molex 63825-7570 User manual

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
F
orm
O
nly (3)
AWG
mm²
mm
In.
mm
In.
mm
In.
35725 35725-2710
35725-2740
10
5.25
3.80
-
4.55
.150
-
.179
5.30
.209
5.20-5.80 .205-.228
12
3.30
3.80
.150
5.30
.209
14
2.0
0
N/A
N/A
5.30
.209
(1)
To achieve optimum IPC
-
A620 insulation crimps, use this insulation OD rang
e.
(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
1
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
2
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
mm
2
mm
In.
mm
In.
A
B
C
35725
10
5.25
2.
60
-
2.
70
.10
2
-
.10
6
3.
7
0
-
3.
90
.14
6
-
.154
X
12
3.30
2.
15
-
2.
25
.08
5
-
.0
89
3.
7
0
-
3.
90
.14
6
-
.154
X
14
2.0
0
1.9
0
-
2.0
0
.07
5
-
.0
79
3.
7
0
-
3.
90
.14
6
-
.154
X
T rminal S ri s No.
Wir Siz
Insulation Crimp
Pull Forc Minimum
H ight
Width
AWG
mm
2
mm
In.
mm
In.
N
Lbs
35725
10
5.25
5.10
-
5.30
.201
-
.209
4.85
-
5.15
.1
91
-
.
203
343
77.1
12
3.30
4.
80
-
4.95
.189
-
.195
4.85
-
5.15
.1
91
-
.
203
290
65.2
14
2.00
4.50
-
4.65
.177
-
.183
4.85
-
5.15
.1
91
-
.
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
OR
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
0
-
1050
Hand Crimp Frame (Short)
N/A
N/A
9
6381
0
-
100
0
Hand Crimp Frame (Long)
N/A
N/A
9
63816
-
0200
Battery Power
Tool (110 V)
63816
-
0300
Power Crimp Head
10
63816
-
0250
Battery Power
Tool (220 V)
63816
-
0300
Power Crimp Head
10
Applications for th Tool Kit
Hand Crimp Tool
Batt ry Pow r d Tool
Figur
7
Figur
8
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
2
1
3
M4 X 18mm
LONG BHCS
M4 X 10mm
LONG BHCS
2
4
WITH TOOL KIT
LOCATOR ONLY
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
-
75
70
Tool Kit with
Locator
1
3
63811
-
47
7
3
Locator Base
1
4
63825
-
75
75
Locator (o
nly)
R
EF

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
1
2
2
M
4
by
8
Long
BHCS
M
4
by
18
Long
BHCS
M
4
by
10
Long
BHCS
1
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
63825-7570 63825-7570 Tool Kit with Locator 1
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