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Hand Crimp Tool for Commoning Crimp Terminals 

Doc No: ATS-638250500 

Release Date: 02-14-11 

UNCONTROLLED COPY

 

Page 1 of 7 

Revision: A 

Revision Date: 02-14-11 

BRUSH 

STRIP 

LENGTH 

BELL MOUTH 

CONDUCTOR 

CRIMP HEIGHT 

BEND 

DOWN 

BEND UP 

ROLLING 

CONDUCTOR 

CRIMP 

TWISTING 

CUT-OFF TAB 

SEAM 

INSULATION 

CRIMP 

TYPE 4D 

HAND CRIMP 

TOOL

 

 

 

Application Tooling 

Specification Sheet

 

Order No. 63825-0500 

 

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 

 

This tool is WHMA-IPCA620 Class 2 compliant as indicated 

 

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

 

SCOPE 

 
Products:  Commoning Terminals, 28-30 AWG. 
 

Terminal 

Series No. 

Terminal Order No. 

 

Wire Size 

%

 

Insulation Diameter

 

Strip Length 

Loose Piece 

+

 

Reel 

AWG 

mm² 

mm 

In. 

mm 

In. 

1457-6 

05-02-0092 

05-02-0091  28-30  0.09-.055 

0.90-0.80 

.035-.031 

3.96-5.54 

.156-.218 

+

 

Customer to cut off terminal from reel: 0.18mm (.007”) maximum Cut-off Tab. 

%

 

To Achieve IPC-A-620 Class 2 Crimps, the following wire insulation diameter limits are recommended: 

1.

 

28 AWG 0.89mm (.035 inch) UL1061. 

2.

 

30 AWG 0.81mm (.032 inch) UL1061.

 

 

For Crimping 24-26 AWG Wire- Use 63823-1200 Hand Crimp Tool.

 

 

DEFINITION OF TERMS 

 
 
 
 
 
 
 
 
 
 
 
 
 
 

Summary of Contents for 63825-0500

Page 1: ...s terminals in the proper crimping position Right and Left handed applications This tool is WHMA IPCA620 Class 2 compliant as indicated This tool is RoHS compliant however RoHS compliant is not required SCOPE Products Commoning Terminals 28 30 AWG Terminal Series No Terminal Order No Wire Size Insulation Diameter Strip Length Loose Piece Reel AWG mm mm In mm In 1457 6 05 02 0092 05 02 0091 28 30 0...

Page 2: ...1 10 043 1 65 Max 065 Max 1 35 053 Terminal Series No Wire Size Pull Force Minimum Profile AWG mm2 N Lb 28 30 1457 6 28 0 09 11 2 2 5 X 30 0 055 4 4 1 0 X Tool Qualification Notes 1 Pull Force should be measured with no influence from the insulation crimp 2 The above specifications are guidelines to an optimum crimp OPERATION CAUTION Install only Molex terminals listed above with this tool Do not ...

Page 3: ...ges 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 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 loca...

Page 4: ...nstallation 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 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...

Page 5: ...he 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 w...

Page 6: ...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 NOT intended for production use Repetitive use of ...

Page 7: ...LED COPY Page 7 of 7 Revision A Revision Date 02 14 11 RATCHET RELEASE LEVER 2 Figure 13 1 3 PARTS LIST Item Number Order Number Description Quantity REF 63825 0500 Hand Crimp Tool Figure 13 1 63825 0575 Locator Assembly 1 2 63810 0104 Spring Return 1 3 63810 0105 Spring Ratchet 1 http www molex com ...

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