molex 11-01-0185 User manual

Hand Crimp Tool for Crimp Terminals
Doc No: ATS-011010185 Release Date: 10-07-03 UNCONTROLLED COPY Page 1 of 8
Revision: G Revision Date: 04-09-08
HAND CRIMP TOOL
SPECIFICATION SHEET
Order No. 11-01-0185
Engineering No. CR2262C
FEATURES
 Small handle spread which make this style tool ideally suited for end users
 Ratchet with safety release that ensures consistent performance
 A precision user-friendly terminal locator wire stop holds terminals in the proper crimping position
SCOPE
Products: 3.96mm (.156") Pitch KK® Crimp Terminal for 22-30 AWG,
1.57mm (.062") Diameter, Standard .062" Pin and Socket Crimp Terminal for 24-30 AWG,
2.50mm (.098") Pitch SPOX™ Wire-to-Wire Male Crimp Terminal for 22-28 AWG,
KK® Anti Fish Hook and KK® Cat Ear Crimp Terminal for 22-30 AWG,
MINI KK® Crimp Receptacles for 22-30AWG,
The following is a partial list of the product part numbers and their specifications that this tool is designed to run.
We will be adding to this list and an up to date copy is available on www.molex.com
Terminal Order No. Wire Size Insulation Diameter Strip LengthTerminal
Series No.
Loose Piece  Reel AWG mm² mm In. mm In.
02-06-2132 02-06-6144 02-06-2131 02-06-6143
02-06-6135 04-01-0811 02-06-6130 04-01-0809
02-06-6136 39-00-0335 02-06-6137 39-00-0280
1854
02-06-6139 39-00-0337 02-06-6138 39-00-0336
24-30 0.20-0.05 1.02-2.29 .040-.090 3.17-3.96 .125-.156
02-06-1132 02-06-5148 02-06-1131 02-06-5147
02-06-1143 04-01-0812 02-06-1141 04-01-0810
02-06-5135 39-00-0339 02-06-5130 39-00-0338
1855
02-06-5139 39-00-0341 02-06-5138 39-00-0340
24-30 0.20-0.05 1.02-2.29 .040-.090 3.17-3.96 .125-.156
02-06-1232 02-06-1231 02-06-5203
02-06-3203 02-06-1233 02-06-5212
2189
02-06-5204 02-06-3202
24-30 0.20-0.05 1.02-2.29 .040-.090 3.17-3.96 .125-.156
02-06-2232 02-06-2231 02-06-6207
2190 02-06-4203
02-06-4202 24-30
0.20-0.05 1.02-2.29 .040-.090 3.17-3.96 .125-.156
2717 02-06-1140 24-30 0.20-0.05 1.02-2.29 .040-.090 3.17-3.96 .125-.156
08-50-0114 39-00-0107 08-50-0113 08-55-0130
08-50-0160 39-00-0373 08-50-0124 08-56-0109
08-50-0275 39-00-0375 08-50-0159 39-00-0032
08-51-0102 39-00-0377 08-50-0273 39-00-0064
08-55-0102 39-00-0379 08-50-0274 39-00-0372
08-55-0131 39-00-0381 08-51-0101 39-00-0374
08-56-0110 50-29-1638 08-51-0108 39-00-0376
39-00-0033 08-55-0101 39-00-0378
08-55-0101 39-00-0380
2759
08-55-0126 50-29-1757
22-30 0.35-0.05 1.02-1.57 .040-.062 2.54-3.17 .100-.125
2951 16-02-1003 16-02-1002 24-30 0.20-0.05 1.02-2.29 .040-.090 3.17-3.96 .125-.156
08-50-0322 97-00-0445 08-50-0321 97-00-0444
40445 97-00-0921
97-00-0920
22-30 0.35-0.05 1.02-1.57 .040-.062 2.54-3.17 .100-.125

Hand Crimp Tool for Crimp Terminals
Doc No: ATS-011010185 Release Date: 10-07-03 UNCONTROLLED COPY Page 2 of 8
Revision: G Revision Date: 04-09-08
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
BELL MOUTH
CRIMP HEIGHT
BEND
DOWN
BE
ND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
Terminal Order No. Wire Size Insulation Diameter Strip LengthTerminal
Series No.
Loose Piece  Reel AWG mm² mm In. mm In.
41572 08-65-0805 08-65-0804 22-30 0.20-0.05 1.02-2.29 .040-.090 3.17-3.96 .125-.156
02-06-1109 02-06-5211
4559 02-06-1111
24-30
0.20-0.05 1.02-2.29 .040-.090 3.17-3.96 .125-.156
08-50-0032 08-56-0115 08-50-0021 08-56-0120
08-50-0136 40-01-0830 08-50-0022 08-56-0155
08-55-0111 97-00-0451 08-50-0030 08-56-0158
08-50-0031 40-01-0829
08-50-0135 40-01-0831
08-55-0110 97-00-0001
08-55-0112 97-00-0450
4809
08-55-0119
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 08-70-0048 08-70-0064 24-30 0.20-0.05 1.02-2.29 .040-.090 3.17-3.96 .125-.156
5241 08-70-0103 08-70-0102 22-28 .035-0.08 1.15-1.90 .045-.075 2.60-3.20 .102-.126
08-52-0122 08-65-0814 08-52-0101 08-65-0813
08-52-0123 08-65-0816 08-52-0118 08-65-0815
08-65-0812 08-65-0818 08-52-0121 08-65-0817
08-65-0801 40-07-0815
6459
08-65-0811
22-30 0.35-0.05 1.02-1.57 .040-.062 2.54-3.17 .100-.125
6796 02-06-1138 02-06-1137 24-30 0.20-0.05 1.02-2.29 .040-.090 3.17-3.96 .125-.156
08-50-0005 50-29-1745 08-50-0004 50-29-1635
08-55-0127 08-55-0124 50-29-1744
7879
08-55-0129 08-55-0128 50-29-1900
22-30 0.35-0.05 1.02-1.57 .040-.062 2.54-3.17 .100-.125
08-52-0104 97-00-0226 08-52-0103 97-00-0225
8088 08-65-0106
97-00-0228 08-65-0105 97-00-0227
22-30 0.35-0.05 1.02-1.57 .040-.062 2.54-3.17 .100-.125
 Follow the Cut-Off Tab specifications on Applicator specification sheets.
DEFINITION OF TERMS
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the
scope.

Hand Crimp Tool for Crimp Terminals
Doc No: ATS-011010185 Release Date: 10-07-03 UNCONTROLLED COPY Page 3 of 8
Revision: G Revision Date: 04-09-08
CONDITIONS:
After crimping, the conductor profiles should measure the following (see notes on page 6).
Conductor Conductor
Wire Size Crimp Height (REF) Crimp Width
Pull Force
Minimum Profile
Terminal Series No.
AWG mm
2mm In. mm In. N Lb. A B
24 0.20 0.76-0.86 .030-.034 1.40 .055 35.6 8.00 X
26 0.12 0.71-0.81 .028-.032 1.40 .055 22.2 4.99 X
28 0.08 0.69-0.79 .027-.031 1.40 .055 13.3 2.99 X
1854
30 0.05 0.69-0.79 .027-.031 1.40 .055 8.9 2.00 X
24 0.20 0.76-0.86 .030-.034 1.40 .055 35.6 8.00 X
26 0.12 0.71-0.81 .028-.032 1.40 .055 22.2 4.99 X
28 0.08 0.69-0.79 .027-.031 1.40 .055 13.3 2.99 X
1855
30 0.05 0.69-0.79 .027-.031 1.40 .055 8.9 2.00 X
24 0.20 0.76-0.86 .030-.034 1.40 .055 28.9 6.50 X
26 0.12 0.71-0.81 .028-.032 1.40 .055 17.8 4.00 X
28 0.08 0.69-0.79 .027-.031 1.40 .055 11.1 2.50 X
2189
30 0.05 0.69-0.79 .027-.031 1.40 .055 6.7 1.50 X
24 0.20 0.76-0.86 .030-.034 1.40 .055 28.9 6.50 X
26 0.12 0.71-0.81 .028-.032 1.40 .055 17.8 4.00 X
28 0.08 0.69-0.79 .027-.031 1.40 .055 11.1 2.50 X
2190
30 0.05 0.69-0.79 .027-.031 1.40 .055 6.7 1.50 X
24 0.20 0.76-0.86 .030-.034 1.40 .055 28.9 6.50 X
26 0.12 0.71-0.81 .028-.032 1.40 .055 17.8 4.00 X
28 0.08 0.69-0.79 .027-.031 1.40 .055 11.1 2.50 X
2717
30 0.05 0.69-0.79 .027-.031 1.40 .055 6.7 1.50 X
22 0.35 0.76-0.86 .030-.034 1.40 .055 44.8 10.00 X
24 0.20 0.76-0.86 .030-.034 1.40 .055 28.9 6.50 X
26 0.12 0.71-0.81 .028-.032 1.40 .055 17.8 4.00 X
28 0.08 0.69-0.79 .027-.031 1.40 .055 11.1 2.50 X
2759
30 0.05 0.69-0.79 .027-.031 1.40 .055 6.7 1.50 X
24 0.20 0.76-0.86 .030-.034 1.40 .055 28.9 6.50 X
26 0.12 0.71-0.81 .028-.032 1.40 .055 17.8 4.00 X
28 0.08 0.69-0.79 .027-.031 1.40 .055 11.1 2.50 X
2951
30 0.05 0.69-0.79 .027-.031 1.40 .055 6.7 1.50 X
22 0.35 0.76-0.86 .030-.034 1.40 .055 44.8 10.00 X
24 0.20 0.76-0.86 .030-.034 1.40 .055 28.9 6.50 X
26 0.12 0.71-0.81 .028-.032 1.40 .055 17.8 4.00 X
28 0.08 0.69-0.79 .027-.031 1.40 .055 11.1 2.50 X
40445
30 0.05 0.69-0.79 .027-.031 1.40 .055 6.7 1.50 X
22 0.35 0.76-0.86 .030-.034 1.40 .055 44.8 10.00 X
24 0.20 0.76-0.86 .030-.034 1.40 .055 28.9 6.50 X
26 0.12 0.71-0.81 .028-.032 1.40 .055 17.8 4.00 X
28 0.08 0.69-0.79 .027-.031 1.40 .055 11.1 2.50 X
41572
30 0.05 0.69-0.79 .027-.031 1.40 .055 6.7 1.50 X
24 0.20 0.76-0.86 .030-.034 1.40 .055 28.9 6.50 X
26 0.12 0.71-0.81 .028-.032 1.40 .055 17.8 4.00 X
28 0.08 0.69-0.79 .027-.031 1.40 .055 11.1 2.50 X
4559
30 0.05 0.69-0.79 .027-.031 1.40 .055 6.7 1.50 X
22 0.35 0.76-0.86 .030-.034 1.40 .055 44.8 10.00 X
24 0.20 0.76-0.86 .030-.034 1.40 .055 28.9 6.50 X
26 0.12 0.71-0.81 .028-.032 1.40 .055 17.8 4.00 X
4809
28 0.08 0.69-0.79 .027-.031 1.40 .055 11.1 2.50 X

Hand Crimp Tool for Crimp Terminals
Doc No: ATS-011010185 Release Date: 10-07-03 UNCONTROLLED COPY Page 4 of 8
Revision: G Revision Date: 04-09-08
Figure 1
Conductor Conductor
Wire Size Crimp Height (REF) Crimp Width
Pull Force
Minimum Profile
Terminal Series No.
AWG mm
2mm In. mm In. N Lb. A B
30 0.05 0.69-0.79 .027-.031 1.40 .055 6.7 1.50 X
24 0.20 0.76-0.86 .030-.034 1.40 .055 28.9 6.50 X
26 0.12 0.71-0.81 .028-.032 1.40 .055 17.8 4.00 X
28 0.08 0.69-0.79 .027-.031 1.40 .055 11.1 2.50 X
5159
30 0.05 0.69-0.79 .027-.031 1.40 .055 6.7 1.50 X
22 0.35 0.76-0.86 .030-.034 1.40 .055 39.2 8.80 X
24 0.20 0.76-0.86 .030-.034 1.40 .055 29.4 6.60 X
26 0.12 0.71-0.81 .028-.032 1.40 .055 19.6 4.40 X
5241
28 0.08 0.69-0.79 .027-.031 1.40 .055 9.8 2.20 X
22 0.35 0.76-0.86 .030-.034 1.40 .055 44.8 10.00 X
24 0.20 0.76-0.86 .030-.034 1.40 .055 28.9 6.50 X
26 0.12 0.71-0.81 .028-.032 1.40 .055 17.8 4.00 X
28 0.08 0.69-0.79 .027-.031 1.40 .055 11.1 2.50 X
6459
30 0.05 0.69-0.79 .027-.031 1.40 .055 6.7 1.50 X
24 0.20 0.76-0.86 .030-.034 1.40 .055 28.9 6.50 X
26 0.12 0.71-0.81 .028-.032 1.40 .055 17.8 4.00 X
28 0.08 0.69-0.79 .027-.031 1.40 .055 11.1 2.50 X
6796
30 0.05 0.69-0.79 .027-.031 1.40 .055 6.7 1.50 X
22 0.35 0.76-0.86 .030-.034 1.40 .055 44.8 10.00 X
24 0.20 0.76-0.86 .030-.034 1.40 .055 28.9 6.50 X
26 0.12 0.71-0.81 .028-.032 1.40 .055 17.8 4.00 X
28 0.08 0.69-0.79 .027-.031 1.40 .055 11.1 2.50 X
7879
30 0.05 0.69-0.79 .027-.031 1.40 .055 6.7 1.50 X
22 0.35 0.76-0.86 .030-.034 1.40 .055 44.8 10.00 X
24 0.20 0.76-0.86 .030-.034 1.40 .055 28.9 6.50 X
26 0.12 0.71-0.81 .028-.032 1.40 .055 17.8 4.00 X
28 0.08 0.69-0.79 .027-.031 1.40 .055 11.1 2.50 X
8088
30 0.05 0.69-0.79 .027-.031 1.40 .055 6.7 1.50 X
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.
TERMINAL
Figure 2
LOCATOR
BLADE
CONDUCTOR
GRIPS
INSULATION
GRIPS
WIRE
LOCATOR
✹
The above terminal drawing is a generic
terminal representation. It is not an image
of a terminal listed in the scope.

Hand Crimp Tool for Crimp Terminals
Doc No: ATS-011010185 Release Date: 10-07-03 UNCONTROLLED COPY Page 5 of 8
Revision: G Revision Date: 04-09-08

Hand Crimp Tool for Crimp Terminals
Doc No: ATS-011010185 Release Date: 10-07-03 UNCONTROLLED COPY Page 6 of 8
Revision: G Revision Date: 04-09-08
Crimping Terminals
1. Lift the locator blade and place the terminal into the correct die profile (A or B), release the locator blade.
Not all tools are equipped with a locator or locator blade.
2. Partially close the tool until the terminal is held in place. See Figure 2.
3. Insert the proper wire over the terminal and up against the locator blade. See Figure 3. On tools without
locators line the wire up with the conductor and insulation grips visually.
4. Compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been
completed. Release handles to open the jaws. See Figure 4.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
5. Lift the locator blade or wire stop up.
6. Carefully remove the crimped terminal.
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.
4. 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 4.
How to Adjust Tool Crimp Force
(See Figure 4)
It may be necessary over the life of the tool to adjust tool-crimping force. Listed below are the steps required to
adjust the crimping force of the hand tool to obtain proper crimp conditions:
1. Remove the screw and washer. Located over the adjustment ring.
2. Lift the adjusting ring slightly, off of the locating pin.
3. Turn the adjusting ring in the desired direction (L= less force, T= more force) to increase or decrease crimp
pressure.
4. Press the adjusting wheel flat against the tool and engage the locking pin.
5. Replace the washer and screw.
6. Check the crimp specifications after tool crimp force is adjusted.
Figure 3

Hand Crimp Tool for Crimp Terminals
Doc No: ATS-011010185 Release Date: 10-07-03 UNCONTROLLED COPY Page 7 of 8
Revision: G Revision Date: 04-09-08
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 Crimp Terminals
Doc No: ATS-011010185 Release Date: 10-07-03 UNCONTROLLED COPY Page 8 of 8
Revision: G Revision Date: 04-09-08
M4 NUT
RATCHET
RELEASE LEVER
ADJUSTMENT
RING
LOCATOR
BLADE
2
Figure 4
1
M4 X 18LG BHCS
3
PARTS LIST
Item Number Order Number Description Quantity
1 11-11-0311 Locator Assembly** 1
2 11-11-0324 Spring (Main) 1
3 11-11-0320 Spring (Ratchet) 1
** Not all tools are equipped with a locator or locator blade.
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Lisle, Illinois 60532 U.S.A.
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[email protected]
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Yamato, Kanagawa, Japan
81-462-65-2324
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65-6-268-6868
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[email protected]
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Lisle, IL 60532 U.S.A.
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Fax: [phone]
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