Molex 63825-6770 Manuale utente

Tool Kit for P-Lock Flag Female Terminal

Doc No: ATS-6382567 M Release Date: 03-19-13 UNCONTROLLED COPY Page 1 of 8

Revision: A Revision Date: 03-19-13

STRIP LENGTH

INSULATION CRIMP

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR CRIMP

TWISTING

CUT-OFF TAB

SEAM

Application Tooling

Sp cification Sh t

Tool Kit

Ord r No. 63825-6770

Hand Crimp Tool

Ord r No. 63825-6700

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 and Crimp Tool or the 63816-0300 Power Crimp ead 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/W MA-A-620 Class 2 and Ro S compliant.

 Separate Punch set for 24 AWG wire and separate punch set for 2 x 24 AWG wires, one anvil set.

SCOPE

Products: 2.8 (.110”) P-Lock Flag Terminal 24 AWG and 24 + 24 AWG.

T rminal

S ri s No.

T rminal Ord r No.

 Availabl in R l form only

Wir Siz

Insulation Diam t r

Strip L ngth

T rminal



AWG

mm²

In.

104442 104442-9702

N/A

1.45

1.55

.057

.061

3.40-3.90 .134-.154

24 + 24

N/A

1.00

.039

.051

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

 Overall insulation OD specification for terminal.

DEFINITION OF TERMS

TYPE 4C

Tool Kit for P-Lock Flag Female Terminal

Doc No: ATS-6382567 M Release Date: 03-19-13 UNCONTROLLED COPY Page 2 of 8

Revision: A Revision Date: 03-19-13

ANVILS

POWER

CRIMP

HEAD

Figur

PUNCHES

M4 X 8 LONG

BHCS

M4 X 18 LONG

BHCS

HAND TOOL

OPEN

TERMINAL

Figur 2

NEST

CONDITIONS:

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

T rminal

S ri s No.

Wir Siz

Conductor Crimp

Insulation Crimp

Pull Forc

Minimum

● Punch

S t

H ight

Width

(R f)

H ight

Width

(R f)

AWG

In.

Lbs

104442

N/A

0.85

0.95

.033

.037

1.60

.063

---

29.4

6.6

24 + 24

N/A

1.00

1.10

.039

.043

1.60

.063

---

29.4

6.6

●

Pag 3, Figur 3 to d t rmin which Punch S t to us for ach wir awg.

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 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 ead follow the steps below:

Anvils and Punch s Installation

1. Insert the Anvils into the bottom slots of the nest. Install the M4 x 8 long B CS and tighten in place.

2. Insert the Punches into the top slots of the nest. Install the M4 x 18 long B CS and tighten in place. See

Figure 1.

Tool Kit for P-Lock Flag Female Terminal

Doc No: ATS-6382567 M Release Date: 03-19-13 UNCONTROLLED COPY Page 3 of 8

Revision: A Revision Date: 03-19-13

MARKING FOR

AWG 24

Figur 3

TERMINAL IN NEST

MARKING FOR

2x AWG 24

TERMINAL IN NEST

WIRE

INSULATION

PUNCH

CONDUCTOR

ANVIL

INSULATION

ANVIL

CONDUCTOR

PUNCH

TERMINAL

Figur 4

PARTIALLY

CLOSED

WIRE

TERMINAL

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. Insert the terminal centered in the proper nest and up against the terminal stop.

3. ● If using a 24 AWG wire, load in the profile marked A from the front. See Figure 2.

4. ● If using a 24 + 24 AWG wires, load in the profile marked B from the front.

5. Lower tooling nest does not change.

6. Make sure when choosing the nest opening, it will correspond with the A or B profile on the hand tool. See

Figure 3.

7. Partially close the tool to hold the terminal in place.

8. Insert the properly stripped wire into the insulation crimp nest. See Figure 4.

9. Now close the handle completely and release. The jaws will open when the tool has fully closed.

10. Make sure the insulation grips wrapped snug around the insulation of the wire.

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

Tool Kit for P-Lock Flag Female Terminal

Doc No: ATS-6382567 M Release Date: 03-19-13 UNCONTROLLED COPY Page 4 of 8

Revision: A Revision Date: 03-19-13

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. 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. 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 5A or 5B 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 8)

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 8.

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.

LUBRICATION

POINTS

(BOTH SIDES)

LIGHT OIL

(EVERY MONTH

5,000 CRIMPS)

Figur 5A

Figur 5B

Tool Kit for P-Lock Flag Female Terminal

Doc No: ATS-6382567 M Release Date: 03-19-13 UNCONTROLLED COPY Page 5 of 8

Revision: A Revision Date: 03-19-13

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.

CAUTION: Repetitive use of this tool should be avoided.

C rtification

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 andbook 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 P-Lock Flag Female Terminal

Doc No: ATS-6382567 M Release Date: 03-19-13 UNCONTROLLED COPY Page 6 of 8

Revision: A Revision Date: 03-19-13

HAND CRIMP

FRAME LONG

AND SHORT

TOOLING

KIT

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.

63825-6770

6381

1050

and Cr

imp Frame (Short)

N/A

6381

100

and Crimp Frame (Long)

N/A

63816

0200

Battery Power

Tool (110 V)

63816

0300

Power Crimp ead

63816

0250

Battery Power

Tool (220 V)

63816

0300

Power Crimp ead

Applications for th Tool Kit

Hand Cri

mp Tool

Batt ry Pow r d Tool

Figur

WARNING: NEVER operate service, install tool kits, or adjust the Power Crimp ead 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

Tool Kit for P-Lock Flag Female Terminal

Doc No: ATS-6382567 M Release Date: 03-19-13 UNCONTROLLED COPY Page 7 of 8

Revision: A Revision Date: 03-19-13

RATCHET

RELEASE SCREW

Figur 8

M4 X 18mm

LONG BHCS

M4 X 12mm

LONG BHCS

HAND TOOL PARTS LIST

It m Numb r

Ord r Numb r

D scription

Quantity

63810

1000

and Crimp Frame (Long)

63825

Tool Kit

Tool Kit for P-Lock Flag Female Terminal

Doc No: ATS-6382567 M Release Date: 03-19-13 UNCONTROLLED COPY Page 8 of 8

Revision: A Revision Date: 03-19-13

Figur 9

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 ead

63825

Tool Kit

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

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