molex 63825-4800 User manual

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
mm
In.
mm
In.
57990
57990
-
9710
20
-
26
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
0
mm (.0
2
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
mm
in.
mm
in.
mm
in.
mm
in.
N
Lb.
A
B
C
D
57990
20
0.50
0.99
-
1.09
.039
-
.0 3
1. 7-1.67 .058-.066
--
--
3. 6-3.66 .136-.1
68.6
15.
X
22
0.35
0.96
-
1.06
.038
-
.0 2
--
--
9.0
11.0
X
2
0.20
0.8
9
-
0.9
9
.03
5
-
.03
9
--
--
29.
6.6
X
26
012
0.85
-
0.95
.033
-
.037
--
--
19.
.
X

To Achieve IPC
-
A
-
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
2
ANVILS
POWER
CRIMP
HEAD
Fi ure
1
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
OR
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
0
-
1050
Hand Crimp Frame (Short)
N/A
N/A
10
6381
0
-
100
0
Hand Crimp Frame (Long)
N/A
N/A
10
63816
-
0200
Battery Power
Tool (110 V)
63816
-
0300
Power
Crimp Head
11
63816
-
0250
Battery Power
Tool (220 V)
63816
-
0300
Power Crimp Head
11
Applications for the Tool Kit
Hand Crimp Tool
Battery Powered Tool
Fi ure
10
Fi ure
11
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
2
1
1
M4 X 18mm
LONG BHCS
M4 X 10mm
LONG BHCS
2
3
WITH TOOL KIT
LOCATOR ONLY
HAND TOOL PARTS LIST
Item Number
Order Number
Description
Quantity
1
63810
-
1000
Hand Crimp Frame (
Short
)
1
2
63825
-
8
70
Tool Kit with
Locator
1
3
63825
-
8
75
Locator (only)
R
EF

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
1
2
2
M
4
by
8
Lon
BHCS
M
4
by
18
Lon
BHCS
M
4
by
10
Lon
BHCS
1
POWER HEAD PARTS LIST
Item
Order No
En ineerin No.
Description
Quantity
1
63816-0300 63816-0300 Power Crimp Head 1
2
63825- 870 63825- 870 Tool Kit with Locator 1
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