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Hand Crimp Tool for Commoning Crimp Terminals 

Doc No: ATS-638250500 

Release Date: 02-14-11 

UNCONTROLLED COPY

 

Page 4 of 7 

Revision: A 

Revision Date: 02-14-11 

Figure 8 

PUSH ON 

HANDLE 

JAWS OPEN 

PULL OPEN 

TOOLING 

TOOLING 

M3 BHCS 

SQUEEZE 

HERE 

LOCATOR 

Figure 7A 

SQUEEZE 

HERE 

TOP HOOKS 

TOP SLOTS OF 

HANDTOOL 

LOWER TABS 

MAKE SURE 

CENTER OF LOCATOR 

IS IN THE 

DOWN POSITION 

Figure 7B 

 

Note: 

A crimp height chart is provided with this manual 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. 
 

Locator Installation 

 
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 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 locator 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. 

MATCH 

UP MARKS 

FRONT 

BACK 

Figure 9 

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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