Molex 207128 Series Manuel utilisateur

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

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 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 Order No. Wire Size



Insulation Diameter

Strip LengthTerminal

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 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

Termina

Series No.

Hand Tool

Locator AWG

2mm 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

20 0.50 1.01-1.11 .040-.044 2.00 .079 2.50 .098 57.8 13.00

22 0.35 0.86-0.96 .034-.038 2.00 .079 2.50 .098 35.6 8.00

2477 Black

24 0.20 0.86-0.96 .034-.038 2.00 .079 2.50 .098 22.2 5.00

18 0.80 1.01-1.11 .040-.044 2.00 .079 2.50 .098 89.0 20.00

20 0.50 1.01-1.11 .040-.044 2.00 .079 2.50 .098 57.8 13.00

2478 Black

22 0.35 0.86-0.96 .034-.038 2.00 .079 2.50 .098 35.6 8.00

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

2mm 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

18 0.80 1.01-1.11 .040-.044 2.00 .079 2.50 .098 89.0 20.00

2878 Black 20 0.50 1.01-1.11 .040-.044 2.00 .079 2.50 .098 57.8 13.00

18 0.80 1.01-1.11 .040-.044 2.00 .079 2.50 .098 89.0 20.00

20 0.50 1.01-1.11 .040-.044 2.00 .079 2.50 .098 57.8 13.00

4838 Black

22 0.35 0.86-0.96 .034-.038 2.00 .079 2.50 .098 35.6 8.00

18 0.80 1.01-1.11 .040-.044 2.00 .079 2.50 .098 89.0 20.00

20 0.50 1.01-1.11 .040-.044 2.00 .079 2.50 .098 57.8 13.00

22 0.35 0.86-0.96 .034-.038 2.00 .079 2.50 .098 35.6 8.00

5167 Black

24 0.20 0.86-0.96 .034-.038 2.00 .079 2.50 .098 22.2 5.00

18 0.80 1.01-1.11 .040-.044 2.00 .079 2.50 .098 89.0 20.00

6438 Black 20 0.50 1.01-1.11 .040-.044 2.00 .079 2.50 .098 57.8 13.00

18 0.80 1.01-1.11 .040-.044 2.00 .079 2.50 .098 89.0 20.00

6838 Black 20 0.50 1.01-1.11 .040-.044 2.00 .079 2.50 .098 57.8 13.00

18 0.80 1.01-1.11 .040-.044 2.00 .079 2.50 .098 89.0 20.00

20 0.50 1.01-1.11 .040-.044 2.00 .079 2.50 .098 57.8 13.00

8818 Gray

22 0.35 0.86-0.96 .034-.038 2.00 .079 2.50 .098 35.6 8.00

18 0.80 1.01-1.11 .040-.044 2.00 .079 2.50 .098 89.0 20.00

20 0.50 1.01-1.11 .040-.044 2.00 .079 2.50 .098 57.8 13.00

22 0.35 0.86-0.96 .034-.038 2.00 .079 2.50 .098 35.6 8.00

8993 Black

24 0.20 0.86-0.96 .034-.038 2.00 .079 2.50 .098 22.2 5.00



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.

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 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

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.

Figure

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

TERMINAL IN PLACE

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 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.

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 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 and 63811-

7575, which is gray. Make sure the correct locator is installed for

the proper terminal and wire. Follow the steps below 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 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.

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.

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.

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 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.

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

[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

RATCHET

RELEASE LEVER

Figure 7

M4 X 5LG

BHCS

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