Molex 63825-7570 Manuel utilisateur

Tool Kit for 250 Slip-in Receptacle Terminals

Doc No: ATS-6382575H Release Date: 05-17-13 UNCONTROLLED COPY Page 1 of 8

Revision:A Revision Date: 05-17-13

INSULATION

CRIMP

BRUSH

STRIP LENGTH

CONDUCTOR

CRIMP HEIGHT

FRONT

CUT-OFF TAB

SEAM

BELL MOUTH

WIRE

Application Tooling

Sp cification Sh t

Tool Kit

Ord r No. 63825-7570

Hand Crimp Tool

Ord r No. 63825-7500

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.

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

 This tool is IPC/WH A-A-620 Class 2 and RoHS compliant.

SCOPE

Products: .250 Slip-on Receptacle Terminals for 10-14 AWG Wire.

T rminal

S ri s No.

T rminal Ord r No.

Wir Siz

Insulation Diam t r

Strip L ngth

IPC/WHMA-A620 (1)

T rminal

Insulation

Maximum (2)

R l

orm

nly (3)

AWG

mm²

In.

35725 35725-2710

35725-2740

5.25

3.80

4.55

.150

.179

5.30

.209

5.20-5.80

.205-.228

3.30

3.80

.150

5.30

.209

2.0

N/A

5.30

.209

(1)

To achieve optimum IPC

A620 insulation crimps, use this insulation OD rang

(2) Overall insulation OD specification for terminal.

(3) The terminals above are reeled parts only. Customer to cut off terminal from reel: 0.50 mm (.020”) maximum

DEFINITION OF TERMS

TYPE 4C

Tool Kit for 250 Slip-in Receptacle Terminals

Doc No: ATS-6382575H Release Date: 05-17-13 UNCONTROLLED COPY Page 2 of 8

Revision:A Revision Date: 05-17-13

ANVILS

POWER

CRIMP

HEAD

Figur

PUNCHES

M4 X 10 LONG

BHCS

M4 X 18 LONG

BHCS

SWING

LOCATOR

OPEN

PRESS DOWN

ON THE BRASS

PIVOT SHAFT

LIFT UP ON

THE LOCATOR

Figur

CONDITIONS:

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

T rminal S ri s No.

Wir Siz

Conductor Crimp

Profil

H ight

Width

AWG

In.

35725

5.25

.10

.14

.154

3.30

.08

.14

.154

2.0

1.9

2.0

.07

.14

.154

T rminal S ri s No.

Wir Siz

Insulation Crimp

Pull Forc Minimum

H ight

Width

AWG

In.

Lbs

35725

5.25

5.10

5.30

.201

.209

4.85

5.15

203

343

77.1

3.30

4.95

.189

.195

4.85

5.15

203

290

65.2

2.00

4.50

4.65

.177

.183

4.85

5.15

203

190

42.7

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.

Not :

A crimp height chart is provided with this manual as Reference Only. Due to the wide range of wires, strands,

insulation diameters, and durometers, 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.

CAUTION: Install only olex 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:

Tool Kit for 250 Slip-in Receptacle Terminals

Doc No: ATS-6382575H Release Date: 05-17-13 UNCONTROLLED COPY Page 3 of 8

Revision:A Revision Date: 05-17-13

Figur 4

WIRE IN TERMINAL

JAWS

PARTIALLY

CLOSED

WIRE AGAINST

WIRE STOP

HANDLE

OPEN

LOCATOR

CLOSED

Figur 3

TERMINAL

PUSH HERE TO

OPEN WIRE STOP

Anvils and Punch s Installation

1. Insert the Anvils into the bottom slots of the nest. Install the 4 x 10 long BHCS and tighten in place.

2. Insert the Punches into the top slots of the nest. Install the 4 x 18 long BHCS and tighten in place. See

Figure 1.

Locator Installation and R moval

Follow the steps below to install or replace the locator. See Figure 2.

To install th locator

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

To r mov th 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.

Crimping T rminals

1. Select the desired terminal listed in the

preceding charts.

2. Some terminals with large insulation grips may

interfere with the crimp tooling when swinging

the locator into position. This terminal must

then be loaded into the locator in the

closed/crimp position. See Figure 3.

3. Press down on the wire stop on the locator as

shown in Figure1. Insert the proper terminal

into the proper nest opening. ake sure when

choosing the nest opening, it will correspond with the A, B or C profile on the hand tool.

Figur 5

WIRE

INSULATION

PUNCH

CONDUCTOR ANVIL

LOCATOR

INSULATION

ANVIL

WIRES AGAINST

LOCATOR STOP

CONDUCTOR

PUNCH

TERMINAL

Tool Kit for 250 Slip-in Receptacle Terminals

Doc No: ATS-6382575H Release Date: 05-17-13 UNCONTROLLED COPY Page 4 of 8

Revision:A Revision Date: 05-17-13

4. Insert the proper wire over the terminal.

5. Gently touch the wire stop with the end of the wire. See Figure 4 and 5.

6. Compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.

Release handles to open the jaws.

7. 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.

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

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

For th Batt ry Pow r 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.

Maint nanc

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. ake 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. This tool was engineered for durability, but like any fine piece of

equipment, it needs cleaning and lubrication for a maximum service life of trouble-free crimping. 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 6A or 6B for lubrication points.

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

Miscrimps or Jams for Crimp Hand Tools Only (S Figur 9)

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 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: olex crimp specifications are valid only when used with olex terminals and tooling.

LUBRICATION

POINTS

(BOTH SIDES)

LIGHT OIL

(EVERY MONTH

5,000 CRIMPS)

Figur 6A

Figur 6B

Tool Kit for 250 Slip-in Receptacle Terminals

Doc No: ATS-6382575H Release Date: 05-17-13 UNCONTROLLED COPY Page 5 of 8

Revision:A Revision Date: 05-17-13

CAUTIONS

1. anually 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 olex terminals specified for crimping with this tool.

CAUTION: Repetitive use of this tool should be avoided.

C rtification

olex 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 olex 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.

Tool Kit for 250 Slip-in Receptacle Terminals

Doc No: ATS-6382575H Release Date: 05-17-13 UNCONTROLLED COPY Page 6 of 8

Revision:A Revision Date: 05-17-13

The chart below shows all applications for this Tool Kit.

Tool Kit

Ord r No.

Tool

Ord r no.

Tool

D scription

Pow r

H ad

Ord r No.

Adapt r

D scription

Figur

No.

63825-7570

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 th Tool Kit

Hand Crimp Tool

Batt ry Pow r d Tool

Figur

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 anual or

Specification Sheet. See Chart above for the correct anual or Specification Sheet.

WARNING: NEVER install tooling or service this tool while it is into any power source. ake 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 250 Slip-in Receptacle Terminals

Doc No: ATS-6382575H Release Date: 05-17-13 UNCONTROLLED COPY Page 7 of 8

Revision:A Revision Date: 05-17-13

RATCHET

RELEASE SCREW

Figur 9

M4 X 8mm

LONG BHCS

M4 X 18mm

LONG BHCS

M4 X 10mm

LONG BHCS

WITH TOOL KIT

LOCATOR ONLY

HAND TOOL PARTS LIST

It m Numb r

Ord r Numb r

D scription

Quantity

63810

1000

Hand Crimp Frame (Long)

63825

Tool Kit with

Locator

63811

Locator Base

63825

Locator (o

nly)

Tool Kit for 250 Slip-in Receptacle Terminals

Doc No: ATS-6382575H Release Date: 05-17-13 UNCONTROLLED COPY Page 8 of 8

Revision:A Revision Date: 05-17-13

Figur 10

Long

BHCS

Long

BHCS

Long

BHCS

POWER HEAD PARTS LIST

It m

Ord r No

Engin ring No.

D scription

Quantity

63816-0300 63816-0300 Power Crimp Head 1

63825-7570 63825-7570 Tool Kit with Locator 1

Visit our Web site at http://www.molex.com

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