Molex 63825-4800 Manuel utilisateur

Tool Kit for MP-Lock™ Female Terminal

Doc No: ATS-63825 8HM Release Date: 07-23-12 UNCONTROLLED COPY Page 1 of 8

Revision: A Revision Date: 07-23-12

INSULATION

CRIMP

▲SEE NOTE

BRUSH

STRIP

LENGTH

TERMINAL

STRIP

CONDUCTOR

CRIMP HEIGHT

CUT

OFF

TAB

SEAM

BELL MOUTH

WIRE

Application Toolin

Specification Sheet

Tool Kit

Order No. 63825-4870

Hand Crimp Tool

Order No. 63825-4800

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

 Tool kits are easily installed into the Hand Crimp Tool or the 63816-0300 Power Crimp Head which is installed

into the 63816-0200 (110 V) or the 63816-0250 (220 V) Battery Powered Tool.

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

 This tool is IPC/WHMA-A-620 Class 2 as indicated, and RoHS compliant.

SCOPE

Products: MP-Lock™ Female Terminal, for 20-26 AWG (0.50-0.13mm²), Metal Strip.

Terminal

Series No.

Terminal Order No.





 Available in

Reel form only

Wire Size

Insulation Diameter

Strip Len th



Terminal

Maximum

AWG

mm²

In.

57990

9710

0.50

0.13

1.30

3.60

.051

.1 2

. 0

5.00

.173

.197







The terminals above are reeled parts only. Customer to cut off terminal from reel: 0.5

mm (.0

0”) maximum.

Overall insulation OD specification for terminal.

DEFINITION OF TERMS

TYPE 4C

Tool Kit for MP-Lock™ Female Terminal

Doc No: ATS-63825 8HM Release Date: 07-23-12 UNCONTROLLED COPY Page 2 of 8

Revision: A Revision Date: 07-23-12

▲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.

(Some tools with multiple crimp pockets may not have

the “overlap” profile on all pockets).

CONDITIONS:

After crimping, the conductor profiles should measure the following (See notes below).

Terminal

Series No.

Wire Size

Conductor

Insulation

Pull Force

Minimum Profile

Crimp Hei ht

Crimp Width

Maximum

Insulation

Hei ht

Insulation Width

Maximum

AWG

mm2

in.

Lb.

57990

0.50

0.99

1.09

.039

.0 3

1. 7-1.67

.058-.066

3. 6-3.66

.136-.1

68.6

15.

0.35

0.96

1.06

.038

.0 2

9.0

11.0

0.20

0.8

0.9

.03

29.

6.6

012

0.85

0.95

.033

.037

19.



To Achieve IPC

620 Class 2 Crimps, the following over

all wire insulation diameter ranges are recommended:

Profile A (20): 2.35-3.00mm (.093-.118 in.)

Profile B (22): 2.35-3.00mm (.093-.118 in.)

Profile C (2 ): 2.35-2.85mm (.093-.112 in.)

Profile D (26): 2.35-2.85mm (.093-.112 in.)

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.

CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects as damage

can occur to the tool or die.

INSTALLATION

To install the Tool Kit into the Power Crimp Head follow the steps below:

Anvils and Punches Installation

1. Insert the Anvils into the bottom slots of the nest. Install the M x 10 long BHCS and tighten in place.

2. Insert the Punches into the top slots of the nest. Install the M x 18 long BHCS and tighten in place. See

Figure 1.

Locator Installation and Removal

Follow the steps below to install or replace the locator.

See Figure 2.

OVERLAP

INSULATION

CRIMP

OVERLAP FORM GEOMETRY

ANVIL

PUNCH

WIRE

Tool Kit for MP-Lock™ Female Terminal

Doc No: ATS-63825 8HM Release Date: 07-23-12 UNCONTROLLED COPY Page 3 of 8

Revision: A Revision Date: 07-23-12

SWING

LOCATOR

OPEN

PRESS DOWN

ON THE BRASS

PIVOT SHAFT

LIFT UP ON

THE LOCATOR

Fi ure

ANVILS

POWER

CRIMP

HEAD

Fi ure

PUNCHES

M4 X 10 LONG

BHCS

M4 X 18 LONG

BHCS

SWING OPEN

TERMINAL

PUSH HERE TO

OPEN WIRE STOP LOCATOR

TERMINAL

IN PLACE

Fi ure 4

LOCATOR LATCH

IN OPEN POSITION

To install the locator

1. Position the locator with the hole over the brass pivot shaft and snap it into place.

To remove the locator

1. Open the crimp hand tool.

2. Swing the existing locator open and away from the hand tool.

3. Firmly press down on the brass pivot shaft with your thumb, while pulling the locator up. Slip the locator off the

top of the brass pivot shaft.

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.

Crimpin Terminals

1. Select the desired terminal listed in the preceding

charts.

2. Turn the Locator Lock Latch down to unlock. See

Figure 3.

Fi ure 3

LATCH LOCKED

LATCH UNLOCKED

Tool Kit for MP-Lock™ Female Terminal

Doc No: ATS-63825 8HM Release Date: 07-23-12 UNCONTROLLED COPY Page of 8

Revision: A Revision Date: 07-23-12

Fi ure 6

WIRE IN TERMINAL

JAWS

PARTIALLY

CLOSED

WIRE AGAINST

WIRE STOP

HANDLE

OPEN

LOCATOR

CLOSED

Fi ure 5

TERMINAL

PUSH HERE TO

OPEN WIRE STOP

3. Swing the terminal locator away from the crimp tool shown in

Figure . Some terminals with large insulation grips may

interfere with the crimp tooling when swinging the locator into

position. The terminal must then be loaded into the locator in

the closed crimp position. See Figure 5.

. Press down on the wire stop on the locator as shown in Figure

5. Insert the proper terminal into the proper nest opening. Make

sure when choosing the nest opening, it will correspond with

the A, B, or C profile on the hand tool.

6. Return the locator to its original position.

7. Turn the Locator Lock Latch up to lock. Make sure that the terminal is visually centered over the punch.

8. Insert the proper wire over the terminal.

9. Gently touch the wire stop with the end of the wire. See Figure 6 and 7.

10. Compress the terminal by squeezing the tool

handles until the ratchet mechanism cycle has been completed. Release handles to open the jaws.

11. Remove the crimped terminal from the terminal locator by pressing down on the wire stop and gently pulling on

the wire. The terminal locator can be in either position.

12. Visually inspect the crimped terminal for proper crimp location.

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

For the Battery Power Tool:

1. Cycle the Battery Power Tool to crimp the terminal to the wire.

2. Remove the crimped terminal from the terminal locator by pressing down on the wire stop and gently pulling on

the wire. The terminal locator can be in either position.

3. Visually inspect the crimped terminal for proper crimp location.

Maintenance

It is recommended that each operator of the tool be made aware of, and responsible for, the following maintenance

steps:

Fi ure 7

WIRE

INSULATION

PUNCH

CONDUCTOR ANVIL

LOCATOR

INSULATION

ANVIL

WIRES AGAINST

LOCATOR STOP

CONDUCTOR

PUNCH

TERMINAL

Tool Kit for MP-Lock™ Female Terminal

Doc No: ATS-63825 8HM Release Date: 07-23-12 UNCONTROLLED COPY Page 5 of 8

Revision: A Revision Date: 07-23-12

Fi ure 9

RETRACTOR

SLIDE

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 in the tool head are protected with a thin

coat of high quality machine oil. Do not oil

excessively. The use of light oil, such as 30 weight

automotive oil, every 5,000 crimps or monthly, will

significantly enhance the tool life and ensure a

stable calibration. See Figure 8A or 8B for

lubrication points.

. Store the tool in a clean and dry area when not in

use.

Miscrimps or Jams (Crimp Hand Tools Only)

(See Fi ure 12)

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 rotating the small slotted screw marked with an arrow. See Figure 12.

Miscrimps or Jams (Battery Powered Tools)

(See Fi ure 9)

Should this tool ever become stuck or jammed in a partially closed position, Do

Not force the power head open or closed. The ram can be retracted before the

crimping cycle is complete. To do this push the retractor slide towards the battery.

See Figure 9.

Warranty

This tool kit is for electrical terminal crimping purposes only. This tool kit 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 kit free of charge. This repair or exchange

will not be applicable to altered, misused, or damaged tools.

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.

. Use only the Molex terminals specified for crimping with this tool.

CAUTION: Repetitive use of this tool should be avoided.

Fi ure 8B

LUBRICATION

POINTS

(BOTH SIDES)

LIGHT OIL

(EVERY MONTH

5,000 CRIMPS)

Fi ure 8A

Tool Kit for MP-Lock™ Female Terminal

Doc No: ATS-63825 8HM Release Date: 07-23-12 UNCONTROLLED COPY Page 6 of 8

Revision: A Revision Date: 07-23-12

Certification

Molex does not certify or re-certify commercial grade 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.

% When the hand tool is no longer capable of achieving minimum pull force, it should be taken out of service and

replaced.

% This tool is very difficult to disassemble and reassemble. Customer repair is not recommended.

The chart below shows all applications for this Tool Kit.

Tool Kit

Order No.

Tool

Order no.

Tool

Description

Power

Head

Order No.

Adapter

Description

Fi ure

No.

63825- 870

6381

1050

Hand Crimp Frame (Short)

N/A

6381

100

Hand Crimp Frame (Long)

N/A

63816

0200

Battery Power

Tool (110 V)

63816

0300

Power

Crimp Head

63816

0250

Battery Power

Tool (220 V)

63816

0300

Power Crimp Head

Applications for the Tool Kit

Hand Crimp Tool

Battery Powered Tool

Fi ure

WARNING: NEVER operate service, install tool kits, or adjust the Power Crimp Head without proper instruction

and without first reading and understanding the instructions in the proper Manual or Specification Sheet. See

Chart above for the correct Manual or Specification Sheet.

WARNING: NEVER install tooling or service this tool while it is into any power source. Make sure the power is

turned off.

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.

POWER

CRIMP

HEAD

LOCKING PINS

BATTERY

POWERED

TOOL

TOOLING KIT

HAND CRIMP

FRAME LONG

AND SHORT

TOOLING KIT

Tool Kit for MP-Lock™ Female Terminal

Doc No: ATS-63825 8HM Release Date: 07-23-12 UNCONTROLLED COPY Page 7 of 8

Revision: A Revision Date: 07-23-12

RATCHET

RELEASE SCREW

Fi ure 12

M4 X 8mm

LONG BHCS

M4 X 18mm

LONG BHCS

M4 X 10mm

LONG BHCS

WITH TOOL KIT

LOCATOR ONLY

HAND TOOL PARTS LIST

Item Number

Order Number

Description

Quantity

63810

1000

Hand Crimp Frame (

Short

)

63825

Tool Kit with

Locator

63825

Locator (only)

Tool Kit for MP-Lock™ Female Terminal

Doc No: ATS-63825 8HM Release Date: 07-23-12 UNCONTROLLED COPY Page 8 of 8

Revision: A Revision Date: 07-23-12

Fi ure 13

Lon

BHCS

Lon

BHCS

Lon

BHCS

POWER HEAD PARTS LIST

Item

Order No

En ineerin No.

Description

Quantity

63816-0300 63816-0300 Power Crimp Head 1

63825- 870 63825- 870 Tool Kit with Locator 1

http://www.molex.com

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