molex 63825-6770 User manual

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
m
m
In.
mm
In.
104442 104442-9702
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-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
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
104442
24
N/A
0.85
-
0.95
.033
-
.037
1.60
.063
---
---
---
---
29.4
6.6
X
24 + 24
N/A
1.00
-
1.10
.039
-
.043
1.60
.063
---
---
---
---
29.4
6.6
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 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
OR
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
0
-
1050
and Cr
imp Frame (Short)
N/A
N/A
6
6381
0
-
100
0
and Crimp Frame (Long)
N/A
N/A
6
63816
-
0200
Battery Power
Tool (110 V)
63816
-
0300
Power Crimp ead
7
63816
-
0250
Battery Power
Tool (220 V)
63816
-
0300
Power Crimp ead
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 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
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
and Crimp Frame (Long)
1
2
63825
-
67
70
Tool Kit
1

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
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 ead
1
2
63825
-
67
70
63825
-
67
70
Tool Kit
1
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