0638117500

Tool Kit for KK Crimp Terminals TYPE 2C Tool Kit Order No. 63811-7570 Application Tooling Specification Sheet Hand Crimp Tool Order No. 63811-7500 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 as indicated Both black and gray locators are included with hand tool SCOPE Products: 3.96mm (.156") Pitch KK Crimp Terminal for 18-24 AWG. Terminal Order No. Wire Size Terminal Series No. Loose Piece Reel AWG mm2 2477 08-50-0110 08-56-0114 08-50-0109 08-56-0113 18-24 0.80-0.20 08-50-0006 08-56-0106 08-50-0001 08-52-0073 08`-50-0016 08-56-0154 08-50-0014 08-52-0114 08-50-0045 08-58-0104 08-50-0015 08-52-0811 08-50-0046 08-58-0115 08-50-0047 08-53-0004 08-50-0056 08-58-0122 08-50-0055 08-53-0811 08-50-0064 08-65-0115 08-50-0063 08-55-0103 08-50-0074 39-00-0345 08-50-0073 08-55-0133 08-50-0093 39-00-0344 08-50-0091 08-56-0105 08-50-0106 39-00-0346 08-50-0103 08-56-0153 08-50-0120 39-00-0348 08-50-0105 08-58-0103 2478 08-50-0147 40-01-1120 08-50-0119 08-58-0114 18-24 0.80-0.20 08-52-0024 50-29-1762 08-50-0146 08-58-0121 08-52-0045 50-30-4428 08-50-0271 08-65-0114 08-52-0047 50-30-4429 08-50-0281 39-00-0286 08-52-0072 08-51-0000 39-00-0343 08-52-0074 08-51-0720 39-00-0345 08-52-0115 08-52-0023 39-00-0347 08-52-0812 08-52-0027 40-01-1118 08-53-0812 08-52-0044 50-29-1689 08-55-0104 08-52-0046 50-29-1768 08-55-0134 08-52-0071 Doc No: ATS-6381175HM Revision: K Release Date: 12-06-06 Revision Date: 08-03-17 Insulation Diameter Strip Length mm In. mm In. 1.39-2.79 .055-.110 2.54-3.17 .100-.125 1.39-2.79 .055-.110 2.54-3.17 .100-.125 UNCONTROLLED COPY Page 1 of 12 Tool Kit for KK Crimp Terminals Terminal Series No. 2878 838 5167 6348 6838 8818 8993 172160 Terminal Order No. Wire Size Insulation Diameter Loose Piece Reel AWG mm2 mm In. 08-50-0116 08-50-0115 08-55-0138 08-52-0127 08-51-0109 08-58-0127 18-20 0.80-0.50 1.52-2.79 .060-.110 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 08-55-0140 08-55-0146 08-55-0125 08-55-0145 18-22 0.80-0.35 1.52-2.41 .060-.095 08-55-0141 08-55-0148 08-55-0139 08-55-0147 08-70-0013 08-70-1034 08-70-0012 08-70-0097 18-24 0.80-0.20 1.39-2.48 .055-.098 08-50-0165 08-56-0139 08-50-0164 08-53-0813 08-51-0802 08-51-0801 08-56-0135 18-20 0.80-0.50 1.52-2.41 .060-.095 08-56-0133 08-51-0813 08-56-0137 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 18-20 0.80-0.50 1.52-2.79 .060-.110 08-53-1102 50-29-1879 08-51-0106 08-58-0187 08-58-0106 08-52-0112 08-60-0001 08-58-0109 08-53-0101 50-29-1639 08-58-0111 08-58-0102 08-50-0023 08-58-0136 08-50-0008 08-58-0135 08-50-0706 08-65-0129 08-50-0705 08-65-0128 18-22 0.80-0.35 1.52-2.79 .060-.110 08-52-0132 08-52-0131 40-01-1181 08-56-0188 08-56-0187 40-01-1182 08-50-0276 08-50-0011 08-50-0277 18-24 0.80-0.20 1.39-2.79 .055-.110 172160-1803 172160-1804 172160-1801 172160-1802 18-20 0.80-0.50 1.52-2.79 .060-.110 172160-1805 172160-1806 Customer to cut off terminal from reel: 2.72 ± .13mm (.107 ± .005”) maximum cut off tab. See Conditions on page 4. Strip Length mm In. 2.54-3.17 .100-.125 2.54-3.17 .100-.125 2.54-3.17 .100-.125 2.54-3.17 .100-.125 2.54-3.17 .100-.125 4.00-4.75 .157-.187 2.54-3.17 .100-.125 2.54-3.17 .100-.125 DEFINITION OF TERMS CONDUCTOR CRIMP INSULATION CRIMP ▲SEE NOTE BEND UP LOCKING TANG HEIGHT ROLLING BRUSH BELL MOUTH SEAM TWISTING CUT-OFF TAB STRIP LENGTH BEND DOWN CRIMP HEIGHT Doc No: ATS-6381175HM Revision: K Release Date: 12-06-06 Revision Date: 08-03-17 UNCONTROLLED COPY Page 2 of 12 Tool Kit for KK 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 WIRE ANVIL CONDITIONS After crimping, the conductor profiles should measure the following (see notes below): Terminal Series No. Hand Tool Locator 2477 Black 63811-7576 2478 Black 63811-7576 2878 Black 63811-7576 4838 Black 63811-7576 5167 Black 63811-7576 6438 Black 63811-7576 6838 Black 63811-7576 8818 Gray 63811-7575 Doc No: ATS-6381175HM Revision: K Wire Size AWG 18 20 22 24 18 20 22 24 18 20 18 20 22 18 20 22 24 18 20 18 20 18 20 22 mm2 0.80 0.50 0.35 0.20 0.80 0.50 0.35 0.20 0.80 0.50 0.80 0.50 0.35 0.80 0.50 0.35 0.20 0.80 0.50 0.80 0.50 0.80 0.50 0.35 Conductor Crimp Height (REF) mm In. 1.01-1.11 .040-.044 1.01-1.11 .040-.044 0.86-0.96 .034-.038 0.86-0.96 .034-.038 1.01-1.11 .040-.044 1.01-1.11 .040-.044 0.86-0.96 .034-.038 0.86-0.96 .034-.038 1.01-1.11 .040-.044 1.01-1.11 .040-.044 1.01-1.11 .040-.044 1.01-1.11 .040-.044 0.86-0.96 .034-.038 1.01-1.11 .040-.044 1.01-1.11 .040-.044 0.86-0.96 .034-.038 0.86-0.96 .034-.038 1.01-1.11 .040-.044 1.01-1.11 .040-.044 1.01-1.11 .040-.044 1.01-1.11 .040-.044 1.01-1.11 .040-.044 1.01-1.11 .040-.044 0.86-0.96 .034-.038 Release Date: 12-06-06 Revision Date: 08-03-17 Punch Width (Ref) Conductor Insulation mm In. mm In. 2.00 .079 2.50 .098 2.00 .079 2.50 .098 2.00 .079 2.50 .098 2.00 .079 2.50 .098 2.00 .079 2.50 .098 2.00 .079 2.50 .098 2.00 .079 2.50 .098 2.00 .079 2.50 .098 2.00 .079 2.50 .098 2.00 .079 2.50 .098 2.00 .079 2.50 .098 2.00 .079 2.50 .098 2.00 .079 2.50 .098 2.00 .079 2.50 .098 2.00 .079 2.50 .098 2.00 .079 2.50 .098 2.00 .079 2.50 .098 2.00 .079 2.50 .098 2.00 .079 2.50 .098 2.00 .079 2.50 .098 2.00 .079 2.50 .098 2.00 .079 2.50 .098 2.00 .079 2.50 .098 2.00 .079 2.50 .098 UNCONTROLLED COPY Pull Force Minimum N Lb. 89.0 20.00 57.8 13.00 35.6 8.00 22.2 5.00 89.0 20.00 57.8 13.00 35.6 8.00 22.2 5.00 89.0 20.00 57.8 13.00 89.0 20.00 57.8 13.00 35.6 8.00 89.0 20.00 57.8 13.00 35.6 8.00 22.2 5.00 89.0 20.00 57.8 13.00 89.0 20.00 57.8 13.00 89.0 20.00 57.8 13.00 35.6 8.00 Profile A X X B X X X X X X X X X X X X X X X X X X X X X X Page 3 of 12 Tool Kit for KK Crimp Terminals Terminal Hand Tool Series No. Locator 8993 Black 638117576 Wire Size AWG 18 20 22 24 18 mm2 0.80 0.50 0.35 0.20 0.80 Conductor Crimp Height (REF) mm In. 1.01-1.11 .040-.044 1.01-1.11 .040-.044 0.86-0.96 .034-.038 0.86-0.96 .034-.038 1.01-1.11 .040-.044 Punch Width (Ref) Conductor Insulation mm In. mm In. 2.00 .079 2.50 .098 2.00 .079 2.50 .098 2.00 .079 2.50 .098 2.00 .079 2.50 .098 2.00 .079 2.50 .098 Pull Force Minimum N Lb. 89.0 20.00 57.8 13.00 35.6 8.00 22.2 5.00 89.0 20.00 Profile A X X B X X Black X 6381120 0.50 1.01-1.11 .040-.044 2.00 .079 2.50 .098 57.8 13.00 X 7576 To Achieve IPC-A-620 Class 2 Crimps, the following overall wire insulation diameter ranges are recommended: 1. Profile A: 1.70-2.00mm (.067-.079”) 2. Profile B: 1.65-1.85mm (.065-.073”) 172160 Tool Qualification Notes 1. Pull force should be measured with no influence from the insulation crimp. 2. The above specifications are guidelines to an optimal crimp. 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. CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects because damage can occur to the tool or die. Doc No: ATS-6381175HM Revision: K Release Date: 12-06-06 Revision Date: 08-03-17 UNCONTROLLED COPY Page 4 of 12 Tool Kit for KK Crimp Terminals OPERATION TERMINAL 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. Figure 1 SWING OPEN Crimping Terminals PUSH HERE TO LOCATOR OPEN WIRE STOP 1. Select the desired terminal and hand tool locator listed in the preceding charts (see Locator Removal and Installation). 2. Swing the terminal locator away from the crimp tool shown in Figure 1. Some terminals with large insulation grips may interfere Figure 2 with the crimp tooling when swinging the locator into position. The terminal must then be loaded into the locator in the original position. 3. Insert the proper terminal into the proper nest opening. Make sure when choosing the nest opening that it corresponds with the LOCATOR TERMINAL IN PLACE A or B profiles on the hand tool. 4. Press down on the wire stop on the locator as shown in Figure 2. For terminal series 8818 (using the gray hand tool locator), WIRE STOP the wire stop will fall between the contact and the anti-fish hooking feature. See Figure 4. WIRE 5. Return the locator to its original position. 6. Insert the proper wire over the terminal. Some large OD 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 3. 7. Compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed. Release handles TERMINAL LOCATOR to open the jaws. IN PLACE 8. 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. 9. Visually inspect the crimped terminal for proper crimp location. WIRE STOP WIRE STOP WIRE AGAINST STOP Figure 3 ANTI-FISH HOOKING FEATURE Figure 4 LOCATOR Note: The tamper-proof ratchet action will not release the tool until it has been fully closed. Doc No: ATS-6381175HM Revision: K Release Date: 12-06-06 Revision Date: 08-03-17 UNCONTROLLED COPY Page 5 of 12 Tool Kit for KK Crimp Terminals For the Battery Power Tool Operation: 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 LIFT UP location. LOCATOR Locator Removal and Installation 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 up on the locator. Slip the locator off of the top of the brass pivot shaft. See Figure 5. 4. Replace it with the proper locator by putting it over the brass pivot shaft and snapping it into place. Locator Replacement JAWS OPEN PRESS DOWN ON BRASS PIVOT SHAFT SWING LOCATOR OPEN Figure 5 See the parts list on the last page of this document for the proper locator order number. Follow the steps above to replace the locator. Maintenance Figure 6B 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 LUBRICATION contaminants with a clean brush or a soft, POINTS lint-free cloth. (BOTH SIDES) 2. Do not use any abrasive materials that LIGHT OIL could damage the tool. (EVERY MONTH 3. Make certain all pins, pivot points and OR 5,000 CRIMPS) bearing surfaces are protected with a thin coat of high-quality machine oil. Do not oil Figure 6A 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. A 30 weight automotive (light) oil used at the oil points every 5,000 crimps or 3 months will significantly enhance the tool life. See Figures 6A and 6B. 4. Wipe excess oil from the hand tool, particularly from the crimping area. Oil transferred from the crimping area onto certain terminations may affect the electrical characteristics of an application. 5. When the 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. Doc No: ATS-6381175HM Revision: K Release Date: 12-06-06 Revision Date: 08-03-17 UNCONTROLLED COPY Page 6 of 12 Tool Kit for KK Crimp Terminals 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 7. How to Adjust Tool Preload (See Figure 7) This hand tool is factory preset to 25-45 pounds 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: PRELOAD CHECK POINT 25.4MM SETTING WHEEL ECCENTRIC AXLE RATCHET 1. Remove or fold back the handle grip from the HANDLE RELEASE LEVER handle to expose the eccentric axle and GRIP setting wheel. REMOVED 2. Remove the locking screw with a 2mm hex WRENCH SET Figure 7 wrench. The wrench set (63810-0101) is not LOCKING HANDLE (SOLD supplied. It is sold separately from the hand SCREW GRIP SEPERATELY) tool. 3. Turn the eccentric axle and setting wheel with the wrench or pliers counterclockwise (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-6381175HM Revision: K Release Date: 12-06-06 Revision Date: 08-03-17 UNCONTROLLED COPY Page 7 of 12 Tool Kit for KK Crimp Terminals INSTALLATION To install the Tool Kit into the Power Crimp Head, follow the steps below: POWER CRIMP HEAD PUNCHES M4 X 18 LONG BHCS M4 X 10 LONG BHCS Figure 8 ANVILS LIFT UP ON THE LOCATOR PRESS DOWN ON THE BRASS PIVOT SHAFT SWING LOCATOR OPEN Figure 9 Anvils and Punches Installation 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 8. Locator Removal and Installation 3. Open the power crimp head. 4. Swing the existing locator open and away from the crimp tool. 5. Firmly press down on the brass pivot shaft with your thumb while pulling up on the locator. Slip the locator off of the top of the brass pivot shaft. See Figure 9. 6. Replace it with the proper locator by putting the locator over the brass pivot shaft and snapping it into place. Doc No: ATS-6381175HM Revision: K Release Date: 12-06-06 Revision Date: 08-03-17 UNCONTROLLED COPY Page 8 of 12 Tool Kit for KK Crimp 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, Molex 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 use 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 that has been stripped 12.7mm (1/2”) long so that 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 website 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 should be 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-6381175HM Revision: K Release Date: 12-06-06 Revision Date: 08-03-17 UNCONTROLLED COPY Page 9 of 12 Tool Kit for KK Crimp Terminals The chart below shows all applications for this Tool Kit. Tool Kit Order No. Tool Tool Power Head Adapter Figure Order No. Description Order No. Description No. 63810-0100 Hand Crimp Frame (Short) N/A N/A 9 63810-0400 Hand Crimp Frame (Long) N/A N/A 9 63811-7570 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 connected to 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-6381175HM Revision: K Release Date: 12-06-06 Revision Date: 08-03-17 UNCONTROLLED COPY Page 10 of 12 Tool Kit for KK Crimp Terminals HAND TOOL PARTS LIST Item Number 1 2 3 4 5 6 7 7 LOCATOR ONLY 6 LOCATOR ONLY 5 WITH TOOL KIT Order Number Description 63810-0100 Hand Crimp Frame (Short) 63810-0101 Wrench Set (Not included) 63810-0102 Locator Base 63810-0103 Repair Kit (Not included) 63811-7570 Tool Kit with Locator 63811-7575 *Gray Locator (only) 63811-7576 *Black Locator (only) *Both Locators are included with hand tool Quantity 1 0 1 0 1 REF REF 2 4 3 1 M4 X 6mm LONG BHCS RATCHET RELEASE SCREW Figure 11 4 5 Doc No: ATS-6381175HM Revision: K M4 X 12mm LONG BHCS Release Date: 12-06-06 Revision Date: 08-03-17 M4 X 12mm LONG BHCS UNCONTROLLED COPY Page 11 of 12 Tool Kit for KK Crimp Terminals POWER HEAD PARTS LIST Item 1 2 Order No. 63816-0300 63811-7570 Engineering No. 63816-0300 63811-7570 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 Application Tooling Support Phone: (402) 458-TOOL (8665) E-Mail: applicationtooling@molex.com Website: www.molex.com/applicationtooling Molex is a registered trademark of Molex, LLC in the United States of America and may be registered in other countries; all other trademarks listed herein belong to their respective owners. Doc No: ATS-6381175HM Revision: K Release Date: 12-06-06 Revision Date: 08-03-17 UNCONTROLLED COPY Page 12 of 12