Datasheet

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

Doc No: ATS-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. 63811-8200

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 RoHS compliant, however RoHS 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

Summary of content (9 pages)

PAGE 1
Hand Crimp Tool For 2.54mm (.100) KK® Crimp Terminals HAND CRIMP TOOL Specification Sheet Order No.
PAGE 2
Hand Crimp Tool For 2.54mm (.100) KK® Crimp Terminals DEFINITION OF TERMS CONDUCTOR CRIMP INSULATION CRIMP LOCKING TANG HEIGHT BEND UP BRUSH SEAM ROLLING BELL MOUTH TWISTING STRIP LENGTH CUT-OFF TAB BEND DOWN CRIMP HEIGHT CONDITIONS: After crimping, the conductor profiles should measure the following. Terminal Series No 2759 4809 5159 6459 8088 Doc No: ATS-638118200 Revision: D Wire Size AWG 22 24 26 28 30 22 24 26 28 30 22 24 26 28 22 24 26 28 30 22 24 26 28 30 mm2 0.35 0.20 0.12 0.08 0.
PAGE 3
Hand Crimp Tool For 2.54mm (.100) KK® Crimp Terminals Terminal Series No 40445 41572 Wire Size AWG 22 24 26 28 30 22 24 26 28 30 mm2 0.35 0.20 0.12 0.08 0.05 0.35 0.20 0.12 0.08 0.05 Terminal Series No 2759 4809 5159 6459 8088 40445 41572 Doc No: ATS-638118200 Revision: D Conductor Crimp Insulation Crimp Height (Ref.) Width (Ref.) Height (Ref.) Width (Ref.) mm In. mm In. mm In. mm In. 0.71-0.81 .028-.032 1.40 .055 1.42 .056 1.64 .065 0.71-0.81 .028-.032 1.40 .055 1.39 .054 1.64 .065 0.63-0.
PAGE 4
Hand Crimp Tool For 2.54mm (.100) KK® Crimp Terminals 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. See Figure 1. LOCATOR IN DOWN POSTION HANDLE WILL SPRING OPEN Crimping Terminals 1.
PAGE 5
Hand Crimp Tool For 2.54mm (.100) KK® Crimp Terminals 6. Insert the properly stripped wire through the terminal and against the wire stop. See 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. TERMINAL WIRE AGAINST THE WIRE STOP WIRE STOP IS PART OF THE LOCATOR PRE-STRIPPED WIRE Figure 5 TERMINAL WIRE Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
PAGE 6
Hand Crimp Tool For 2.54mm (.100) KK® Crimp Terminals LOCATOR 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. SQUEEZE HERE MAKE SURE CENTER OF LOCATOR IS IN THE DOWN POSITION SQUEEZE HERE 1. Open the crimp hand tool. Figure 7A 2. Squeeze gently on the lower area shown in TOP SLOTS OF Figure 7A with your thumb and index finger.
PAGE 7
Hand Crimp Tool For 2.54mm (.100) KK® Crimp Terminals Maintenance MATCH UP MARKS It is recommended that each operator of the tool be made aware of, and responsible for, the following maintenance steps: Figure 9 1. Remove dust, moisture, and other contaminants with a clean brush, or soft, lint free cloth. BACK FRONT 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.
PAGE 8
Hand Crimp Tool For 2.54mm (.100) KK® Crimp Terminals 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.
PAGE 9
Hand Crimp Tool For 2.54mm (.100) KK® Crimp Terminals PARTS LIST Item Number REF 1 2 3 Order Number 63811-8200 63811-8275 63810-0104 63810-0105 Description Hand Crimp Tool Locator Assembly Spring, Return Spring, Ratchet Quantity Figure 13 1 1 1 2 1 RATCHET RELEASE LEVER Figure 13 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.