molex 63811-7400 User manual

Hand Crimp Tool for 3.96mm (.156") Pitch KK® Crimp Terminal
Doc No: ATS-638117400 Release Date: 10-31-06 UNCONTROLLED COPY Page 1 of 7
Revision: B Revision Date: 04-08-08
TYPE 2C
Hand Crimp Tool
Specification Sheet
Order No. 63811-7400
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
SCOPE
Products: 3.96mm (.156") Pitch KK® Crimp Terminal for 22-26 AWG
Terminal Order No. Wire Size Insulation Diameter Strip LengthTerminal
Series No.
Loose Piece  Reel AWG mm² mm In. mm In.
08-50-0019 08-56-0122 08-50-0018 08-56-0161
08-50-0062 08-56-0163 08-50-0061 08-56-0162
08-50-0066 08-58-0126 08-50-0065 08-58-0125
08-50-0108 08-60-0004 08-50-0107 08-59-0101
08-50-0112 08-65-0107 08-50-0111 08-60-0003
08-50-0134 08-65-0111 08-50-0133 08-65-0108
08-52-0117 08-65-0117 08-50-0504 08-65-0109
08-55-0106 40-01-1119 08-52-0116 08-65-0110
08-55-0132 40-07-1106 08-55-0105 08-65-0116
08-56-0108 50-29-1878 08-55-0121 40-01-1117
08-55-0123 40-07-1105
08-55-0137 50-29-1767
08-56-0107 50-29-1877
2578
08-56-0121
22 - 26 0.35-0.12 1.20-1.52 .047-.060 2.54-3.17 .100-.125
5168 08-70-0019 08-70-0099 08-70-0018 08-70-0098 22 - 26 0.35-0.12 1.20-1.52 .047-.060 2.54-3.17 .100-.125
08-50-0185 08-58-0134 08-04-0001 08-56-0181
08-52-0125 08-65-0122 08-50-0183 08-58-0133
08-56-0124 08-65-0127 08-50-0283 08-65-0121
08-56-0182 08-52-0124 08-65-0126
7258
08-56-0123
22 - 26 0.35-0.12 1.20-1.52 .047-.060 2.54-3.17 .100-.125
 Customer to cut off terminal from reel: .2.80mm (.110”) maximum Cut-off Tab center.
 See Conditions on page 2.

Hand Crimp Tool for 3.96mm (.156") Pitch KK® Crimp Terminal
Doc No: ATS-638117400 Release Date: 10-31-06 UNCONTROLLED COPY Page 2 of 7
Revision: B Revision Date: 04-08-08
INSULATION CRIMP
BRUSH
STRIP
LE
NGTH
BELL
MOUTH
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLLING
LOCKING
TANG HEIGHT
TWISTING
CUT
-
OFF
TAB
SEAM
CONDUCTOR CRIMP
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
Terminal Series No.
AWG
mm
2mm In. mm In. mm In. N Lb. A
B
22 0.35 .94-1.04 .037-.041 1.56 .061 1.94 .076 44.0 10.0 X
24 0.20 .84-.94 .033-.037 1.56 .061 1.56 .061 29.0 6.5 X
2578
26 0.12 .84-.94 .033-.037 1.56 .061 1.56 .061 18.0 4.0 X
22 0.35 .94-1.04 .037-.041 1.56 .061 1.94 .076 44.0 10.0 X
24 0.20 .84-.94 .033-.037 1.56 .061 1.56 .061 29.0 6.5 X
5168
26 0.12 .84-.94 .033-.037 1.56 .061 1.56 .061 18.0 4.0 X
22 0.35 .94-1.04 .037-.041 1.56 .061 1.94 .076 44.0 10.0 X
24 0.20 .84-.94 .033-.037 1.56 .061 1.56 .061 29.0 6.5 X
7258
26 0.12 .84-.94 .033-.037 1.56 .061 1.56 .061 18.0 4.0 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.

Hand Crimp Tool for 3.96mm (.156") Pitch KK® Crimp Terminal
Doc No: ATS-638117400 Release Date: 10-31-06 UNCONTROLLED COPY Page 3 of 7
Revision: B Revision Date: 04-08-08
SWING OPEN
TERMINAL
PUSH HERE TO
OPEN WIRE STOP
LOCATOR
LOCATOR
TERMINAL IN PLACE
Figure 2
LOCATOR
IN PLACE
WIRE STOP
TERMINAL
WIRE
WIRE STOP
WIRE
AGAINST STOP
Figure 3
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 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. When using the locator, 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.
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 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.
Figure 1
LOCATOR
JAWS OPEN

Hand Crimp Tool for 3.96mm (.156") Pitch KK® Crimp Terminal
Doc No: ATS-638117400 Release Date: 10-31-06 UNCONTROLLED COPY Page 4 of 7
Revision: B Revision Date: 04-08-08
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.
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 4.
4. Replace it with the proper 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.
SWING
LOCATOR
OPEN
PRESS DOWN
ON BRASS PIVOT
SHAFT
LIFT UP
LOCATOR
JAWS
OPEN
Figure 4
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figure 5

Hand Crimp Tool for 3.96mm (.156") Pitch KK® Crimp Terminal
Doc No: ATS-638117400 Release Date: 10-31-06 UNCONTROLLED COPY Page 5 of 7
Revision: B Revision Date: 04-08-08
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.
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.
RATCHET
RELEASE LEVER
Figure 6
HANDLE
GRIP
REMOVED
ECCENTRIC AXLE
HANDLE
GRIP
LOCKING
SCREW
WRENCH SET
(SOLD
SEPERATELY)
PRELOAD
CHECK POINT
25.4MM
SETTING WHEEL

Hand Crimp Tool for 3.96mm (.156") Pitch KK® Crimp Terminal
Doc No: ATS-638117400 Release Date: 10-31-06 UNCONTROLLED COPY Page 6 of 7
Revision: B Revision Date: 04-08-08
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 3.96mm (.156") Pitch KK® Crimp Terminal
Doc No: ATS-638117400 Release Date: 10-31-06 UNCONTROLLED COPY Page 7 of 7
Revision: B Revision Date: 04-08-08
RATCHET
RELEASE LEVER
2
Figure 7
M4 X 5LG
BHCS
3
4
1
3
PARTS LIST
Item Number Order Number Description Quantity
REF 63811-7400 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
4 63811-7475 Locator 1
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