molex 63811-6670 User manual

Tool Kit for KK® .156 Centers Crimp Terminals
Doc No: ATS-6381166H Release Date: 08-02-06 UNCONTROLLED COPY Page 1 of 9
Revision: D Revision Date: 04-24-12
Application Tooling
Specification Sheet
Tool Kit
Order No. 6 811-6670
Hand Crimp Tool
Order No. 6 811-6600
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.
 any different Tool kits can be used with a single Battery Powered Tool.
 This tool is IPC/WH A-A-620 Class 2 and RoHS compliant.
SCOPE
Products: “KK®” .156 Centers Crimp Terminals, 18-30 AWG.
Terminal
Series No.
Terminal Order No. Wire Size Insulation Diameter Strip Length
Loose Piece 

Reel AWG mm² mm In. mm In.
1797
08-01-0102 08-05-0104 08-01-0101 08-06-0101
18-24 0.80-0.20 1.78-2.79 .070-.110 3.06-3.96 .120-.156
08-01-0122 08-06-0102 08-01-0121 08-05-0103
08-01-0124 08-07-0102 08-01-0123 08-07-0101
08-03-0102 08-03-0101
08-01-0106 08-05-0106 08-01-0105 08-05-0105
24-30 0.20-0.05 0.76-1.78 .030-.070 3.06-3.96 .120-.156
08-01-0126 08-01-0125
4366
08-03-0304 08-05-0301 40-01-1194
18-24 0.80-0.20 1.78-2.79 .070-.110 3.06-3.96 .120-.156 08-05-0302 08-03-0303 50-36-1873
08-05-0305
4573 08-05-0304 08-03-0306 08-05-0303 08-03-0305 24-30 0.20-0.05 0.76-1.78 .030-.070 3.06-3.96 .120-.156
 Customer to cut off terminal from reel: 0.25mm (.010”) maximum Cut-off Tab.
DEFINITION OF TERMS
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the scope.
TYPE 2C
INSULATION
CRIMP
▲SEE NOTE
BRUSH
STRIP
LENGTH
BELL MOUTH
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
CRIMP HEIGHT

Tool Kit for KK® .156 Centers Crimp Terminals
Doc No: ATS-6381166H Release Date: 08-02-06 UNCONTROLLED COPY Page 2 of 9
Revision: D Revision Date: 04-24-12
▲Insulation Crimp Note:
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).
CONDITIONS:
After crimping, the conductor profiles should measure the following (see notes below).
Terminal Series No. Wire Size Conductor Crimp Pull Force
Minimum Profile
Height (Ref) Width (Ref)
AWG mm2 mm In. mm In. N Lb. A B
1797
18 0.80 0.92-1.02 .036-.040 1.93 .076 111.2 25.00 X
20 0.50 0.91-1.01 .035-.039 1.93 .076 66.7 15.00 X
22 0.35 0.91-1.01 .035-.039 1.93 .076 53.4 12.00 X
24 0.20 0.89-0.99 .034-.038 1.93 .076 31.1 7.00 X
4366
18 0.80 0.92-1.02 .036-.040 1.93 .076 111.2 25.00 X
20 0.50 0.91-1.01 .035-.039 1.93 .076 66.7 15.00 X
22 0.35 0.91-1.01 .035-.039 1.93 .076 53.4 12.00 X
24 0.20 0.89-0.99 .034-.038 1.93 .076 31.1 7.00 X
1797
24 0.20 0.85-0.95 .033-.037 1.68 .066 31.1 7.00 X
26 0.12 0.80-0.90 .031-.035 1.68 .066 17.8 4.00 X
28 0.08 0.78-0.88 .030-.035 1.68 .066 11.1 2.50 X
30 0.05 0.77-0.87 .030-.034 1.68 .066 6.7 1.50 X
4573
24 0.20 0.85-0.95 .033-.037 1.68 .066 31.1 7.00 X
26 0.12 0.80-0.90 .031-.035 1.68 .066 17.8 4.00 X
28 0.08 0.78-0.88 .030-.035 1.68 .066 11.1 2.50 X
30 0.05 0.77-0.87 .030-.034 1.68 .066 6.7 1.50 X
Tool Qualification Notes:
1. Pull Force should be measured with no influence from the insulation crimp.
2. The above specifications are guidelines to an optimum crimp.
3. Wires with tinned conductors will have higher pull strength than bare copper.
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 ust exceed the
inimum pull force specifications listed on this page.
OVERLAP
INSULATION
CRIMP
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
WIRE

Tool Kit for KK® .156 Centers Crimp Terminals
Doc No: ATS-6381166H Release Date: 08-02-06 UNCONTROLLED COPY Page 3 of 9
Revision: D Revision Date: 04-24-12
SWING
LOCATOR
OPEN
PRESS DOWN
ON THE BRASS
PIVOT SHAFT
LIFT UP ON
THE LOCATOR
Figure 2
ANVILS
POWER
CRIMP
HEAD
Figure 1
PUNCHES
M4 X 10 LONG
BHCS
M4 X 18 LONG
BHCS
CAUTION: Install only olex terminals listed above with this tool. Do not crimp hardened objects as damage
can occur to the tool or die.
INSTALLATION
To install the Tool Kit into the Power Crimp Head follow the steps below:
Anvils and Punches Installation
1. Insert the Anvils into the bottom slots of the nest. Install the 4 x 10 long BHCS and tighten in place.
2. Insert the Punches into the top slots of the nest. Install the 4 x 18 long BHCS and tighten in place. See
Figure 1.
Locator Installation and Removal
Follow the steps below to install or replace the locator. See Figure 2.
To install the locator
1. Position the locator with the hole over the brass pivot shaft and snap it
into place.
To remove the locator
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.
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.
Figure
LOCATOR
JAWS OPEN

Tool Kit for KK® .156 Centers Crimp Terminals
Doc No: ATS-6381166H Release Date: 08-02-06 UNCONTROLLED COPY Page 4 of 9
Revision: D Revision Date: 04-24-12
TERMINAL
PUSH HERE TO
OPEN WIRE STOP
SWING OPEN
LOCATOR LOCATOR TERMINAL IN PLACE
Figure 4
LOCATOR
IN PLACE
WIRE STOP
TERMINAL
WIRE
WIRE STOP
WIRE
AGAINST STOP Figure 5
Crimping Terminals
1. Select the desired terminal listed in
the preceding charts.
2. Swing the terminal locator away from
the crimp tool shown in Figure 4.
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. When using the locator, press down on the wire stop on the locator as shown in Figure 4. Insert the proper
terminal into the proper nest opening. ake sure when choosing the nest opening, it will correspond with the
A or B profile on the hand tool.
4. Return the locator to its original position.
5. Insert the proper wire over the terminal. Some large O.D. 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 5.
6. Compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.
Release handles to open the jaws.
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: The tamper proof ratchet action will not release the tool until it has been fully closed.
For the Battery Power Tool:
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 location.
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.
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 6.
4. Replace it with the proper locator by putting over the brass
pivot shaft and snapping it into place.

Tool Kit for KK® .156 Centers Crimp Terminals
Doc No: ATS-6381166H Release Date: 08-02-06 UNCONTROLLED COPY Page 5 of 9
Revision: D Revision Date: 04-24-12
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. ake 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. Use a 30 weight automotive (light) oil used at the
oil points, every 5,000 crimps or 3 months, shown in Figure
7A or 7B 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 8.
How to Adjust Tool Preload (See Figure 8)
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.
SWING
LOCATOR
OPEN
PRESS DOWN
ON BRASS PIVOT
SHAFT
LIFT UP
LOCATOR
JAWS
OPEN
Figure 6
RATCHET
RELEASE LEVER
Figure 8
HANDLE
GRIP
REMOVED
ECCENTRIC AXLE
HANDLE
GRIP
LOCKING
SCREW
WRENCH SET
(SOLD
SEPERATELY)
PRELOAD
CHECK POINT
25.4MM
SETTING WHEEL
Figure 7B
LUBRICATION
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY MONTH
OR
5,000 CRIMPS)
Figure 7A

Tool Kit for KK® .156 Centers Crimp Terminals
Doc No: ATS-6381166H Release Date: 08-02-06 UNCONTROLLED COPY Page 6 of 9
Revision: D Revision Date: 04-24-12
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.
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: olex crimp specifications are valid only when used with olex terminals and tooling.
CAUTIONS
1. anually 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 olex terminals specified for crimping with this tool.
Certification
olex 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 olex 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.

Tool Kit for KK® .156 Centers Crimp Terminals
Doc No: ATS-6381166H Release Date: 08-02-06 UNCONTROLLED COPY Page 7 of 9
Revision: D Revision Date: 04-24-12
The chart below shows all applications for this Tool Kit.
Tool Kit
Order No.
Tool
Order no.
Tool
Description
Power Head
Order No.
Adapter
Description Figure No.
63811-6670
63810-0100 Hand Crimp Frame (Short) N/A N/A 9
63810-0400 Hand Crimp Frame (Long) N/A N/A 9
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
Figure 9 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 anual or Specification Sheet. See
Chart above for the correct anual or Specification Sheet.
WARNING: NEVER install tooling or service this tool while it is into any power source. ake 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.
POWER
CRIMP
HEAD
LOCKING PINS
BATTERY
POWERED
TOOL
TOOLING KIT
HAND CRIMP
FRAME LONG
AND SHORT
TOOLING
KIT

Tool Kit for KK® .156 Centers Crimp Terminals
Doc No: ATS-6381166H Release Date: 08-02-06 UNCONTROLLED COPY Page 8 of 9
Revision: D Revision Date: 04-24-12
RATCHET
RELEASE SCREW
Figure 11
1
M4 X 6mm
LONG BHCS
M4 X 12mm
LONG BHCS
5
6
WITH TOOL KIT
LOCATOR ONLY
M4 X 12mm
LONG BHCS
4
4
2
5
HAND TOOL PARTS LIST
Item Number Order Number Description Quantity
1 63810-0100 Hand Crimp Frame (Short) 1
2 63810-0101 Wrench Set (Not included) 0
3 63810-0102 Locator Base 1
4 63810-0103 Repair Kit (Not included) 0
5 63811-6670 Tool Kit with Locator 1
6 63811-6675 Locator (only) REF

Tool Kit for KK® .156 Centers Crimp Terminals
Doc No: ATS-6381166H Release Date: 08-02-06 UNCONTROLLED COPY Page 9 of 9
Revision: D Revision Date: 04-24-12
Figure 12
1
2
2
M4 by 8 Long
BHCS
M4 by 18 Long
BHCS
M4 by 10 Long
BHCS
1
POWER HEAD PARTS LIST
Item Order No Engineering No. Description Quantity
1
63816-0300 63816-0300 Power Crimp Head 1
2
63811-6670 63811-6670 Tool Kit 1
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