0638118200

Hand Crimp Tool For 2.54mm (.100) KK® Crimp Terminals HAND CRIMP TOOL Application Tooling Specification Sheet TYPE 4D 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 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 2759 22-30 0.35-0.05 1.09-1.57 .040-.062 2.54-3.17 .100-.125 08-51-0102 39-00-0377 08-55-0102 39-00-0379 08-55-0131 39-00-0381 08-56-0110 50-29-1638 08-50-0032 40-01-0830 08-50-0136 97-00-0451 4809 22-30 0.35-0.05 1.02-1.57 .040-.062 2.54-3.17 .100-.125 08-55-0111 97-00-0453 08-56-0115 5159 08-70-0049 08-70-0069 22-28 0.35-0.08 1.20-1.70 .040-.067 2.54-3.17 .100-.125 08-52-0122 08-65-0814 6459 08-52-0123 08-65-0816 22-30 0.35-0.05 1.02-1.57 .040-.062 2.54-3.17 .100-.125 08-65-0812 08-65-0818 08-52-0104 08-65-0228 08-52-0106 40-07-0813 8088 08-52-0108 97-00-0226 22-30 0.35-0.05 1.02-1.57 .040-.062 2.54-3.17 .100-.125 08-65-0106 97-00-0228 08-65-0226 08-50-0322 97-00-0445 40445 22-30 0.35-0.05 1.02-1.57 .040-.062 2.54-3.17 .100-.125 97-00-0921 41572 08-65-0805 22-30 0.20-0.05 1.02-1.57 .040-.062 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. Terminal Series No. Doc No: ATS-638118200 Revision: F Release Date: 10-26-07 Revision Date: 02-04-11 UNCONTROLLED COPY Page 1 of 9 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: F 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 0.05 0.35 0.20 0.12 0.08 0.05 0.35 0.20 0.12 0.08 0.35 0.20 0.12 0.08 0.05 0.35 0.20 0.12 0.08 0.05 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 0.63-0.73 .025-.029 1.37 .054 1.33 .052 1.42 .056 0.63-0.73 .025-.029 1.37 .054 1.33 .052 1.42 .056 0.63-0.73 .025-.029 1.37 .054 1.33 .052 1.42 .056 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 0.63-0.73 .025-.029 1.37 .054 1.33 .052 1.42 .056 0.63-0.73 .025-.029 1.37 .054 1.33 .052 1.42 .056 0.63-0.73 .025-.029 1.37 .054 1.33 .052 1.42 .056 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 0.63-0.73 .025-.029 1.37 .054 1.33 .052 1.42 .056 0.63-0.73 .025-.029 1.37 .054 1.33 .052 1.42 .056 0.76-0.86 .030-.034 1.42 .056 1.45 .057 1.64 .065 0.73-0.83 .029-.033 1.42 .056 1.40 .055 1.61 .063 0.69-0.79 .027-.031 1.37 .054 1.38 .054 1.40 .055 0.69-0.79 .027-.031 1.37 .054 1.38 .054 1.40 .055 0.69-0.79 .027-.031 1.37 .054 1.38 .054 1.40 .055 0.76-0.86 .030-.034 1.42 .056 1.45 .057 1.64 .065 0.73-0.83 .029-.033 1.42 .056 1.40 .055 1.61 .063 0.69-0.79 .027-.031 1.37 .054 1.38 .054 1.40 .055 0.69-0.79 .027-.031 1.37 .054 1.38 .054 1.40 .055 0.69-0.79 .027-.031 1.37 .054 1.38 .054 1.40 .055 Release Date: 10-26-07 Revision Date: 02-04-11 UNCONTROLLED COPY Page 2 of 9 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: F 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 0.63-0.73 .025-.029 1.37 .054 1.33 .052 1.42 .056 0.63-0.73 .025-.029 1.37 .054 1.33 .052 1.42 .056 0.63-0.73 .025-.029 1.37 .054 1.33 .052 1.42 .056 0.76-0.86 .030-.034 1.42 .056 1.45 .057 1.64 .065 0.73-0.83 .029-.033 1.42 .056 1.40 .055 1.61 .063 0.69-0.79 .027-.031 1.37 .054 1.38 .054 1.40 .055 0.69-0.79 .027-.031 1.37 .054 1.38 .054 1.40 .055 0.69-0.79 .027-.031 1.37 .054 1.38 .054 1.40 .055 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 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 0.35 0.20 0.12 0.08 0.35 0.20 0.12 0.08 0.05 0.35 0.20 0.12 0.08 0.05 0.35 0.20 0.12 0.08 0.05 0.35 0.20 0.12 0.08 0.05 Release Date: 10-26-07 Revision Date: 02-04-11 Profile Pull Force Minimum A B C D N Lb. 26-30 22-24 22-24 26-30 44.8 10.00 X 28.9 6.50 X 17.8 4.00 X 11.1 2.50 X 6.7 1.50 X 44.8 10.00 X 28.9 6.50 X 17.8 4.00 X 11.1 2.50 X 6.7 1.50 X 39.2 8.00 X 28.9 6.50 X 17.8 4.00 X 11.1 2.50 X 44.8 10.00 X 28.9 6.50 X 17.8 4.00 X 11.1 2.50 X 6.7 1.50 X 44.8 10.00 X 28.9 6.50 X 17.8 4.00 X 11.1 2.50 X 6.7 1.50 X 44.8 10.00 X 28.9 6.50 X 17.8 4.00 X 11.1 2.50 X 6.7 1.50 X 44.8 10.00 X 28.9 6.50 X 17.8 4.00 X 11.1 2.50 X 6.7 1.50 X UNCONTROLLED COPY Page 3 of 9 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. Select the desired terminal listed in the preceding charts. 2. Make sure the center of the locator is in the down position. With the locator attached, push the locator button on the back of the hand tool to bring the locator forward through the tooling. See Figure 2. LOCATOR PUSHED THRU TOOLING Figure 2 SQUEEZE HANDLES TOGETHER Figure 1 RELEASE LOCATOR BUTTON LOCATOR LOCATOR BUTTON PUSHED IN TERMINAL Figure 3 TOOLING PARTIALLY CLOSED TERMINAL 3. While holding the locator button in, load the terminal into the proper nest opening in the locator based on the wire gauge or terminal type markings on the hand tooling. See Figure 3. 4. Release the locator button, allowing the locator to return to the crimping position. 5. Close the tool handle until the first ratchet position engages. See Figure 4. Doc No: ATS-638118200 Revision: F PUSH ON THE LOCATOR BUTTON Release Date: 10-26-07 Revision Date: 02-04-11 PARTIALLY CLOSE HANDLE OPEN POSITION FIRST RATCHET POSITION Figure 4 UNCONTROLLED COPY Page 4 of 9 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. WIRE 8. Remove the crimped terminal from the terminal locator by pulling on the wire. 9. Visually inspect the crimped terminal for proper crimp location. 10. On some large O.D. wires, it may not be possible to insert the wire with the tool partially closed. Those wires should be inserted with the hand tool in the open position. Insert the wire above the terminal in the punch and against the wire stop then close the tool. See Figure 6. WIRE STOP Figure 6 TERMINAL 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 available, actual crimp height measurements may very slightly. An occasional, destructive, pull force test should be performed to check hand tool crimp. Pull Force value Must exceed the Minimum pull force specifications listed. Doc No: ATS-638118200 Revision: F Release Date: 10-26-07 Revision Date: 02-04-11 UNCONTROLLED COPY Page 5 of 9 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. HANDTOOL The lower tabs of the locator should disengage from the hand tool. TOP HOOKS 3. Lift and pull away from the hand tool. The top locator hooks should slip out of the top slots easily. See Figure 7A. 4. To reinstall the new locator, make sure the hand tool is in the open position. Figure 7B 5. Press the red insert down as far as it will go as shown in Figure 7B. 6. Holding onto the lower part of the locator with LOWER TABS your thumb and index finger, insert the locators top hooks (2) into the hand tool top slots. 7. Rotate the locator down and press the lower tabs into the two bottom slots of the hand tool. To secure the locator into place, the lower tabs must snap into place on the hand tool frame. Right or Left Hand Operation This hand tool has an added feature that can be converted from a right handed application to a left handed application. It is necessary to reverse the tooling if using the left handed application along with the locator. Follow the steps below: JAWS OPEN PULL OPEN TOOLING TOOLING M3 BHCS 1. The locator must be removed before reversing the tooling. 2. Remove the M3 BHCS which is holding the Figure 8 upper tooling. 3. Flip the upper tooling to the opposite side and replace the M3 BHCS. Make sure the PUSH ON HANDLE small markings on the front and back of the hand tool frame match up and are on the outside of the hand tool frame. See Figure 8 and 9. 4. Do the same thing with the lower tooling and tighten the M3 screws. Be sure the small markings line up. 5. Reinstall the locator by following the Instructions in the locator replacement section. Doc No: ATS-638118200 Revision: F Release Date: 10-26-07 Revision Date: 02-04-11 UNCONTROLLED COPY Page 6 of 9 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. Do not oil excessively. The tool was engineered for durability but like any other 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, will significantly enhance the tool life. 4. Wipe excess oil from hand tool, particularly from crimping area. Oil RATCHET RELEASE transferred from the crimping area LEVER 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 LUBRICATION POINTS area. (BOTH SIDES) LIGHT OIL Figure 11 (EVERY 3 MONTHS OR 5,000 CRIMPS) 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 up on the ratchet release lever in the movable handle. See Figure 11. Figure 10 RATCHET RELEASE LEVER SQUEEZE THE LINK IN THE HANDLE HOLD THE HAND TOOL IN POSITION How to Adjust Tool Preload (See Figure 12) 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: Doc No: ATS-638118200 Revision: F Figure 12 SETTING WHEEL Release Date: 10-26-07 Revision Date: 02-04-11 UNCONTROLLED COPY Page 7 of 9 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. 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 hand tools but rather supplies the following guidelines for customers to re-certify hand tools. % This tool is qualified to pull force only. 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-638118200 Revision: F Release Date: 10-26-07 Revision Date: 02-04-11 UNCONTROLLED COPY Page 8 of 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 3 http://www.molex.com Doc No: ATS-638118200 Revision: F Release Date: 10-26-07 Revision Date: 02-04-11 UNCONTROLLED COPY Page 9 of 9