Hand Crimp Tool for “KK” .156 Center Terminals Hand Crimp Tool Specification Sheet Order No. 63811-7500 TYPE 2C 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 as indicated. SCOPE Products: 3.96mm (.156") Pitch KK® Crimp Terminal for 18-24 AWG Terminal Terminal Order No. Series No. Loose Piece Reel 2477 08-50-0109 08-56-0113 08-50-0110 08-56-0114 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 2478 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 08-52-0044 08-52-0812 08-50-0116 08-50-0115 08-55-0138 08-52-0127 08-51-0109 08-58-0127 2878 08-58-0128 08-52-0126 08-65-0118 08-65-0119 08-53-0814 08-50-0132 08-55-0143 08-50-0131 08-55-0142 4838 08-55-0140 08-55-0146 08-55-0125 08-55-0145 08-55-0141 08-55-0148 08-55-0139 08-55-0147 5167 08-70-0013 08-70-1034 08-70-0012 08-70-0097 08-50-0165 08-56-0139 08-50-0164 08-53-0813 6438 08-51-0802 08-51-0801 08-56-0135 08-56-0133 08-51-0813 08-56-0137 Doc No. ATS-638117500 Revision: C Release Date: 12-06-06 Revision Date: 03-29-08 Wire Size AWG mm² 18-24 0.80-0.20 Insulation Diameter mm 1.39-2.79 In. .055-.110 Strip Length mm In. 2.54-3.17 .100-.125 18-24 0.80-0.20 1.39-2.79 .055-.110 2.54-3.17 .100-.125 18-20 0.80-0.50 1.52-2.79 .060-.110 2.54-3.17 .100-.125 18-22 0.80-0.35 1.52-2.41 .060-.095 2.54-3.17 .100-.125 18-24 0.80-0.20 1.39-2.48 .055-.098 2.54-3.17 .100-.125 18-20 0.80-0.50 1.52-2.41 .060-.095 2.54-3.17 .100-.125 UNCONTROLLED COPY Page 1 of 7 Hand Crimp Tool for “KK” .156 Center Terminals 6838 8818 8993 08-50-0029 08-50-0189 08-50-0251 08-51-0107 08-52-0113 08-53-1102 08-58-0106 08-58-0109 08-58-0111 08-50-0023 08-50-0706 08-52-0132 08-56-0188 08-50-0276 08-58-0119 08-58-0132 08-58-0189 08-60-0002 50-29-1763 50-29-1879 08-50-0024 08-58-0105 08-50-0026 08-58-0108 08-50-0028 08-58-0110 08-50-0187 08-58-0118 08-50-0275 08-58-0131 18-20 0.80-0.50 1.52-2.79 .060-.110 2.54-3.17 .100-.125 08-51-0106 08-58-0187 08-52-0112 08-60-0001 08-53-1101 50-29-1639 08-58-0102 08-58-0136 08-50-0008 08-58-0135 08-65-0129 08-50-0705 08-65-0128 18 - 22 0.80-0.35 1.52-2.79 .060-.110 2.54-3.17 .100-.125 08-52-0131 40-01-1181 08-56-0187 40-01-1182 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 CONDUCTOR CRIMP INSULATION CRIMP BEND UP LOCKING TANG HEIGHT ROLLING BRUSH BELL MOUTH SEAM TWISTING CUT-OFF TAB STRIP LENGTH BEND DOWN CRIMP HEIGHT 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). Termina Series No. Hand Tool Locator 2477 Black 2478 Black Doc No. ATS-638117500 Revision: C Wire Size AWG 18 20 22 24 18 20 22 mm Conductor Crimp Height (REF) Punch Width (Ref) Conductor Insulation Pull Force Minimum Profile 2 mm In. mm In. mm In. N Lb. A 0.80 0.50 0.35 0.20 0.80 0.50 0.35 1.01-1.11 1.01-1.11 0.86-0.96 0.86-0.96 1.01-1.11 1.01-1.11 0.86-0.96 .040-.044 .040-.044 .034-.038 .034-.038 .040-.044 .040-.044 .034-.038 2.00 2.00 2.00 2.00 2.00 2.00 2.00 .079 .079 .079 .079 .079 .079 .079 2.50 2.50 2.50 2.50 2.50 2.50 2.50 .098 .098 .098 .098 .098 .098 .098 89.0 57.8 35.6 22.2 89.0 57.8 35.6 20.00 13.00 8.00 5.00 20.00 13.00 8.00 X X Release Date: 12-06-06 Revision Date: 03-29-08 UNCONTROLLED COPY B X X X X X Page 2 of 7 Hand Crimp Tool for “KK” .156 Center Terminals Termina Series No. Hand Tool Locator Wire Size AWG mm 2 Conductor Crimp Height (REF) mm In. Punch Width (Ref) Conductor Insulation mm In. mm In. Pull Force Minimum N Lb. Profile 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 4838 Black 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 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 5167 Black 22 0.35 0.86-0.96 .034-.038 2.00 .079 2.50 .098 35.6 8.00 X 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 8818 Gray 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 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 8993 Black 22 0.35 0.86-0.96 .034-.038 2.00 .079 2.50 .098 35.6 8.00 X 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 recommended: 1. Profile A: 1.68mm (.066 inch max.)-Up to the maximum 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 mechanism will release the handles, and the hand tool will spring open. JAWS OPEN Crimping Terminals LOCATOR 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 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. Press down on the wire stop on the locator as shown in Figure Figure 1 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. Doc No. ATS-638117500 Revision: C Release Date: 12-06-06 Revision Date: 03-29-08 UNCONTROLLED COPY Page 3 of 7 Hand Crimp Tool for “KK” .156 Center Terminals 4. Return the locator to its original position. 5. Insert the proper wire over the terminal. 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. TERMINAL WIRE STOP WIRE SWING OPEN PUSH HERE TO OPEN WIRE STOP LOCATOR TERMINAL LOCATOR IN PLACE WIRE STOP LOCATOR TERMINAL IN PLACE Figure 2 WIRE AGAINST STOP Figure 3 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. 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 LIFT UP measurements may very slightly. An occasional, destructive, pull LOCATOR force test should be preformed to check hand tool crimp. Pull Force value Must exceed the Minimum pull force specifications JAWS OPEN listed on page 2 and 3. PRESS DOWN ON BRASS PIVOT SHAFT Locator Change Over Two styles of locators are provided with the crimp hand tool 63811-7500. They are 63811-7576, which is black and 638117575, which is gray. Make sure the correct locator is installed for the proper terminal and wire. Follow the steps below to change the locators. Doc No. ATS-638117500 Revision: C Release Date: 12-06-06 Revision Date: 03-29-08 SWING LOCATOR OPEN UNCONTROLLED COPY Figure 4 Page 4 of 7 Hand Crimp Tool for “KK” .156 Center Terminals LUBRICATION POINTS (BOTH SIDES) LIGHT OIL (EVERY 3 MONTHS OR 5,000 CRIMPS) 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 desired locator by putting over the brass pivot shaft and snapping it into place. Figure 5 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. PRELOAD CHECK POINT 25.4MM 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. SETTING WHEEL ECCENTRIC AXLE 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: HANDLE GRIP REMOVED WRENCH SET (SOLD LOCKING SEPERATELY) SCREW RATCHET RELEASE LEVER Figure 6 HANDLE GRIP 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. Doc No. ATS-638117500 Revision: C Release Date: 12-06-06 Revision Date: 03-29-08 UNCONTROLLED COPY Page 5 of 7 Hand Crimp Tool for “KK” .156 Center Terminals 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. 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. Doc No. ATS-638117500 Revision: C Release Date: 12-06-06 Revision Date: 03-29-08 UNCONTROLLED COPY Page 6 of 7 Hand Crimp Tool for “KK” .156 Center Terminals PARTS LIST Item Number REF 1 2 3 4 Order Number 63811-7500 63810-0101 63810-0102 63810-0103 63811-7576 63811-7575 Description Hand Crimp Tool Wrench Set (Not included) Locator Base Assembly Repair Kit (Not included) Locator-Black Locator-Gray Quantity Figure 7 0 1 0 1 1 1 4 3 M4 X 5LG BHCS RATCHET RELEASE LEVER 2 3 Figure 7 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 Doc No. ATS-638117500 Revision: C Release Date: 12-06-06 Revision Date: 03-29-08 UNCONTROLLED COPY Page 7 of 7