molex 63825-6670 User manual

Tool Kit for P-Lock Flag Female Terminal
Doc No: ATS-6382566H Release Date: 01-27-13 UNCONTROLLED COPY Page 1 of 8
Revision: A Revision Date: 01-27-13
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. 63825-6670
Hand Crimp Tool
Ord r No. 63825-6600
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.
 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
m
m
In.
mm
In.
104441 104441-9702
24
N/A
1.45
-
1.55
.057
-
.061
3.40-3.90 .134-.154
24 + 24
N/A
1.00
-
1.
30
.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-6382566H Release Date: 01-27-13 UNCONTROLLED COPY Page 2 of 8
Revision: A Revision Date: 01-27-13
ANVILS
POWER
CRIMP
HEAD
Figur
1
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
mm
2
mm
In.
mm
In.
mm
In.
mm
In.
N
Lbs
A
B
104441
24
N/A
0.85
-
0.95
.033
-
.037
1.60
.063
---
---
---
---
49.0
11.0
X
24 + 24
N/A
0.95
-
1.05
.037
-
.041
1.60
.063
---
---
---
---
49.0
11.0
X
●
S
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 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:
Anvils and Punch s Installation
1. Insert the Anvils into the bottom slots of the nest. Install the 4 x 8 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.

Tool Kit for P-Lock Flag Female Terminal
Doc No: ATS-6382566H Release Date: 01-27-13 UNCONTROLLED COPY Page 3 of 8
Revision: A Revision Date: 01-27-13
MARKING FOR
AWG24
Figur 3
TERMINAL IN NEST
MARKING FOR
2x AWG24
TERMINAL IN NEST
Figur 4
PARTIALLY
CLOSED
WIRE
TERM
INAL
WIRE
INSULATION
PUNCH
CONDUCTOR
ANVIL
INSULATION
ANVIL
CONDUCTOR
PUNCH
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. ake 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. ake 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-6382566H Release Date: 01-27-13 UNCONTROLLED COPY Page 4 of 8
Revision: A Revision Date: 01-27-13
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. 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 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: olex crimp specifications are valid only when used with olex terminals and tooling.
LUBRICATION
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY MONTH
OR
5,000 CRIMPS)
Figur 5A
Figur 5B

Tool Kit for P-Lock Flag Female Terminal
Doc No: ATS-6382566H Release Date: 01-27-13 UNCONTROLLED COPY Page 5 of 8
Revision: A Revision Date: 01-27-13
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 P-Lock Flag Female Terminal
Doc No: ATS-6382566H Release Date: 01-27-13 UNCONTROLLED COPY Page 6 of 8
Revision: A Revision Date: 01-27-13
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.
63825-6670
6381
0
-
1050
Hand Cr
imp Frame (Short)
N/A
N/A
6
6381
0
-
100
0
Hand Crimp Frame (Long)
N/A
N/A
6
63816
-
0200
Battery Power
Tool (110 V)
63816
-
0300
Power Crimp Head
7
63816
-
0250
Battery Power
Tool (220 V)
63816
-
0300
Power Crimp Head
7
Applications for th Tool Kit
Hand Cri
mp Tool
Batt ry Pow r d Tool
Figur
6
Figur
7
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

Tool Kit for P-Lock Flag Female Terminal
Doc No: ATS-6382566H Release Date: 01-27-13 UNCONTROLLED COPY Page 7 of 8
Revision: A Revision Date: 01-27-13
RATCHET
RELEASE SCREW
Figur 8
2
1
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
1
63810
-
1000
Hand Crimp Frame (Long)
1
2
63825
-
66
70
Tool Kit
1

Tool Kit for P-Lock Flag Female Terminal
Doc No: ATS-6382566H Release Date: 01-27-13 UNCONTROLLED COPY Page 8 of 8
Revision: A Revision Date: 01-27-13
Figur 9
1
2
M
4
by
12
Long
BHCS
M
4
by
18
Long
BHCS
POWER HEAD PARTS LIST
It m
Ord r No
Engin ring No.
D scription
Quantity
1
63816
-
0300
63816
-
0300
Power Crimp Head
1
2
63825
-
66
70
63825
-
66
70
Tool Kit
1
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