Tool Kit for KK® .156 Centers Crimp Terminals
Tool Kit
Order No. 63811-6670
Application Tooling
Specification Sheet
TYPE 2C
Hand Crimp Tool
Order No. 63811-6600
FEATURES
A full cycle ratcheting hand tool ensures complete crimps
Ergonomically designed soft handles
% Precisely designed crimping profiles with simple contact positioning
% Easy handling due to outstanding force ratio
Tool kits are easily installed into the Hand Crimp Tool or the 63816-0300 Power Crimp Head which is installed
into the 63816-0200 (110 V) or the 63816-0250 (220 V) Battery Powered Tool.
Many different Tool kits can be used with a single Battery Powered Tool.
This tool is IPC/WHMA-A-620 Class 2 and RoHS compliant.
%
%
SCOPE
Products: “KK®” .156 Centers Crimp Terminals, 18-30 AWG.
Terminal
Series No.
1797
4366
4573
Terminal Order No.
Wire Size
Insulation Diameter
Loose Piece
Reel
AWG
mm²
mm
In.
08-01-0102 08-05-0104 08-01-0101 08-06-0101
08-01-0122 08-06-0102 08-01-0121 08-05-0103
18-24 0.80-0.20 1.78-2.79 .070-.110
08-01-0124 08-07-0102 08-01-0123 08-07-0101
08-03-0102
08-03-0101
08-01-0106 08-05-0106 08-01-0105 08-05-0105
24-30 0.20-0.05 0.76-1.78 .030-.070
08-01-0126
08-01-0125
08-03-0304
08-05-0301 40-01-1194
08-05-0302
08-03-0303 50-36-1873 18-24 0.80-0.20 1.78-2.79 .070-.110
08-05-0305
08-05-0304 08-03-0306 08-05-0303 08-03-0305 24-30 0.20-0.05 0.76-1.78 .030-.070
Customer to cut off terminal from reel: 0.25mm (.010”) maximum Cut-off Tab.
3.06-3.96 .120-.156
3.06-3.96 .120-.156
3.06-3.96 .120-.156
3.06-3.96 .120-.156
BEND UP
DEFINITION OF TERMS
BRUSH
Strip Length
mm
In.
BELL MOUTH
CONDUCTOR
CRIMP
INSULATION
CRIMP
▲SEE NOTE
ROLLING
TWISTING
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.
Doc No: ATS-6381166HM Release Date: 08-02-06
Revision: D
Revision Date: 04-24-12
UNCONTROLLED COPY
Page 1 of 9
Tool Kit for KK® .156 Centers Crimp Terminals
OVERLAP FORM GEOMETRY
▲Insulation Crimp Note:
PUNCH
Due to the terminal’s insulation grip design
and/or insulation diameter range, this tool
uses “overlap” form geometry in the
insulation punch. This produces an overlap
insulation crimp (A620 – compliant). While
the insulation punch profile may appear
“lopsided”, this is a normal condition for this
tool. See figure to the right. (Some tools
with multiple crimp pockets may not have
the “overlap” profile on all pockets).
OVERLAP
INSULATION
CRIMP
CONDITIONS:
WIRE
ANVIL
After crimping, the conductor profiles should measure the following (see notes below).
Terminal Series No.
1797
4366
1797
4573
Wire Size
AWG
18
20
22
24
18
20
22
24
24
26
28
30
24
26
28
30
mm2
0.80
0.50
0.35
0.20
0.80
0.50
0.35
0.20
0.20
0.12
0.08
0.05
0.20
0.12
0.08
0.05
Conductor Crimp
Height (Ref)
Width (Ref)
mm
In.
mm
In.
0.92-1.02 .036-.040 1.93 .076
0.91-1.01 .035-.039 1.93 .076
0.91-1.01 .035-.039 1.93 .076
0.89-0.99 .034-.038 1.93 .076
0.92-1.02 .036-.040 1.93 .076
0.91-1.01 .035-.039 1.93 .076
0.91-1.01 .035-.039 1.93 .076
0.89-0.99 .034-.038 1.93 .076
0.85-0.95 .033-.037 1.68 .066
0.80-0.90 .031-.035 1.68 .066
0.78-0.88 .030-.035 1.68 .066
0.77-0.87 .030-.034 1.68 .066
0.85-0.95 .033-.037 1.68 .066
0.80-0.90 .031-.035 1.68 .066
0.78-0.88 .030-.035 1.68 .066
0.77-0.87 .030-.034 1.68 .066
Pull Force
Minimum
N
Lb.
111.2 25.00
66.7 15.00
53.4 12.00
31.1 7.00
111.2 25.00
66.7 15.00
53.4 12.00
31.1 7.00
31.1 7.00
17.8 4.00
11.1 2.50
6.7 1.50
31.1 7.00
17.8 4.00
11.1 2.50
6.7 1.50
Profile
A
X
X
X
X
X
X
X
X
B
X
X
X
X
X
X
X
X
Tool Qualification Notes:
1. Pull Force should be measured with no influence from the insulation crimp.
2. The above specifications are guidelines to an optimum crimp.
3. Wires with tinned conductors will have higher pull strength than bare copper.
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 this page.
Doc No: ATS-6381166HM Release Date: 08-02-06
Revision: D
Revision Date: 04-24-12
UNCONTROLLED COPY
Page 2 of 9
Tool Kit for KK® .156 Centers Crimp Terminals
CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects as damage
can occur to the tool or die.
INSTALLATION
To install the Tool Kit into the Power Crimp Head follow the steps below:
Anvils and Punches Installation
POWER
CRIMP
HEAD
PUNCHES
M4 X 18 LONG
BHCS
M4 X 10 LONG
BHCS
ANVILS
LIFT UP ON
THE LOCATOR
PRESS DOWN
ON THE BRASS
PIVOT SHAFT
Figure 1
SWING
LOCATOR
OPEN
Figure 2
1. Insert the Anvils into the bottom slots of the nest. Install the M4 x 10 long BHCS and tighten in place.
2. Insert the Punches into the top slots of the nest. Install the M4 x 18 long BHCS and tighten in place. See
Figure 1.
Locator Installation and Removal
Follow the steps below to install or replace the locator. See Figure 2.
To install the locator
1. Position the locator with the hole over the brass pivot shaft and snap it
into place.
JAWS OPEN
LOCATOR
To remove 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.
Figure 3
OPERATION
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.
Doc No: ATS-6381166HM Release Date: 08-02-06
Revision: D
Revision Date: 04-24-12
UNCONTROLLED COPY
Page 3 of 9
Tool Kit for KK® .156 Centers Crimp Terminals
Crimping Terminals
TERMINAL
1. Select the desired terminal listed in
the preceding charts.
2. Swing the terminal locator away from
SWING OPEN
the crimp tool shown in Figure 4.
Some terminals with large insulation
grips may interfere with the crimp
tooling when swinging the locator
LOCATOR
into position. The terminal must then
TERMINAL IN PLACE
PUSH HERE TO LOCATOR
be loaded into the locator in the
Figure 4
OPEN WIRE STOP
closed/crimp position.
3. When using the locator, press down on the wire stop on the locator as shown in Figure 4. 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 5.
6. Compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.
Release handles to open the jaws.
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: The tamper proof ratchet action will not release the tool until it has been fully closed.
For the Battery Power Tool:
1. Cycle the Battery Power Tool to crimp the terminal to the wire.
2. 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.
3. Visually inspect the crimped terminal for proper crimp location.
WIRE STOP
WIRE
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 6.
4. Replace it with the proper locator by putting over the brass
pivot shaft and snapping it into place.
Doc No: ATS-6381166HM Release Date: 08-02-06
Revision: D
Revision Date: 04-24-12
TERMINAL
LOCATOR
IN PLACE
WIRE STOP
WIRE
AGAINST STOP
UNCONTROLLED COPY
Figure 5
Page 4 of 9
Tool Kit for KK® .156 Centers Crimp Terminals
LIFT UP
LOCATOR
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. Use a 30 weight automotive (light) oil used at the
oil points, every 5,000 crimps or 3 months, shown in Figure
7A or 7B 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 8.
How to Adjust Tool Preload (See Figure 8)
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:
JAWS
OPEN
PRESS DOWN
ON BRASS PIVOT
SHAFT
SWING
LOCATOR
OPEN
Figure 6
Figure 7B
LUBRICATION
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY MONTH
OR
5,000 CRIMPS)
Figure 7A
PRELOAD
CHECK POINT
25.4MM
SETTING WHEEL
ECCENTRIC AXLE
HANDLE
GRIP
REMOVED
1. Remove or fold back the handle grip from the
WRENCH SET
handle to expose the eccentric axle and
LOCKING
HANDLE
(SOLD
setting wheel.
SCREW
GRIP
SEPERATELY)
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.
Doc No: ATS-6381166HM Release Date: 08-02-06
Revision: D
Revision Date: 04-24-12
UNCONTROLLED COPY
RATCHET
RELEASE LEVER
Figure 8
Page 5 of 9
Tool Kit for KK® .156 Centers Crimp Terminals
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.
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-6381166HM Release Date: 08-02-06
Revision: D
Revision Date: 04-24-12
UNCONTROLLED COPY
Page 6 of 9
Tool Kit for KK® .156 Centers Crimp Terminals
The chart below shows all applications for this Tool Kit.
Tool Kit
Order No.
Tool
Tool
Power Head
Adapter
Figure No.
Order no.
Description
Order No.
Description
63810-0100 Hand Crimp Frame (Short)
N/A
N/A
9
63810-0400 Hand Crimp Frame (Long)
N/A
N/A
9
63811-6670
63816-0200 Battery Power Tool (110 V) 63816-0300 Power Crimp Head
10
63816-0250 Battery Power Tool (220 V) 63816-0300 Power Crimp Head
10
Applications for the Tool Kit
Hand Crimp Tool
Battery Powered Tool
POWER
CRIMP
HEAD
TOOLING KIT
TOOLING
KIT
HAND CRIMP
FRAME LONG
AND SHORT
BATTERY
POWERED
TOOL
Figure 9
LOCKING PINS
Figure 10
WARNING: NEVER operate service, install tool kits, or adjust the Power Crimp Head without proper instruction
and without first reading and understanding the instructions in the proper Manual or Specification Sheet. See
Chart above for the correct Manual or Specification Sheet.
WARNING: NEVER install tooling or service this tool while it is into any power source. Make sure the power is
turned off.
CAUTION: Keep fingers away from the crimping area when operating this tool. It may cause severe injury.
CAUTION: Wear safety glasses when operating or serving this tool.
Doc No: ATS-6381166HM Release Date: 08-02-06
Revision: D
Revision Date: 04-24-12
UNCONTROLLED COPY
Page 7 of 9
Tool Kit for KK® .156 Centers Crimp Terminals
HAND TOOL PARTS LIST
Item Number
1
2
3
4
5
6
6
LOCATOR ONLY
5
WITH TOOL KIT
Order Number
63810-0100
63810-0101
63810-0102
63810-0103
63811-6670
63811-6675
Description
Hand Crimp Frame (Short)
Wrench Set (Not included)
Locator Base
Repair Kit (Not included)
Tool Kit with Locator
Locator (only)
Quantity
1
0
1
0
1
REF
2
4
3
1
M4 X 6mm
LONG BHCS
RATCHET
RELEASE SCREW
Figure 11
4
5
M4 X 12mm
LONG BHCS
Doc No: ATS-6381166HM Release Date: 08-02-06
Revision: D
Revision Date: 04-24-12
M4 X 12mm
LONG BHCS
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Page 8 of 9
Tool Kit for KK® .156 Centers Crimp Terminals
POWER HEAD PARTS LIST
Item
1
2
Order No
63816-0300
63811-6670
Engineering No.
63816-0300
63811-6670
Description
Power Crimp Head
Tool Kit
Quantity
1
1
2
1
1
M4 by 8 Long
BHCS
M4 by 18 Long
BHCS
M4 by 10 Long
BHCS
2
Figure 12
http://www.molex.com
Doc No: ATS-6381166HM Release Date: 08-02-06
Revision: D
Revision Date: 04-24-12
UNCONTROLLED COPY
Page 9 of 9
