hand crimp tool for ?kk ? .156 center terminals doc no. ats-638117500 release date: 12-06-06 uncontrolled copy page 1 of 7 revision: c revision date: 03-29-08 type 2c hand crimp tool specification sheet order no. 63811-7500 features a full cycle ratcheting hand tool ensures complete crimps ergonomic soft grip handles for comfortable crimpin g a precision user-friendly terminal locator wire sto p holds terminals in the proper crimping position this tool is ipc/whma-a-620 class 2 and rohs compli ant as indicated. scope products: 3.96mm (.156") pitch kk? crimp terminal for 18-24 awg terminal order no. wire size insulation diameter strip length terminal series no. loose piece reel awg mm2 mm in. mm in. 2477 08-50-0109 08-56-0113 08-50-0110 08-56-0114 18-24 0.80-0.20 1.39-2.79 .055-.110 2.54-3.17 .100-.125 08-50-0006 08-53-0812 08-50-0001 08-52-0046 08-50-0016 08-55-0104 08-50-0014 08-52-0071 08-50-0045 08-55-0134 08-50-0015 08-52-0073 08-50-0046 08-56-0106 08-50-0047 08-52-0114 08-50-0056 08-56-0154 08-50-0055 08-53-0004 08-50-0064 08-58-0104 08-50-0063 08-53-0811 08-50-0074 08-58-0115 08-50-0073 08-55-0103 08-50-0093 08-58-0122 08-50-0091 08-55-0133 08-50-0106 08-65-0115 08-50-0103 08-56-0105 08-50-0120 40-01-1120 08-50-0119 08-56-0153 08-50-0147 50-29-1762 08-50-0146 08-58-0103 08-52-0024 50-30-4428 08-50-0271 08-58-0114 08-52-0045 50-30-4429 08-50-0281 08-58-0121 08-52-0047 08-51-0000 08-65-0114 08-52-0072 08-51-0720 40-01-1118 08-52-0074 08-52-0023 50-29-1689 08-52-0115 08-52-0027 50-29-1768 2478 08-52-0812 08-52-0044 18-24 0.80-0.20 1.39-2.79 .055-.110 2.54-3.17 .100-.125 08-50-0116 08-50-0115 08-55-0138 08-52-0127 08-51-0109 08-58-0127 08-58-0128 08-52-0126 08-65-0118 2878 08-65-0119 08-53-0814 18-20 0.80-0.50 1.52-2.79 .060-.110 2.54-3.17 .100-.125 08-50-0132 08-55-0143 08-50-0131 08-55-0142 08-55-0140 08-55-0146 08-55-0125 08-55-0145 4838 08-55-0141 08-55-0148 08-55-0139 08-55-0147 18-22 0.80-0.35 1.52-2.41 .060-.095 2.54-3.17 .100-.125 5167 08-70-0013 08-70-1034 08-70-0012 08-70-0097 18-24 0.80-0.20 1.39-2.48 .055-.098 2.54-3.17 .100-.125 08-50-0165 08-56-0139 08-50-0164 08-53-0813 08-51-0802 08-51-0801 08-56-0135 6438 08-56-0133 08-51-0813 08-56-0137 18-20 0.80-0.50 1.52-2.41 .060-.095 2.54-3.17 .100-.125
hand crimp tool for ?kk ? .156 center terminals doc no. ats-638117500 release date: 12-06-06 uncontrolled copy page 2 of 7 revision: c revision date: 03-29-08 insulation crimp brush strip length bell mouth crimp height bend down bend up rolling locking tang height twisting cut - off tab seam conductor crimp 08-50-0029 08-58-0119 08-50-0024 08-58-0105 08-50-0189 08-58-0132 08-50-0026 08-58-0108 08-50-0251 08-58-0189 08-50-0028 08-58-0110 08-51-0107 08-60-0002 08-50-0187 08-58-0118 08-52-0113 50-29-1763 08-50-0275 08-58-0131 08-53-1102 50-29-1879 08-51-0106 08-58-0187 08-58-0106 08-52-0112 08-60-0001 08-58-0109 08-53-1101 50-29-1639 6838 08-58-0111 08-58-0102 18-20 0.80-0.50 1.52-2.79 .060-.110 2.54-3.17 .100-.125 08-50-0023 08-58-0136 08-50-0008 08-58-0135 08-50-0706 08-65-0129 08-50-0705 08-65-0128 08-52-0132 08-52-0131 40-01-1181 8818 08-56-0188 08-56-0187 40-01-1182 18 - 22 0.80-0.35 1.52-2.79 .060-.110 2.54-3.17 .100-.125 8993 08-50-0276 08-50-0011 08-50-0277 18-24 0.80-0.20 1.39-2.79 .055-.110 2.54-3.17 .100-.125 customer to cut off terminal from reel: 2.72 .13mm (.107 .005?) maximum cut-off tab. see conditions on page 3. definition of terms the above terminal drawing is a generic terminal re presentation. it is not an image of a terminal lis ted in the scope. conditions: after crimping, the conductor profiles should measu re the following (see notes on page 5). punch width (ref) wire size conductor crimp height (ref) conductor insulation pull force minimum profile termina series no. hand tool locator awg mm 2 mm in. mm in. mm in. n lb. a b 18 0.80 1.01-1.11 .040-.044 2.00 .079 2.50 .098 89. 0 20.00 x 20 0.50 1.01-1.11 .040-.044 2.00 .079 2.50 .098 57. 8 13.00 x 22 0.35 0.86-0.96 .034-.038 2.00 .079 2.50 .098 35. 6 8.00 x 2477 black 24 0.20 0.86-0.96 .034-.038 2.00 .079 2.50 .098 22. 2 5.00 x 18 0.80 1.01-1.11 .040-.044 2.00 .079 2.50 .098 89. 0 20.00 x 20 0.50 1.01-1.11 .040-.044 2.00 .079 2.50 .098 57. 8 13.00 x 2478 black 22 0.35 0.86-0.96 .034-.038 2.00 .079 2.50 .098 35. 6 8.00 x
hand crimp tool for ?kk ? .156 center terminals doc no. ats-638117500 release date: 12-06-06 uncontrolled copy page 3 of 7 revision: c revision date: 03-29-08 punch width (ref) wire size conductor crimp height (ref) conductor insulation pull force minimum profile termina series no. hand tool locator awg mm 2 mm in. mm in. mm in. n lb. a b 24 0.20 0.86-0.96 .034-.038 2.00 .079 2.50 .098 22. 2 5.00 x 18 0.80 1.01-1.11 .040-.044 2.00 .079 2.50 .098 89. 0 20.00 x 2878 black 20 0.50 1.01-1.11 .040-.044 2.00 .079 2.50 .098 57. 8 13.00 x 18 0.80 1.01-1.11 .040-.044 2.00 .079 2.50 .098 89. 0 20.00 x 20 0.50 1.01-1.11 .040-.044 2.00 .079 2.50 .098 57. 8 13.00 x 4838 black 22 0.35 0.86-0.96 .034-.038 2.00 .079 2.50 .098 35. 6 8.00 x 18 0.80 1.01-1.11 .040-.044 2.00 .079 2.50 .098 89. 0 20.00 x 20 0.50 1.01-1.11 .040-.044 2.00 .079 2.50 .098 57. 8 13.00 x 22 0.35 0.86-0.96 .034-.038 2.00 .079 2.50 .098 35. 6 8.00 x 5167 black 24 0.20 0.86-0.96 .034-.038 2.00 .079 2.50 .098 22. 2 5.00 x 18 0.80 1.01-1.11 .040-.044 2.00 .079 2.50 .098 89. 0 20.00 x 6438 black 20 0.50 1.01-1.11 .040-.044 2.00 .079 2.50 .098 57. 8 13.00 x 18 0.80 1.01-1.11 .040-.044 2.00 .079 2.50 .098 89. 0 20.00 x 6838 black 20 0.50 1.01-1.11 .040-.044 2.00 .079 2.50 .098 57. 8 13.00 x 18 0.80 1.01-1.11 .040-.044 2.00 .079 2.50 .098 89. 0 20.00 x 20 0.50 1.01-1.11 .040-.044 2.00 .079 2.50 .098 57. 8 13.00 x 8818 gray 22 0.35 0.86-0.96 .034-.038 2.00 .079 2.50 .098 35. 6 8.00 x 18 0.80 1.01-1.11 .040-.044 2.00 .079 2.50 .098 89. 0 20.00 x 20 0.50 1.01-1.11 .040-.044 2.00 .079 2.50 .098 57. 8 13.00 x 22 0.35 0.86-0.96 .034-.038 2.00 .079 2.50 .098 35. 6 8.00 x 8993 black 24 0.20 0.86-0.96 .034-.038 2.00 .079 2.50 .098 22. 2 5.00 x to achieve ipc-a-620 class 2 crimps, the following over-all wire insulation diameter ranges are recom mended: 1. profile a: 1.68mm (.066 inch max.)-up to the maximu m terminal rating. 2. profile b: 1.39-2.38mm (.055-.094 inch) operation caution: install only molex terminals listed above with this tool. do not crimp hardened objects as damage can occur to the tool or die. open the tool by squeezing the handles together, at the end of the closing stroke, the ratchet mechani sm will release the handles, and the hand tool will spring open. crimping terminals 1. select the desired terminal listed in the preceding charts. make sure that the proper locator is mounted on the tool . 2. swing the terminal locator away from the crimp tool shown in figure 2. some terminals with large insulation gri ps may interfere with the crimp tooling when swinging the locator into position. the terminal must then be loaded into th e locator in the closed/crimp position. 3. press down on the wire stop on the locator as shown in figure 2. insert the proper terminal into the proper nest opening. make sure when choosing the nest opening, it will c orrespond with the a or b profile on the hand tool. figure 1 locator jaws open
hand crimp tool for ?kk ? .156 center terminals doc no. ats-638117500 release date: 12-06-06 uncontrolled copy page 4 of 7 revision: c revision date: 03-29-08 swing open terminal push here to open wire stop locator locator terminal in place f igure 2 locator in place wire stop terminal wire wire stop wire against stop figure 3 4. return the locator to its original position. 5. insert the proper wire over the terminal. gently t ouch the wire stop with the end of the wire. see f igure 3. 6. compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been complet ed. release handles to open the jaws. note: the tamper proof ratchet action will not rele ase the tool until it has been fully closed. 7. remove the crimped terminal from the terminal locat or by pressing down on the wire stop and gently pul ling on the wire. the terminal locator can be in either po sition. 8. visually inspect the crimped terminal for proper cr imp location. note: a crimp height chart is provided with this manual a s reference only. due to the wide range of wires, strands, insulation diameters, and durometers, actual crimp height measurements may very slightly. an occasional, des tructive, pull force test should be preformed to check hand tool c rimp. pull force value must exceed the minimum pull force specifications listed on page 2 and 3. locator change over two styles of locators are provided with the crimp hand tool 63811-7500. they are 63811-7576, which is black an d 63811- 7575, which is gray. make sure the correct locator is installed for the proper terminal and wire. follow the steps bel ow to change the locators. swing locator open press down on brass pivot shaft lift up locator jaws open figure 4
hand crimp tool for ?kk ? .156 center terminals doc no. ats-638117500 release date: 12-06-06 uncontrolled copy page 5 of 7 revision: c revision date: 03-29-08 1. open the crimp hand tool. 2. swing the existing locator open and away from the h and tool. 3. firmly press down on the brass pivot shaft with you r thumb, while pulling the locator up. slip the locator off the t op of the brass pivot shaft. see figure 4. 4. replace it with the desired locator by putting over the brass pivot shaft and snapping it into place. 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 sur faces are protected with a thin coat of high qualit y machine oil. do not oil excessively. the tool was enginee red for durability but like any fine piece of equip ment it needs cleaning and lubrication for a maximum servic e life of trouble free crimping. light oil such as 30 weight automotive oil used at the oil points, every 5,000 crimps or 3 months, , shown in figure 6 will significantly enhance the tool life. 4. wipe excess oil from hand tool, particularly from c rimping area. oil transferred from the crimping ar ea onto certain terminations may affect the electrical char acteristics of an application. 5. when tool is not in use, keep the handles closed to prevent objects from becoming lodged in the crimpi ng dies, and store the tool in a clean, dry area. miscrimps or jams 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 pressing the ratchet release lever. see figure 6. how to adjust tool preload ( see figure 6) this hand tool is factory preset to 25-45 lbs. prel oad. it may be necessary over the life of the tool to ad just tool handle preload force. listed below are the st eps required to adjust the crimping force of the hand t ool to obtain proper crimp conditions: 1. remove or fold back the handle grip from the handle to expose the eccentric axle and setting wheel. 2. remove the locking screw with a 2mm hex wrench. th e wrench set (63810-0101), is not supplied. it is sold separately from the hand tool. 3. turn the eccentric axle and setting wheel with the wrench or pliers counter-clockwise (ccw) to increas e handle force. 4. replace the locking screw, aligning the nearest not ch in the setting wheel to locking screw. 5. replace the handle grip. 6. check the crimp specifications or conduct a pull te st after tool handle preload force is adjusted. lubrication points (both sides) light oil (every 3 months or 5,000 crimps) figure 5 ratchet release lever figure 6 handle grip removed eccentric axle han dle grip locking screw wrench set (sold seperately) preload check point 25.4mm setting wheel
hand crimp tool for ?kk ? .156 center terminals doc no. ats-638117500 release date: 12-06-06 uncontrolled copy page 6 of 7 revision: c revision date: 03-29-08 warranty this tool is for electrical terminal crimping purpo ses only. this tool is made of the best quality ma terials. all vital components are long life tested. all tools are war ranted to be free of manufacturing defects for a pe riod of 30 days. should such a defect occur, we will repair o r exchange the tool free of charge. this repair or exchange will not be applicable to altered, misused, or damaged t ools. this tool is designed for hand use only. an y clamping, fixturing, or use of handle extensions voids this w arranty. caution : molex crimp specifications are valid only when u sed with molex terminals and tooling. cautions 1. manually powered hand tools are intended for low vo lume 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. certification molex does not certify or re-certify commercial gra de hand tools but rather supplies the following gui delines for customers to re-certify hand tools. % this tool is qualified to pull force only. to re-c ertify, 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 n o faster than 25mm (1.00?) per minute. see the molex web site fo r the quality crimp handbook for more information o n pull testing. % if the tool does not meet minimum pull force values , handle preload should be increased and the pull t est rerun, (see how to adjust preload). % when the hand tool is no longer capable of achievin g minimum pull force, it should be taken out of ser vice and replaced.
hand crimp tool for ?kk ? .156 center terminals doc no. ats-638117500 release date: 12-06-06 uncontrolled copy page 7 of 7 revision: c revision date: 03-29-08 parts list item number order number description quantity ref 63811-7500 hand crimp tool figure 7 1 63810-0101 wrench set (not included) 0 2 63810-0102 locator base assembly 1 3 63810-0103 repair kit (not included) 0 63811-7576 locator-black 1 4 63811-7575 locator-gray 1 americas headquarters lisle, illinois 60532 u.s.a. 1-800-78molex amerinfo@molex.com far east north headquarters yamato, kanagawa, japan 81-462-65-2324 feninfo@molex.com far east south headquarters jurong, singapore 65-6-268-6868 fesinfo@molex.com european headquarters munich, germany 49-89-413092-0 eurinfo@molex.com corporate headquarters 2222 wellington ct. lisle, il 60532 u.s.a. 630-969-4550 fax: 630-969-1352 visit our web site at http://www.molex.com ratchet release lever 2 figure 7 m4 x 5lg bhcs 3 4 1 3
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