molex 63811-2200 User manual

63811-2200 Hand Crimp Tool for “KK”.156 Cent. Terminals
Doc No. 63811-2200 Release Date: 04-09-01 UNCONTROLLED COPY Page 1 of 5
Revision: F Revision Date: 02-22-06
HAND CRIMP TOOL
Operating Instruction and
Specification Sheet
Order No. 63811-2200
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 18-24 AWG
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
Wire Size Insulation Diameter Strip Length
Terminal Series No. Terminal Order No. AWG mm² mm In. mm In.
2477 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 08-52-0024 08-56-0106
08-50-0014 08-52-0045 08-56-0154
08-50-0016 08-52-0047 08-58-0104
08-50-0046 08-52-0072 08-58-0115
08-50-0064 08-52-0074 08-58-0122
08-50-0074 08-52-0115 08-65-0115
08-50-0093 08-52-0812 40-01-1120
08-50-0106 08-53-0812 50-29-1762
08-50-0120 08-55-0104 50-30-4428
2478
08-50-0147 08-55-0134 50-30-4429
18-24 0.80-0.20 1.39-2.79 .055-.110 2.54-3.17 .100-.125
08-50-0116 08-58-0128
2878 08-52-0127 08-65-0119 18-20 0.80-0.50 1.52-2.79 .060-.110 2.54-3.17 .100-.125
08-50-0132 08-55-0141 08-55-0146
4838 08-55-0140 08-55-0143 08-55-0148 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 18-24 0.80-0.20 1.39-2.48 .055-.098 2.54-3.17 .100-.125
08-50-0165 08-56-0133
6438 08-51-0802 08-56-0139 18-20 0.80-0.50 1.52-2.41 .060-.095 2.54-3.17 .100-.125
08-50-0029 08-53-1102 08-58-0132
08-50-0189 08-58-0106 08-58-0189
08-50-0251 08-58-0109 08-60-0002
08-51-0107 08-58-0111
6838
08-52-0113 08-58-0119
18-20 0.80-0.50 1.52-2.79 .060-.110 2.54-3.17 .100-.125
8993 08-50-0276 18-24 0.80-0.20 1.39-2.79 .055-.110 2.54-3.17 .100-.125

63811-2200 Hand Crimp Tool for “KK”.156 Cent. Terminals
Doc No. 63811-2200 Release Date: 04-09-01 UNCONTROLLED COPY Page 2 of 5
Revision: F Revision Date: 02-22-06
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
BELL MOUTH
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
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 4).
Punch Width (Ref)
Wire Size Cond. Crimp
Height (REF) Cond. Ins.
Pull Force Min. Profile
Terminal Series No.
AWG mm2mm In. mm In. mm In. N Lb. A B
2477 18 0.80 1.01-1.11 .040-.044 2.00 .079 2.50 .098 89.0 20.00 X
2477 20 0.50 1.01-1.11 .040-.044 2.00 .079 2.50 .098 57.8 13.00 X
2477 22 0.35 0.86-0.96 .034-.038 2.00 .079 2.50 .098 35.6 8.00 X
2477 24 0.20 0.86-0.96 .034-.038 2.00 .079 2.50 .098 22.2 5.00 X
2478 18 0.80 1.01-1.11 .040-.044 2.00 .079 2.50 .098 89.0 20.00 X
2478 20 0.50 1.01-1.11 .040-.044 2.00 .079 2.50 .098 57.8 13.00 X
2478 22 0.35 0.86-0.96 .034-.038 2.00 .079 2.50 .098 35.6 8.00 X
2478 24 0.20 0.86-0.96 .034-.038 2.00 .079 2.50 .098 22.2 5.00 X
2878 18 0.80 1.01-1.11 .040-.044 2.00 .079 2.50 .098 89.0 20.00 X
2878 20 0.50 1.01-1.11 .040-.044 2.00 .079 2.50 .098 57.8 13.00 X
4838 18 0.80 1.01-1.11 .040-.044 2.00 .079 2.50 .098 89.0 20.00 X
4838 20 0.50 1.01-1.11 .040-.044 2.00 .079 2.50 .098 57.8 13.00 X
4838 22 0.35 0.86-0.96 .034-.038 2.00 .079 2.50 .098 35.6 8.00 X
5167 18 0.80 1.01-1.11 .040-.044 2.00 .079 2.50 .098 89.0 20.00 X
5167 20 0.50 1.01-1.11 .040-.044 2.00 .079 2.50 .098 57.8 13.00 X
5167 22 0.35 0.86-0.96 .034-.038 2.00 .079 2.50 .098 35.6 8.00 X
5167 24 0.20 0.86-0.96 .034-.038 2.00 .079 2.50 .098 22.2 5.00 X
6438 18 0.80 1.01-1.11 .040-.044 2.00 .079 2.50 .098 89.0 20.00 X
6438 20 0.50 1.01-1.11 .040-.044 2.00 .079 2.50 .098 57.8 13.00 X

63811-2200 Hand Crimp Tool for “KK”.156 Cent. Terminals
Doc No. 63811-2200 Release Date: 04-09-01 UNCONTROLLED COPY Page 3 of 5
Revision: F Revision Date: 02-22-06
Figure 2
Figure 3
Punch Width (Ref)
Wire Size Cond. Crimp
Height (REF) Cond. Ins.
Pull Force Min. Profile
Terminal Series No.
AWG mm2mm In. mm In. mm In. N Lb. A B
6838 18 0.80 1.01-1.11 .040-.044 2.00 .079 2.50 .098 89.0 20.00 X
6838 20 0.50 1.01-1.11 .040-.044 2.00 .079 2.50 .098 57.8 13.00 X
8993 18 0.80 1.01-1.11 .040-.044 2.00 .079 2.50 .098 89.0 20.00 X
8993 20 0.50 1.01-1.11 .040-.044 2.00 .079 2.50 .098 57.8 13.00 X
8993 22 0.35 0.86-0.96 .034-.038 2.00 .079 2.50 .098 35.6 8.00 X
8993 24 0.20 0.86-0.96 .034-.038 2.00 .079 2.50 .098 22.2 5.00 X
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.
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. Place a wire into 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. Close the tool until the ratchet releases, (See Figure 4).
5. Lift the locator blade or wire stop up.
6. Carefully remove the crimped terminal.
TERMINAL
PRE-STRIPPED WIRE
Figure 1

63811-2200 Hand Crimp Tool for “KK”.156 Cent. Terminals
Doc No. 63811-2200 Release Date: 04-09-01 UNCONTROLLED COPY Page 4 of 5
Revision: F Revision Date: 02-22-06
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 lifting 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.
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 would exchange the tool free
of charge. This 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.
Hand held crimping tools are intended for low volume,
prototyping, or repair requirements only.
CAUTION: Repetitive use of this tool should be avoided.
Notes:
1. This tool should only be used for the terminals and
wire gauges specified on this sheet.
2. This tool is not adjustable for crimp height, however
crimp force is adjustable (See instructions above).
Variations in tools, terminals, wire stranding and
insulation types may affect crimp height.
3. This tool is intended for standard conductor sizes. It
may not give a good insulation crimp support for all
insulation sizes.
4. Molex does not repair hand tools (see warranty above)
The replacement parts listed are the only parts
available for repair. If the handles or crimp tooling is
damaged or worn, a new tool must be purchased.
5. Pull force should be used as the final criteria for an
acceptable crimp. Pull force is measured with no
influence from the insulation crimp. The insulation
should be stripped long (1/2 in.) so the insulation
grips on the terminal do not grip the wire insulation or
the conductor. Refer to Molex Quality Crimping
Handbook 63800-0029 for additional information on
crimping and crimp testing.
6. Molex does not certify crimp hand tools.
CAUTION: Molex crimp specifications are valid only
when used with Molex terminals, applicators and
tooling.

63811-2200 Hand Crimp Tool for “KK”.156 Cent. Terminals
Doc No. 63811-2200 Release Date: 04-09-01 UNCONTROLLED COPY Page 5 of 5
Revision: F Revision Date: 02-22-06
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 63811-2275 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.
Molex Application Tooling Group
2200 Wellington Court
Lisle, IL 60532
Tel: [phone]
Fax: [phone]
Visit our Web site at http://www.molex.com