Hand Crimp Tool For 3.18mm (.125”) Lighting Terminals
HAND CRIMP
TOOL
Application Tooling
Specification Sheet
TYPE 4D
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.
Strip Length
Terminal Terminal Order No. Conductor Size Insulation Outside Diameter (1)
Series No. Reel Form only AWG
mm²
mm
In.
mm
In.
42824-4001
42824
16 - 18 1.3 – 0.8 1.90 – 3.10
0.075 – 0.122
42824-4004
3.8 – 4.3 0.15 – 0.17
42825-4001
42825
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
BEND UP
STRIP LENGTH
ROLLING
CONDUCTOR
BRUSH
BELL
MOUTH
TWISTING
INSULATION CRIMP
▲SEE NOTE
BEND
DOWN
CUT-OFF
TAB
CONDUCTOR
CRIMP
Doc No: ATS-638252600
Revision: A
WIRE
SEAM
Release Date: 03-21-12
Revision Date: 03-21-12
UNCONTROLLED COPY
Page 1 of 7
Hand Crimp Tool For 3.18mm (.125”) Lighting Terminals
▲Insulation 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.
OVERLAP FORM GEOMETRY
PUNCH
OVERLAP
INSULATION
CRIMP
CRIMP SPECIFICATIONS
After crimping, the crimped terminals should
measure as follows:
Terminal Series No.
42824 and 42825
Terminal Series No.
Bend up
Bell mouth
mm
In.
0.20 - 0.60 0.008 - 0.024
Bend down
Degrees
42824 and 42825
Terminal
Series No.
42824 and 42825
42824 and 42825
Wire Size
AWG mm2
18
0.8
16
1.3
3
WIRE
ANVIL
3
Twist
Roll
Degrees
4
8
Conductor Brush
mm
In.
1.00 -1.50 0.039 - 0.059
Seam
Seam shall not be open and no wire
Allowed out of the crimping area
Conductor Crimp
Insulation Crimp
Height
Width (Ref) Height Maximum Width Maximum
mm
In.
mm In.
mm
In.
mm
In.
1.52 – 1.60 0.060 – 0.063 2.30 0.090
3.9
0.15
4.0
0.16
1.58 – 1.66 0.062 – 0.065 2.30 0.090
4.2
0.17
4.2
0.17
Pull Force
Minimum
N Lb.
116 26
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 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.
HANDLE WILL
SPRING OPEN
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
Figure 1
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.
Doc No: ATS-638252600
Revision: A
Release Date: 03-21-12
Revision Date: 03-21-12
SQUEEZE HANDLES
TOGETHER
UNCONTROLLED COPY
Page 2 of 7
Hand Crimp Tool For 3.18mm (.125”) Lighting Terminals
Crimping Terminals
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.
LOCATOR
IN DOWN
POSTION
RED
TAB
Figure 2
PUSH UP
ON THE
RED TAB
TERMINAL
TOOLING
PARTIALLY
CLOSED
Figure 3
PARTIALLY
CLOSE HANDLE
TERMINAL
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.
TERMINAL
WIRE AGAINST
THE WIRE
STOP
WIRE
PRE-STRIPPED WIRE
Figure 5
OPEN
POSITION
WIRE STOP IS
PART OF
THE LOCATOR
FIRST
RATCHET
POSITION
Figure 4
TERMINAL
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.
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.
Doc No: ATS-638252600
Revision: A
Release Date: 03-21-12
Revision Date: 03-21-12
UNCONTROLLED COPY
Page 3 of 7
Hand Crimp Tool For 3.18mm (.125”) Lighting Terminals
WIRE
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.
Figure 6
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.
WIRE
STOP
TERMINAL
LOCATOR
SQUEEZE
HERE
SQUEEZE
HERE
Right or Left Hand Operation
TOP SLOTS OF
HANDTOOL
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:
TOP HOOKS
1. The locator must be removed before reversing the tooling.
Figure 7
LOWER TABS
JAWS OPEN
PULL OPEN
TOOLING
TOOLING
M3 BHCS
MATCH
UP MARKS
Figure 9
Figure 9
PUSH ON
HANDLE
Doc No: ATS-638252600
Revision: A
Release Date: 03-21-12
Revision Date: 03-21-12
FRONT
UNCONTROLLED COPY
BACK
Page 4 of 7
Hand Crimp Tool For 3.18mm (.125”) Lighting Terminals
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.
Maintenance
It is recommended that each operator of the tool be made aware of, and
responsible for, the following maintenance steps:
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figure 10
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
RATCHET RELEASE
protected with a thin coat of high quality machine oil. Do not oil
LEVER
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.
Figure 11
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.
RATCHET
RELEASE LEVER
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
How to Adjust Tool Preload
(See Figure 12)
Figure 12
This hand tool is factory preset to 25-45
SETTING
LBS. preload. It may be necessary over
WHEEL
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:
Doc No: ATS-638252600
Revision: A
Release Date: 03-21-12
Revision Date: 03-21-12
UNCONTROLLED COPY
Page 5 of 7
Hand Crimp Tool For 3.18mm (.125”) Lighting Terminals
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.
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:
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.
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
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.
Doc No: ATS-638252600
Revision: A
Release Date: 03-21-12
Revision Date: 03-21-12
UNCONTROLLED COPY
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Hand Crimp Tool For 3.18mm (.125”) Lighting Terminals
PARTS LIST
Item Number
REF
1
2
3
Order Number
63825-2600
63825-2675
63810-0104
63810-0105
Description
Hand Crimp Tool
Locator Assembly
Spring, Return
Spring, Ratchet
Quantity
Figure 13
1
1
1
2
1
RATCHET
RELEASE LEVER
Figure 13
3
http://www.molex.com
Doc No: ATS-638252600
Revision: A
Release Date: 03-21-12
Revision Date: 03-21-12
UNCONTROLLED COPY
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