Molex 63825-7470 User guide

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638257400 - HAND CRIMP TOOL

Excellent Integrated System Limited

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1 / 9

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638257400 - HAND CRIMP TOOL

Tool Kit for 250 Slip-in Receptacle Terminals

Doc No: ATS-6382574 M Release Date: 05-20-13 UNCONTROLLED COPY Page 1 of 8

Revision: A Revision Date: 05-20-13

INSULATION

CRIMP ▲

BRUSH

STRIP LENGTH

CONDUCTOR

CRIMP HEIGHT

FRONT

CUT-OFF TAB

SEAM

BELL MOUTH

WIRE

Application Toolin

Specification Sheet

Tool Kit

Order No. 63825-7470

Hand Crimp Tool

Order No. 63825-7400

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.

SCOPE

Products: .250 Slip-in Receptacle Terminals for 10-14 AWG wire.

Terminal

Series No.

Terminal Order No. Wire Size

Insulation Diameter

Strip Len th

IPC/WHMA-A620 (1)

Terminal Insulation

Maximum (2)

Reel Form Only (3)

AWG

m²

In.

35725 35725-3310

5.25

4.55

.179

3.80

5.00

.150

.197

4.40-4.80 .173-.189

3.30

4.4

.173

3.80

5.00

.150

.197

2.00

3.20

3.80

.126

.150

3.80

5.00

.150

.197

(1) To achieve optimum IPC

A620 insulat

ion crimps, use this insulation OD range.

(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

2 / 9

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638257400 - HAND CRIMP TOOL

Tool Kit for 250 Slip-in Receptacle Terminals

Doc No: ATS-6382574 M Release Date: 05-20-13 UNCONTROLLED COPY Page 2 of 8

Revision: A Revision Date: 05-20-13

▲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 Crimp

Profile

Hei ht

Width

(Ref)

AWG

In.

35725

5.25

.096

.100

1.42

3.30

.081

.085

1.42

2.00

1.8

.069

.073

1.42

Terminal Series No.

Wire Size

Insulation Crimp

Pull Force Minimum

Hei ht

(Ref)

Width

(Ref)

AWG

In.

Lbs

35725

5.25

5.30

.209

5.00

.197

353

79.4

3.30

4.50

.177

4.70

.185

294

66.1

2.00

4.40

.173

4.40

.173

275

61.8

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.

Note:

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:

OVERLAP

INSULATION

CRIMP

OVERLAP FORM GEOMETRY

ANVIL

PUNCH

WIRE

3 / 9

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638257400 - HAND CRIMP TOOL

Tool Kit for 250 Slip-in Receptacle Terminals

Doc No: ATS-6382574 M Release Date: 05-20-13 UNCONTROLLED COPY Page 3 of 8

Revision: A Revision Date: 05-20-13

SWING

LOCATOR

OPEN

PRESS DOWN

ON THE BRASS

PIVOT SHAFT

LIFT UP ON

THE LOCATOR

Fi ure

ANVILS

POWER

CRIMP

HEAD

Fi ure

PUNCHES

M4 X 10 LONG

BHCS

M4 X 18 LONG

BHCS

Anvils and Punches Installation

1. Insert the Anvils into the bottom slots of the nest.

Install the M4 x 10 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.

Locator Installation and Removal

Follow the steps below to install or replace the

locator. See Figure 2.

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.

3. Swing the terminal locator away from the crimp tool

shown in Figure 4. 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.

4. Press down on the wire stop on the locator as shown in

Figure1. 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.

5. Return the locator to its original position.

6. Turn the Locator Lock Latch up to lock. Make sure that the terminal is visually centered over the punch.

Fi ure 3

LATCH LOCKED

LATCH UNLOCKED

4 / 9

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638257400 - HAND CRIMP TOOL

Tool Kit for 250 Slip-in Receptacle Terminals

Doc No: ATS-6382574 M Release Date: 05-20-13 UNCONTROLLED COPY Page 4 of 8

Revision: A Revision Date: 05-20-13

SWING OPEN

TERMINAL

PUSH HERE TO

OPEN WIRE STOP

LOCATOR

TERMINAL

IN PLACE

Fi ure 4

LOCATOR LATCH

IN OPEN POSITION

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

Fi ure 7

WIRE

INSULATION

PUNCH

CONDUCTOR

ANVIL

LOCATOR

INSULATION ANVIL

WIRES AGAINST

LOCATOR STOP

CONDUCTOR

PUNCH

TERMINAL

7. Insert the proper wire over the terminal.

8. Gently touch the wire stop with the end of the wire. See Figure 6 and 7.

9. Compress the terminal by squeezing the tool handles

until the ratchet mechanism cycle has been completed.

Release handles to open the jaws.

10. 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.

11. 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.

5 / 9

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638257400 - HAND CRIMP TOOL

Tool Kit for 250 Slip-in Receptacle Terminals

Doc No: ATS-6382574 M Release Date: 05-20-13 UNCONTROLLED COPY Page 5 of 8

Revision: A Revision Date: 05-20-13

Maintenance

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 8A

or 8B 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 (See Figure 11)

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 11.

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.

4. Use only the Molex terminals specified for crimping with this tool.

CAUTION: Repetitive use of this tool should be avoided.

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

LUBRICATION

POINTS

(BOTH SIDES)

LIGHT OIL

(EVERY MONTH

5,000 CRIMPS)

Fi ure 8A

Fi ure 8B

6 / 9

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638257400 - HAND CRIMP TOOL

Tool Kit for 250 Slip-in Receptacle Terminals

Doc No: ATS-6382574 M Release Date: 05-20-13 UNCONTROLLED COPY Page 6 of 8

Revision: A Revision Date: 05-20-13

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.

The chart below shows all applications for this Tool Kit.

Tool Kit

Order No.

Tool

Order no.

Tool

Description

wer

Head

Order No.

Adapter

Description

Fi ure

No.

63825-7470

6381

1050

and Crimp 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

Too

l (220 V)

63816

0300

Power Crimp ead

Applications for the Tool Kit

Hand Crimp Tool

Battery Powered Tool

Fi ure

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

HAND CRIMP

FRAME LONG

AND SHORT

TOOLING KIT

7 / 9

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638257400 - HAND CRIMP TOOL

Tool Kit for 250 Slip-in Receptacle Terminals

Doc No: ATS-6382574 M Release Date: 05-20-13 UNCONTROLLED COPY Page 7 of 8

Revision: A Revision Date: 05-20-13

RATCHET

RELEASE SCREW

Fi ure 11

M4 X 8mm

LONG BHCS

M4 X 18mm

LONG BHCS

M4 X 10mm

LONG BHCS

WITH TOOL KIT

LOCATOR ONLY

HAND TOOL PARTS LIST

Item Number

Order Number

Description

Quantity

63810

1000

and Crimp Frame (Long)

63825

Tool Kit with

Locator

63811

Locator Base

63825

Locator (only)

8 / 9

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638257400 - HAND CRIMP TOOL

Tool Kit for 250 Slip-in Receptacle Terminals

Doc No: ATS-6382574 M Release Date: 05-20-13 UNCONTROLLED COPY Page 8 of 8

Revision: A Revision Date: 05-20-13

Fi ure 12

Lon

BHCS

Lon

BHCS

Lon

BHCS

POWER HEAD PARTS LIST

Item

Order No

En ineerin No.

Description

Quantity

63816-0300 63816-0300 Power Crimp ead 1

63825-7470 63825-7470 Tool Kit with Locator 1

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

9 / 9

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