Molex 63811-7400 User manual

Hand Crimp Tool for 3.96mm (.156") Pitch KK® Crimp Terminal

Doc No: ATS-638117400 Release Date: 10-31-06 UNCONTROLLED COPY Page 1 of 7

Revision: B Revision Date: 04-08-08

TYPE 2C

Hand Crimp Tool

Specification Sheet

Order No. 63811-7400

FEATURES



A full cycle ratcheting hand tool ensures complete crimps



Ergonomic soft grip handles for comfortable crimping



A precision user-friendly terminal locator wire stop holds terminals in the proper crimping position



This tool is IPC/WHMA-A-620 Class 2 and RoHS compliant

SCOPE

Products: 3.96mm (.156") Pitch KK® Crimp Terminal for 22-26 AWG

Terminal Order No. Wire Size Insulation Diameter Strip LengthTerminal

Series No.

Loose Piece



Reel AWG mm² mm In. mm In.

08-50-0019

08-56-0122

08-50-0018

08-56-0161

08-50-0062

08-56-0163

08-50-0061

08-56-0162

08-50-0066

08-58-0126

08-50-0065

08-58-0125

08-50-0108

08-60-0004

08-50-0107

08-59-0101

08-50-0112

08-65-0107

08-50-0111

08-60-0003

08-50-0134

08-65-0111

08-50-0133

08-65-0108

08-52-0117

08-65-0117

08-50-0504

08-65-0109

08-55-0106

40-01-1119

08-52-0116

08-65-0110

08-55-0132

40-07-1106

08-55-0105

08-65-0116

08-56-0108

50-29-1878

08-55-0121

40-01-1117

08-55-0123

40-07-1105

08-55-0137

50-29-1767

08-56-0107

50-29-1877

2578

08-56-0121

22 - 26

0.35-0.12

1.20-1.52

.047-.060

2.54-3.17

.100-.125

5168 08-70-0019

08-70-0099

08-70-0018

08-70-0098

22 - 26

0.35-0.12

1.20-1.52

.047-.060

2.54-3.17

.100-.125

08-50-0185

08-58-0134

08-04-0001

08-56-0181

08-52-0125

08-65-0122

08-50-0183

08-58-0133

08-56-0124

08-65-0127

08-50-0283

08-65-0121

08-56-0182

08-52-0124

08-65-0126

7258

08-56-0123

22 - 26

0.35-0.12

1.20-1.52

.047-.060

2.54-3.17

.100-.125



Customer to cut off terminal from reel: .2.80mm (.110”) maximum Cut-off Tab center.



See Conditions on page 2.

Hand Crimp Tool for 3.96mm (.156") Pitch KK® Crimp Terminal

Doc No: ATS-638117400 Release Date: 10-31-06 UNCONTROLLED COPY Page 2 of 7

Revision: B Revision Date: 04-08-08

INSULATION CRIMP

BRUSH

STRIP

NGTH

BELL

MOUTH

CRIMP HEIGHT

BEND

DOWN

BEND UP

ROLLING

LOCKING

TANG HEIGHT

TWISTING

CUT

OFF

TAB

SEAM

CONDUCTOR CRIMP

DEFINITION OF TERMS

The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the

scope.

CONDITIONS:

After crimping, the conductor profiles should measure the following (see notes on page 5).

Punch Width (Ref)

Wire Size Conductor

Crimp Height (Ref) Conductor Insulation

Pull Force

Minimum Profile

Terminal Series No.

AWG

2mm In. mm In. mm In. N Lb. A

22 0.35 .94-1.04 .037-.041 1.56 .061 1.94 .076 44.0 10.0

24 0.20 .84-.94 .033-.037 1.56 .061 1.56 .061 29.0 6.5 X

2578

26 0.12 .84-.94 .033-.037 1.56 .061 1.56 .061 18.0 4.0 X

22 0.35 .94-1.04 .037-.041 1.56 .061 1.94 .076 44.0 10.0

24 0.20 .84-.94 .033-.037 1.56 .061 1.56 .061 29.0 6.5 X

5168

26 0.12 .84-.94 .033-.037 1.56 .061 1.56 .061 18.0 4.0 X

22 0.35 .94-1.04 .037-.041 1.56 .061 1.94 .076 44.0 10.0

24 0.20 .84-.94 .033-.037 1.56 .061 1.56 .061 29.0 6.5 X

7258

26 0.12 .84-.94 .033-.037 1.56 .061 1.56 .061 18.0 4.0 X

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 mechanism will

release the handles, and the hand tool will spring open.

Hand Crimp Tool for 3.96mm (.156") Pitch KK® Crimp Terminal

Doc No: ATS-638117400 Release Date: 10-31-06 UNCONTROLLED COPY Page 3 of 7

Revision: B Revision Date: 04-08-08

SWING OPEN

TERMINAL

PUSH HERE TO

OPEN WIRE STOP

LOCATOR

TERMINAL IN PLACE

Figure 2

LOCATOR

IN PLACE

WIRE STOP

TERMINAL

WIRE

WIRE STOP

WIRE

AGAINST STOP

Figure 3

Crimping Terminals

1. Select the desired terminal listed in the preceding charts.

2. Swing the terminal locator away from the crimp tool shown in

Figure 2. 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.

3. When using the locator, 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 correspond with the A or B profile on the hand

tool.

4. Return the locator to its original position.

5. Insert the proper wire over the terminal. Some large O.D. wires

may need to be placed into the terminal before closing the tool. Gently touch the wire stop with the end of the

wire. See Figure 3.

6. Compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.

Release handles to open the jaws.

Note: The tamper proof ratchet action will not release the tool until it has been fully closed.

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.

Figure 1

LOCATOR

JAWS OPEN

Hand Crimp Tool for 3.96mm (.156") Pitch KK® Crimp Terminal

Doc No: ATS-638117400 Release Date: 10-31-06 UNCONTROLLED COPY Page 4 of 7

Revision: B Revision Date: 04-08-08

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 on page

Locator Replacement

See the parts list on the last page of this document for the proper

locator order number. Follow the steps below to replace 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. See Figure 4.

4. Replace it with the proper 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 surfaces are

protected with a thin coat of high quality machine oil. Do not oil

excessively. The 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.

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 crimping area. Oil transferred from the crimping area onto

certain terminations may affect the electrical characteristics of an application.

5. When tool is not in use, keep the handles closed to prevent objects from becoming lodged in the crimping

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.

SWING

LOCATOR

OPEN

PRESS DOWN

ON BRASS PIVOT

SHAFT

LIFT UP

LOCATOR

JAWS

OPEN

Figure 4

LUBRICATION POINTS

(BOTH SIDES) LIGHT OIL

(EVERY 3 MONTHS OR

5,000 CRIMPS)

Figure 5

Hand Crimp Tool for 3.96mm (.156") Pitch KK® Crimp Terminal

Doc No: ATS-638117400 Release Date: 10-31-06 UNCONTROLLED COPY Page 5 of 7

Revision: B Revision Date: 04-08-08

How to Adjust Tool Preload

(See Figure 6)

This hand tool is factory preset to 25-45 LBS.

preload. It may be necessary over the life of

the tool to adjust tool handle preload force.

Listed below are the steps required to adjust

the crimping force of the hand tool 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. The 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 increase

handle force.

4. Replace the locking screw, aligning the nearest notch in the setting wheel to locking screw.

5. Replace the handle grip.

6. Check the crimp specifications or conduct a pull test after tool handle preload force is adjusted.

Warranty

This tool is for electrical terminal crimping purposes only. This tool 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 free of charge. This repair or exchange will

not be applicable to altered, misused, or damaged tools. This tool is designed for hand use only. Any clamping,

fixturing, or use of handle extensions voids this warranty.

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.

RATCHET

RELEASE LEVER

Figure 6

HANDLE

GRIP

REMOVED

ECCENTRIC AXLE

HANDLE

GRIP

LOCKING

SCREW

WRENCH SET

(SOLD

SEPERATELY)

PRELOAD

CHECK POINT

25.4MM

SETTING WHEEL

Hand Crimp Tool for 3.96mm (.156") Pitch KK® Crimp Terminal

Doc No: ATS-638117400 Release Date: 10-31-06 UNCONTROLLED COPY Page 6 of 7

Revision: B Revision Date: 04-08-08

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

25mm (1.00”) per minute. See the Molex web site for the Quality Crimp Handbook for more information on pull

testing.

%If the tool does not meet minimum pull force values, handle preload should be increased and the pull test

rerun, (See How To Adjust Preload).

%When the hand tool is no longer capable of achieving minimum pull force, it should be taken out of service and

replaced.

Hand Crimp Tool for 3.96mm (.156") Pitch KK® Crimp Terminal

Doc No: ATS-638117400 Release Date: 10-31-06 UNCONTROLLED COPY Page 7 of 7

Revision: B Revision Date: 04-08-08

RATCHET

RELEASE LEVER

Figure 7

M4 X 5LG

BHCS

PARTS LIST

Item Number Order Number Description Quantity

REF 63811-7400 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

4 63811-7475 Locator 1

Americas Headquarters

Lisle, Illinois 60532 U.S.A.

1-800-78MOLEX

[email protected]

Far East North Headquarters

Yamato, Kanagawa, Japan

81-462-65-2324

[email protected]

Far East South Headquarters

Jurong, Singapore

65-6-268-6868

[email protected]

European Headquarters

Munich, Germany

49-89-413092-0

[email protected]

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

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