Molex 63811-8200 User manual

Hand Crimp Tool For 2.54mm (.100) KK® Crimp Terminals

Doc No: AT -638118200 Release Date: 10-26-07 UNCONTROLLED COPY Page 1 of 9

Revision: D Revision Date: 08-27-08

HAND CRIMP TOOL

Specification Sheet

Order No. 6 811-8200

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

 Right and Left handed applications

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

 This tool is RoH compliant, however RoH compliant is not required

SCOPE

Products: 2.54mm (.100) KK® Crimp Terminals, 22-30 AWG.

Terminal Order No. Wire Size Insulation Diameter Strip Length Terminal

Series No. Loose Piece Only AWG mm² mm In. mm In.

08-50-0114 39-00-0033

08-50-0124 39-00-0107

08-50-0160 39-00-0373

08-50-0275 39-00-0375

08-51-0102 39-00-0377

08-55-0102 39-00-0379

08-55-0131 39-00-0381

2759

08-56-0110 50-29-1638

22-30 0.35-0.05 1.09-1.57 .040-.062 2.54-3.17 .100-.125

08-50-0032 40-01-0830

08-50-0136 97-00-0451

08-55-0111 97-00-0453

4809

08-56-0115

22-30 0.35-0.05 1.02-1.57 .040-.062 2.54-3.17 .100-.125

5159 08-70-0049 08-70-0069 22-28 0.35-0.08 1.20-1.70 .040-.090 2.54-3.17 .100-.125

08-52-0122 08-65-0814

08-52-0123 08-65-0816

6459

08-65-0812 08-65-0818

22-30 0.35-0.05 1.02-1.57 .040-.062 2.54-3.17 .100-.125

08-52-0104 40-07-0813

08-52-0108 97-00-0226

8088

08-65-0106 97-00-0228

22-30 0.35-0.05 1.02-1.57 .040-.062 2.54-3.17 .100-.125

08-50-0322 97-00-0445

40445 97-00-0921 22-30 0.35-0.05 1.02-1.57 .040-.062 2.54-3.17 .100-.125

41572 08-65-0805 22-30 0.20-0.05 1.02-2.29 .040-.090 3.17-3.96 .125-.156

 Terminals in this chart have a center cut-off tab. They cannot be removed from the reel by manual cutting them.

All these terminals are loose piece only.

An applicator must be used when using reel terminals or the terminals will not function properly.

TYPE 4D

Hand Crimp Tool For 2.54mm (.100) KK® Crimp Terminals

Doc No: AT -638118200 Release Date: 10-26-07 UNCONTROLLED COPY Page 2 of 9

Revision: D Revision Date: 08-27-08

INSULATION CRIMP

BRUSH

STRIP LENGTH

BELL

MOUTH

CRIMP HEIGHT

BEND

DOWN

BEND UP

ROLLING

LOCKING TANG

HEIGHT

TWISTING

CUT

OFF

TAB

SEAM

CONDUCTOR CRIMP

DEFINITION OF TERMS

CONDITIONS:

After crimping, the conductor profiles should measure the following.

Conductor Crimp Insulation Crimp

Wire Size Height (Ref.) Width (Ref.)

Height (Ref.)

Width (Ref.)

Terminal

Series No

AWG

mm2

mm In. mm In. mm In. mm In.

22 0.35 0.71-0.81

.028-.032

1.40 .055 1.42 .056 1.64 .065

24 0.20 0.71-0.81

.028-.032

1.40 .055 1.39 .054 1.64 .065

26 0.12 0.63-0.73

.025-.029

1.37 .054 1.33 .052 1.42 .056

28 0.08 0.63-0.73

.025-.029

1.37 .054 1.33 .052 1.42 .056

2759

30 0.05 0.63-0.73

.025-.029

1.37 .054 1.33 .052 1.42 .056

22 0.35 0.71-0.81

.028-.032

1.40 .055 1.42 .056 1.64 .065

24 0.20 0.71-0.81

.028-.032

1.40 .055 1.39 .054 1.64 .065

26 0.12 0.63-0.73

.025-.029

1.37 .054 1.33 .052 1.42 .056

28 0.08 0.63-0.73

.025-.029

1.37 .054 1.33 .052 1.42 .056

4809

30 0.05 0.63-0.73

.025-.029

1.37 .054 1.33 .052 1.42 .056

22 0.35 0.71-0.81

.028-.032

1.40 .055 1.42 .056 1.64 .065

24 0.20 0.71-0.81

.028-.032

1.40 .055 1.39 .054 1.64 .065

26 0.12 0.63-0.73

.025-.029

1.37 .054 1.33 .052 1.42 .056

5159

28 0.08 0.63-0.73

.025-.029

1.37 .054 1.33 .052 1.42 .056

22 0.35 0.76-0.86

.030-.034

1.42 .056 1.45 .057 1.64 .065

24 0.20 0.73-0.83

.029-.033

1.42 .056 1.40 .055 1.61 .063

26 0.12 0.69-0.79

.027-.031

1.37 .054 1.38 .054 1.40 .055

28 0.08 0.69-0.79

.027-.031

1.37 .054 1.38 .054 1.40 .055

6459

30 0.05 0.69-0.79

.027-.031

1.37 .054 1.38 .054 1.40 .055

22 0.35 0.76-0.86

.030-.034

1.42 .056 1.45 .057 1.64 .065

24 0.20 0.73-0.83

.029-.033

1.42 .056 1.40 .055 1.61 .063

26 0.12 0.69-0.79

.027-.031

1.37 .054 1.38 .054 1.40 .055

28 0.08 0.69-0.79

.027-.031

1.37 .054 1.38 .054 1.40 .055

8088

30 0.05 0.69-0.79

.027-.031

1.37 .054 1.38 .054 1.40 .055

Hand Crimp Tool For 2.54mm (.100) KK® Crimp Terminals

Doc No: AT -638118200 Release Date: 10-26-07 UNCONTROLLED COPY Page 3 of 9

Revision: D Revision Date: 08-27-08

Conductor Crimp Insulation Crimp

Wire Size Height (Ref.) Width (Ref.)

Height (Ref.)

Width (Ref.)

Terminal

Series No

AWG

mm2

mm In. mm In. mm In. mm In.

22 0.35 0.71-0.81

.028-.032

1.40 .055 1.42 .056 1.64 .065

24 0.20 0.71-0.81

.028-.032

1.40 .055 1.39 .054 1.64 .065

26 0.12 0.63-0.73

.025-.029

1.37 .054 1.33 .052 1.42 .056

28 0.08 0.63-0.73

.025-.029

1.37 .054 1.33 .052 1.42 .056

40445

30 0.05 0.63-0.73

.025-.029

1.37 .054 1.33 .052 1.42 .056

22 0.35 0.76-0.86

.030-.034

1.42 .056 1.45 .057 1.64 .065

24 0.20 0.73-0.83

.029-.033

1.42 .056 1.40 .055 1.61 .063

26 0.12 0.69-0.79

.027-.031

1.37 .054 1.38 .054 1.40 .055

28 0.08 0.69-0.79

.027-.031

1.37 .054 1.38 .054 1.40 .055

41572

30 0.05 0.69-0.79

.027-.031

1.37 .054 1.38 .054 1.40 .055

Profile

Wire Size Pull Force

Minimum A B C D

Terminal

Series No

AWG

mm2

N Lb. 26- 0

22-24

26- 0

22 0.35 44.8

10.00

24 0.20 28.9

6.50 X

26 0.12 17.8

4.00 X

28 0.08 11.1

2.50 X

2759

30 0.05 6.7 1.50 X

22 0.35 44.8

10.00

24 0.20 28.9

6.50 X

26 0.12 17.8

4.00 X

28 0.08 11.1

2.50 X

4809

30 0.05 6.7 1.50 X

22 0.35 39.2

8.00 X

24 0.20 28.9

6.50 X

26 0.12 17.8

4.00 X

5159

28 0.08 11.1

2.50 X

22 0.35 44.8

10.00

24 0.20 28.9

6.50 X

26 0.12 17.8

4.00 X

28 0.08 11.1

2.50 X

6459

30 0.05 6.7 1.50 X

22 0.35 44.8

10.00

24 0.20 28.9

6.50 X

26 0.12 17.8

4.00 X

28 0.08 11.1

2.50 X

8088

30 0.05 6.7 1.50 X

22 0.35 44.8

10.00

24 0.20 28.9

6.50 X

26 0.12 17.8

4.00 X

28 0.08 11.1

2.50 X

40445

30 0.05 6.7 1.50 X

22 0.35 44.8

10.00

24 0.20 28.9

6.50 X

26 0.12 17.8

4.00 X

28 0.08 11.1

2.50 X

41572

30 0.05 6.7 1.50 X

Hand Crimp Tool For 2.54mm (.100) KK® Crimp Terminals

Doc No: AT -638118200 Release Date: 10-26-07 UNCONTROLLED COPY Page 4 of 9

Revision: D Revision Date: 08-27-08

RELEASE

LOCATOR BUTTON

TERMINAL

Figure

LOCATOR

PUSHED THRU

TOOLING

TERMINAL

LOCATOR

BUTTON

PUSHED IN

LOCATOR

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.

ee Figure 1.

Crimping Terminals

1. elect the desired terminal listed in the

preceding charts.

2. Make sure the center of the locator is in

the down position. With the locator

attached, push the locator button on

the back of the hand tool to bring the

locator forward through the tooling.

ee Figure 2.

3. While holding the locator button in, load the terminal into the proper

nest opening in the locator based on the wire gauge or terminal type

markings on the hand tooling. ee Figure 3.

4. Release the locator button, allowing the locator to return to the

crimping position.

5. Close the tool handle until the first ratchet position engages. ee

Figure 4.

PARTIALLY

CLOSE HANDLE

TOOLING

PARTIALLY

CLOSED

Figure 4

FIRST RATCHET

POSITION

OPEN

POSITION

SQUEEZE

HANDLES

TOGETHER

HANDLE WILL

SPRING OPEN

Figure 1

LOCATOR

IN DOWN

POSTION

PUSH ON THE

LOCATOR BUTTON

Figure 2

Hand Crimp Tool For 2.54mm (.100) KK® Crimp Terminals

Doc No: AT -638118200 Release Date: 10-26-07 UNCONTROLLED COPY Page 5 of 9

Revision: D Revision Date: 08-27-08

Figure 5

TERMINAL

WIRE AGAINST THE

WIRE STOP

WIRE

WIRE STOP IS PART

OF THE LOCATOR

PRE

STRIPPED

WIRE

TERMINAL

6. Insert the properly stripped wire through the terminal and against the wire stop. ee Figure 5.

7. Crimp the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.

Release the handles to open the jaws.

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

8. Remove the crimped terminal from the terminal

locator by pulling on the wire.

9. Visually inspect the crimped terminal for proper

crimp location.

10. On some large O.D. wires, it may not be possible

to insert the wire with the tool partially closed.

Those wires should be inserted with the hand

tool in the open position. Insert the wire above

the terminal in the punch and against the wire

stop then close the tool. ee Figure 6.

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 available, actual crimp height measurements may very slightly. An

occasional, destructive, pull force test should be performed to check hand tool crimp. Pull Force value Must exceed

the Minimum pull force specifications listed.

TERMINAL

Figure 6

WIRE

WIRE STOP

Hand Crimp Tool For 2.54mm (.100) KK® Crimp Terminals

Doc No: AT -638118200 Release Date: 10-26-07 UNCONTROLLED COPY Page 6 of 9

Revision: D Revision Date: 08-27-08

Figure

PUSH ON

HANDLE

JAWS OPEN

PULL OPEN

TOOLING

M BHCS

Locator Replacement

ee 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. queeze gently on the lower area shown in

Figure 7A with your thumb and index finger.

The lower tabs of the locator should disengage

from the hand tool.

3. Lift and pull away from the hand tool. The top

locator hooks should slip out of the top slots

easily. ee Figure 7A.

4. To reinstall the new locator, make sure the

hand tool is in the open position.

5. Press the red insert down as far as it will go as

shown in Figure 7B.

6. Holding onto the lower part of the locator with

your thumb and index finger, insert the locators

top hooks (2) into the hand tool top slots.

7. Rotate the locator down and press the lower tabs into the two bottom slots of the hand tool. To secure the

locator into place, the lower tabs must snap into place on the hand tool frame.

Right or Left Hand Operation

This hand tool has an added feature that can be

converted from a right handed application to a

left handed application. It is necessary to

reverse the tooling if using the left handed

application along with the locator. Follow the

steps below:

1. The locator must be removed before

reversing the tooling.

2. Remove the M3 BHC which is holding the

upper tooling.

3. Flip the upper tooling to the opposite side

and replace the M3 BHC . Make sure the

small markings on the front and back of the

hand tool frame match up and are on the

outside of the hand tool frame. ee Figure 8 and 9.

4. Do the same thing with the lower tooling and tighten the M3 screws. Be sure the small markings line up.

5. Reinstall the locator by following the Instructions in the locator replacement section.

SQUEEZE

HERE

SQUEEZE

HERE

LOCATOR

Figure 7A

TOP HOOKS

TOP SLOTS OF

HANDTOOL

LOWER TABS

MAKE SURE

CENTER OF LOCATOR

IS IN THE

DOWN POSITION

Figure 7B

Hand Crimp Tool For 2.54mm (.100) KK® Crimp Terminals

Doc No: AT -638118200 Release Date: 10-26-07 UNCONTROLLED COPY Page 7 of 9

Revision: D Revision Date: 08-27-08

Figure 1

QUEEZE

THE LINK IN

THE HANDLE

HOLD THE HAND

TOOL IN POSITION

SETTING

WHEEL

RATCHET

RELEASE LEVER

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 other 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, 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

hould 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 up on the

ratchet release lever in the movable

handle. ee Figure 11.

How to Adjust Tool Preload

(See Figure 12)

This hand tool is factory preset to 25-45

LB . 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:

LUBRICATION POINTS

(BOTH SIDES) LIGHT OIL

(EVERY MONTHS OR

5,000 CRIMPS)

Figure

RATCHET RELEASE

LEVER

Figure

MATCH

UP MARKS

FRONT

BACK

Figure

Hand Crimp Tool For 2.54mm (.100) KK® Crimp Terminals

Doc No: AT -638118200 Release Date: 10-26-07 UNCONTROLLED COPY Page 8 of 9

Revision: D Revision Date: 08-27-08

1. Hold the hand tool in the palm of your hand as shown in Figure 10. Using the index finger squeeze the link

towards the top of the hand tool frame. This will release the preload adjustment wheel.

2. Rotate the setting wheel counter-clockwise (CCW) to increase handle force. The numbers will display higher.

To decrease handle force rotate the setting wheel clockwise (CW).

3. Release the link to lock the setting wheel in place.

4. 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. hould 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.

Certification

Molex does not certify or re-certify hand tools but rather supplies the following guidelines for customers to re-certify

hand tools.

% This tool is qualified to pull force only. ee 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, ( ee 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 2.54mm (.100) KK® Crimp Terminals

Doc No: AT -638118200 Release Date: 10-26-07 UNCONTROLLED COPY Page 9 of 9

Revision: D Revision Date: 08-27-08

RATCHET

RELEASE LEVER

Figure 1

PARTS LIST

Item Number Order Number Description Quantity

REF 63811-8200 Hand Crimp Tool Figure 13

1 63811-8275 Locator Assembly 1

2 63810-0104 pring, Return 1

3 63810-0105 pring, Ratchet 1

Americas Headquarters

Lisle, Illinois 60532 U. .A.

1-800-78MOLEX

[email protected]

Far East North Headquarters

Yamato, Kanagawa, Japan

81-462-65-2324

[email protected]

Far East South Headquarters

Jurong, ingapore

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. .A.

630-969-4550

Fax: 630-969-1352

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

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