molex 207128 Series User manual

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
2C
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
mm
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 X
20 0.50 1.01-1.11 .040-.044 2.00 .079 2.50 .098 57.8 13.00 X
22 0.35 0.86-0.96 .034-.038 2.00 .079 2.50 .098 35.6 8.00 X
2477 Black
24 0.20 0.86-0.96 .034-.038 2.00 .079 2.50 .098 22.2 5.00 X
18 0.80 1.01-1.11 .040-.044 2.00 .079 2.50 .098 89.0 20.00 X
20 0.50 1.01-1.11 .040-.044 2.00 .079 2.50 .098 57.8 13.00 X
2478 Black
22 0.35 0.86-0.96 .034-.038 2.00 .079 2.50 .098 35.6 8.00 X

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
mm
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 X
18 0.80 1.01-1.11 .040-.044 2.00 .079 2.50 .098 89.0 20.00 X
2878 Black 20 0.50 1.01-1.11 .040-.044 2.00 .079 2.50 .098 57.8 13.00
X
18 0.80 1.01-1.11 .040-.044 2.00 .079 2.50 .098 89.0 20.00 X
20 0.50 1.01-1.11 .040-.044 2.00 .079 2.50 .098 57.8 13.00 X
4838 Black
22 0.35 0.86-0.96 .034-.038 2.00 .079 2.50 .098 35.6 8.00 X
18 0.80 1.01-1.11 .040-.044 2.00 .079 2.50 .098 89.0 20.00 X
20 0.50 1.01-1.11 .040-.044 2.00 .079 2.50 .098 57.8 13.00 X
22 0.35 0.86-0.96 .034-.038 2.00 .079 2.50 .098 35.6 8.00 X
5167 Black
24 0.20 0.86-0.96 .034-.038 2.00 .079 2.50 .098 22.2 5.00 X
18 0.80 1.01-1.11 .040-.044 2.00 .079 2.50 .098 89.0 20.00 X
6438 Black 20 0.50 1.01-1.11 .040-.044 2.00 .079 2.50 .098 57.8 13.00
X
18 0.80 1.01-1.11 .040-.044 2.00 .079 2.50 .098 89.0 20.00 X
6838 Black 20 0.50 1.01-1.11 .040-.044 2.00 .079 2.50 .098 57.8 13.00
X
18 0.80 1.01-1.11 .040-.044 2.00 .079 2.50 .098 89.0 20.00 X
20 0.50 1.01-1.11 .040-.044 2.00 .079 2.50 .098 57.8 13.00 X
8818 Gray
22 0.35 0.86-0.96 .034-.038 2.00 .079 2.50 .098 35.6 8.00 X
18 0.80 1.01-1.11 .040-.044 2.00 .079 2.50 .098 89.0 20.00 X
20 0.50 1.01-1.11 .040-.044 2.00 .079 2.50 .098 57.8 13.00 X
22 0.35 0.86-0.96 .034-.038 2.00 .079 2.50 .098 35.6 8.00 X
8993 Black
24 0.20 0.86-0.96 .034-.038 2.00 .079 2.50 .098 22.2 5.00 X
 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
1
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
LOCATOR
TERMINAL IN PLACE
F
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: [phone]
Visit our Web site at http://www.molex.com
RATCHET
RELEASE LEVER
2
Figure 7
M4 X 5LG
BHCS
3
4
1
3