken off after the crimp is complete.

Crimping Terminals

1. Load the terminal with carrier strip into the proper crimp profile.

Make sure the carrier strip pilot hole fits over the positioning pin.

2. Place the properly stripped wire into the open terminal barrel. Push

the wire into the tool until the end of the wire contacts the wire stop,

making sure that all wire strands are inside of the conductor barrel.

See Figures 3 and 4.

3. While holding the wire with one hand, slowly squeeze the tool

handles together to close the tool jaws until the ratchet mechanism releases. At this point the handles can be

released and will spring open.

4. Remove the crimped terminal and inspect for acceptable crimp attributes.

Figure 2

LOCATOR

Figure 3

TERMINAL

CARRIER STRIP

POSITIONING

Hand Crimp Tool for Board-In Crimp Terminals

Doc No: ATS-6382552HM Release Date: 06-01-12 UNCONTROLLED COPY Page 3 of 5

Revision: C Revision Date: 04-01-14

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

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 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 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 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. 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.

TERMINAL

BARREL

PUNCH

WIRE

INSULATION

PUNCH

CONDUCTOR

ANVIL

INSULATION

ANVIL

Figure 4

CONDUCTOR

PUNCH

BARREL ANVIL

LOCATOR

WIRE STOP

Hand Crimp Tool for Board-In Crimp Terminals

Doc No: ATS-6382552HM Release Date: 06-01-12 UNCONTROLLED COPY Page 4 of 5

Revision: C Revision Date: 04-01-14

MODULAR

CRIMP

HEAD

BATTERY

POWER

CRIMP

ADAPTER

LOCKING

PINS

LOCKING PINS

BATTERY

POWERED

TOOL

AIR

POWER

TOOL

MODULAR

CRIMP HEAD

LOCKING

PINS

LOCKING

PINS

AIR

POWER

CRIMP

ADAPTER

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 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 Head

Order No.

Tool

Order no.

Tool

Description

Adapter

Order No.

Adapter

Description

Figure

No.

63825-5270

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

Battery Power

Tool (220 V)

63816

0600

Battery Power Crimp Adapter

63816

0100

Air

Tool

63816

0700

Air Power Crimp Adapter

Applications for the Modular Crimp Head

Hand 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-6382552HM Release Date: 06-01-12 UNCONTROLLED COPY Page 5 of 5

Revision: C Revision Date: 04-01-14

RATCHET

RELEASE LEVER

HANDLE

SPRING

CRIMPING

SPRING (2)

Figure 6

M4 X

LONG BHCS

(2)

PARTS LIST

Item

Order Number

Description

Quantity

638

Modular

Crimp

Head

1 (

ef)

63816

Hand Crimp

Frame

(

Short

)

(

ef)

638

Locator

Plate

63816

0001

Locking

6360

0525

Handle Spring

63600

0520

Crimping Spring

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