molex 63811-8200 User manual

Hand Crimp Tool For 2.54mm (.100) KK® Crimp Terminals
Doc No: AT -638118200 Release Date: 10-26-07 UNCONTROLLED COPY Page 1 of 9
Revision: D Revision Date: 08-27-08
HAND CRIMP TOOL
Specification Sheet
Order No. 6 811-8200
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
 Right and Left handed applications
 This tool is IPC/WHMA A-620 Class 2 compliant
 This tool is RoH compliant, however RoH compliant is not required
SCOPE
Products: 2.54mm (.100) KK® Crimp Terminals, 22-30 AWG.
Terminal Order No. Wire Size Insulation Diameter Strip Length Terminal
Series No. Loose Piece Only AWG mm² mm In. mm In.
08-50-0114 39-00-0033
08-50-0124 39-00-0107
08-50-0160 39-00-0373
08-50-0275 39-00-0375
08-51-0102 39-00-0377
08-55-0102 39-00-0379
08-55-0131 39-00-0381
2759
08-56-0110 50-29-1638
22-30 0.35-0.05 1.09-1.57 .040-.062 2.54-3.17 .100-.125
08-50-0032 40-01-0830
08-50-0136 97-00-0451
08-55-0111 97-00-0453
4809
08-56-0115
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 22-28 0.35-0.08 1.20-1.70 .040-.090 2.54-3.17 .100-.125
08-52-0122 08-65-0814
08-52-0123 08-65-0816
6459
08-65-0812 08-65-0818
22-30 0.35-0.05 1.02-1.57 .040-.062 2.54-3.17 .100-.125
08-52-0104 40-07-0813
08-52-0108 97-00-0226
8088
08-65-0106 97-00-0228
22-30 0.35-0.05 1.02-1.57 .040-.062 2.54-3.17 .100-.125
08-50-0322 97-00-0445
40445 97-00-0921 22-30 0.35-0.05 1.02-1.57 .040-.062 2.54-3.17 .100-.125
41572 08-65-0805 22-30 0.20-0.05 1.02-2.29 .040-.090 3.17-3.96 .125-.156
 Terminals in this chart have a center cut-off tab. They cannot be removed from the reel by manual cutting them.
All these terminals are loose piece only.
An applicator must be used when using reel terminals or the terminals will not function properly.
TYPE 4D

Hand Crimp Tool For 2.54mm (.100) KK® Crimp Terminals
Doc No: AT -638118200 Release Date: 10-26-07 UNCONTROLLED COPY Page 2 of 9
Revision: D Revision Date: 08-27-08
INSULATION CRIMP
BRUSH
STRIP LENGTH
BELL
MOUTH
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLLING
LOCKING TANG
HEIGHT
TWISTING
CUT
-
OFF
TAB
SEAM
CONDUCTOR CRIMP
DEFINITION OF TERMS
CONDITIONS:
After crimping, the conductor profiles should measure the following.
Conductor Crimp Insulation Crimp
Wire Size Height (Ref.) Width (Ref.)
Height (Ref.) Width (Ref.)
Terminal
Series No
AWG mm2 mm In. mm In. mm In. mm In.
22 0.35 0.71-0.81 .028-.032 1.40 .055 1.42 .056 1.64 .065
24 0.20 0.71-0.81 .028-.032 1.40 .055 1.39 .054 1.64 .065
26 0.12 0.63-0.73 .025-.029 1.37 .054 1.33 .052 1.42 .056
28 0.08 0.63-0.73 .025-.029 1.37 .054 1.33 .052 1.42 .056
2759
30 0.05 0.63-0.73 .025-.029 1.37 .054 1.33 .052 1.42 .056
22 0.35 0.71-0.81 .028-.032 1.40 .055 1.42 .056 1.64 .065
24 0.20 0.71-0.81 .028-.032 1.40 .055 1.39 .054 1.64 .065
26 0.12 0.63-0.73 .025-.029 1.37 .054 1.33 .052 1.42 .056
28 0.08 0.63-0.73 .025-.029 1.37 .054 1.33 .052 1.42 .056
4809
30 0.05 0.63-0.73 .025-.029 1.37 .054 1.33 .052 1.42 .056
22 0.35 0.71-0.81 .028-.032 1.40 .055 1.42 .056 1.64 .065
24 0.20 0.71-0.81 .028-.032 1.40 .055 1.39 .054 1.64 .065
26 0.12 0.63-0.73 .025-.029 1.37 .054 1.33 .052 1.42 .056
5159
28 0.08 0.63-0.73 .025-.029 1.37 .054 1.33 .052 1.42 .056
22 0.35 0.76-0.86 .030-.034 1.42 .056 1.45 .057 1.64 .065
24 0.20 0.73-0.83 .029-.033 1.42 .056 1.40 .055 1.61 .063
26 0.12 0.69-0.79 .027-.031 1.37 .054 1.38 .054 1.40 .055
28 0.08 0.69-0.79 .027-.031 1.37 .054 1.38 .054 1.40 .055
6459
30 0.05 0.69-0.79 .027-.031 1.37 .054 1.38 .054 1.40 .055
22 0.35 0.76-0.86 .030-.034 1.42 .056 1.45 .057 1.64 .065
24 0.20 0.73-0.83 .029-.033 1.42 .056 1.40 .055 1.61 .063
26 0.12 0.69-0.79 .027-.031 1.37 .054 1.38 .054 1.40 .055
28 0.08 0.69-0.79 .027-.031 1.37 .054 1.38 .054 1.40 .055
8088
30 0.05 0.69-0.79 .027-.031 1.37 .054 1.38 .054 1.40 .055

Hand Crimp Tool For 2.54mm (.100) KK® Crimp Terminals
Doc No: AT -638118200 Release Date: 10-26-07 UNCONTROLLED COPY Page 3 of 9
Revision: D Revision Date: 08-27-08
Conductor Crimp Insulation Crimp
Wire Size Height (Ref.) Width (Ref.)
Height (Ref.) Width (Ref.)
Terminal
Series No
AWG mm2 mm In. mm In. mm In. mm In.
22 0.35 0.71-0.81 .028-.032 1.40 .055 1.42 .056 1.64 .065
24 0.20 0.71-0.81 .028-.032 1.40 .055 1.39 .054 1.64 .065
26 0.12 0.63-0.73 .025-.029 1.37 .054 1.33 .052 1.42 .056
28 0.08 0.63-0.73 .025-.029 1.37 .054 1.33 .052 1.42 .056
40445
30 0.05 0.63-0.73 .025-.029 1.37 .054 1.33 .052 1.42 .056
22 0.35 0.76-0.86 .030-.034 1.42 .056 1.45 .057 1.64 .065
24 0.20 0.73-0.83 .029-.033 1.42 .056 1.40 .055 1.61 .063
26 0.12 0.69-0.79 .027-.031 1.37 .054 1.38 .054 1.40 .055
28 0.08 0.69-0.79 .027-.031 1.37 .054 1.38 .054 1.40 .055
41572
30 0.05 0.69-0.79 .027-.031 1.37 .054 1.38 .054 1.40 .055
Profile
Wire Size Pull Force
Minimum A B C D
Terminal
Series No
AWG mm2 N Lb. 26- 0 22-24 22-24 26- 0
22 0.35 44.8 10.00 X
24 0.20 28.9 6.50 X
26 0.12 17.8 4.00 X
28 0.08 11.1 2.50 X
2759
30 0.05 6.7 1.50 X
22 0.35 44.8 10.00 X
24 0.20 28.9 6.50 X
26 0.12 17.8 4.00 X
28 0.08 11.1 2.50 X
4809
30 0.05 6.7 1.50 X
22 0.35 39.2 8.00 X
24 0.20 28.9 6.50 X
26 0.12 17.8 4.00 X
5159
28 0.08 11.1 2.50 X
22 0.35 44.8 10.00 X
24 0.20 28.9 6.50 X
26 0.12 17.8 4.00 X
28 0.08 11.1 2.50 X
6459
30 0.05 6.7 1.50 X
22 0.35 44.8 10.00 X
24 0.20 28.9 6.50 X
26 0.12 17.8 4.00 X
28 0.08 11.1 2.50 X
8088
30 0.05 6.7 1.50 X
22 0.35 44.8 10.00 X
24 0.20 28.9 6.50 X
26 0.12 17.8 4.00 X
28 0.08 11.1 2.50 X
40445
30 0.05 6.7 1.50 X
22 0.35 44.8 10.00 X
24 0.20 28.9 6.50 X
26 0.12 17.8 4.00 X
28 0.08 11.1 2.50 X
41572
30 0.05 6.7 1.50 X

Hand Crimp Tool For 2.54mm (.100) KK® Crimp Terminals
Doc No: AT -638118200 Release Date: 10-26-07 UNCONTROLLED COPY Page 4 of 9
Revision: D Revision Date: 08-27-08
RELEASE
LOCATOR BUTTON
TERMINAL
Figure
LOCATOR
PUSHED THRU
TOOLING
TERMINAL
LOCATOR
BUTTON
PUSHED IN
LOCATOR
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.
ee Figure 1.
Crimping Terminals
1. elect the desired terminal listed in the
preceding charts.
2. Make sure the center of the locator is in
the down position. With the locator
attached, push the locator button on
the back of the hand tool to bring the
locator forward through the tooling.
ee Figure 2.
3. While holding the locator button in, load the terminal into the proper
nest opening in the locator based on the wire gauge or terminal type
markings on the hand tooling. ee Figure 3.
4. Release the locator button, allowing the locator to return to the
crimping position.
5. Close the tool handle until the first ratchet position engages. ee
Figure 4.
PARTIALLY
CLOSE HANDLE
TOOLING
PARTIALLY
CLOSED
Figure 4
FIRST RATCHET
POSITION
OPEN
POSITION
SQUEEZE
HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Figure 1
LOCATOR
IN DOWN
POSTION
PUSH ON THE
LOCATOR BUTTON
Figure 2

Hand Crimp Tool For 2.54mm (.100) KK® Crimp Terminals
Doc No: AT -638118200 Release Date: 10-26-07 UNCONTROLLED COPY Page 5 of 9
Revision: D Revision Date: 08-27-08
Figure 5
TERMINAL
WIRE AGAINST THE
WIRE STOP
WIRE
WIRE STOP IS PART
OF THE LOCATOR
PRE
-
STRIPPED
WIRE
TERMINAL
6. Insert the properly stripped wire through the terminal and against the wire stop. ee Figure 5.
7. Crimp the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.
Release the handles to open the jaws.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
8. Remove the crimped terminal from the terminal
locator by pulling on the wire.
9. Visually inspect the crimped terminal for proper
crimp location.
10. On some large O.D. wires, it may not be possible
to insert the wire with the tool partially closed.
Those wires should be inserted with the hand
tool in the open position. Insert the wire above
the terminal in the punch and against the wire
stop then close the tool. ee Figure 6.
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 available, actual crimp height measurements may very slightly. An
occasional, destructive, pull force test should be performed to check hand tool crimp. Pull Force value Must exceed
the Minimum pull force specifications listed.
TERMINAL
Figure 6
WIRE
WIRE STOP

Hand Crimp Tool For 2.54mm (.100) KK® Crimp Terminals
Doc No: AT -638118200 Release Date: 10-26-07 UNCONTROLLED COPY Page 6 of 9
Revision: D Revision Date: 08-27-08
Figure
8
PUSH ON
HANDLE
JAWS OPEN
PULL OPEN
TOOLING
TOOLING
M BHCS
Locator Replacement
ee 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. queeze gently on the lower area shown in
Figure 7A with your thumb and index finger.
The lower tabs of the locator should disengage
from the hand tool.
3. Lift and pull away from the hand tool. The top
locator hooks should slip out of the top slots
easily. ee Figure 7A.
4. To reinstall the new locator, make sure the
hand tool is in the open position.
5. Press the red insert down as far as it will go as
shown in Figure 7B.
6. Holding onto the lower part of the locator with
your thumb and index finger, insert the locators
top hooks (2) into the hand tool top slots.
7. Rotate the locator down and press the lower tabs into the two bottom slots of the hand tool. To secure the
locator into place, the lower tabs must snap into place on the hand tool frame.
Right or Left Hand Operation
This hand tool has an added feature that can be
converted from a right handed application to a
left handed application. It is necessary to
reverse the tooling if using the left handed
application along with the locator. Follow the
steps below:
1. The locator must be removed before
reversing the tooling.
2. Remove the M3 BHC which is holding the
upper tooling.
3. Flip the upper tooling to the opposite side
and replace the M3 BHC . Make sure the
small markings on the front and back of the
hand tool frame match up and are on the
outside of the hand tool frame. ee Figure 8 and 9.
4. Do the same thing with the lower tooling and tighten the M3 screws. Be sure the small markings line up.
5. Reinstall the locator by following the Instructions in the locator replacement section.
SQUEEZE
HERE
SQUEEZE
HERE
LOCATOR
Figure 7A
TOP HOOKS
TOP SLOTS OF
HANDTOOL
LOWER TABS
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
Figure 7B

Hand Crimp Tool For 2.54mm (.100) KK® Crimp Terminals
Doc No: AT -638118200 Release Date: 10-26-07 UNCONTROLLED COPY Page 7 of 9
Revision: D Revision Date: 08-27-08
Figure 1
2
S
QUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
SETTING
WHEEL
RATCHET
RELEASE LEVER
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 other 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, 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
hould 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 up on the
ratchet release lever in the movable
handle. ee Figure 11.
How to Adjust Tool Preload
(See Figure 12)
This hand tool is factory preset to 25-45
LB . 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:
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY MONTHS OR
5,000 CRIMPS)
Figure
10
RATCHET RELEASE
LEVER
Figure
11
MATCH
UP MARKS
FRONT
BACK
Figure
9

Hand Crimp Tool For 2.54mm (.100) KK® Crimp Terminals
Doc No: AT -638118200 Release Date: 10-26-07 UNCONTROLLED COPY Page 8 of 9
Revision: D Revision Date: 08-27-08
1. Hold the hand tool in the palm of your hand as shown in Figure 10. Using the index finger squeeze the link
towards the top of the hand tool frame. This will release the preload adjustment wheel.
2. Rotate the setting wheel counter-clockwise (CCW) to increase handle force. The numbers will display higher.
To decrease handle force rotate the setting wheel clockwise (CW).
3. Release the link to lock the setting wheel in place.
4. 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. hould 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 hand tools but rather supplies the following guidelines for customers to re-certify
hand tools.
% This tool is qualified to pull force only. ee 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, ( ee 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 2.54mm (.100) KK® Crimp Terminals
Doc No: AT -638118200 Release Date: 10-26-07 UNCONTROLLED COPY Page 9 of 9
Revision: D Revision Date: 08-27-08
RATCHET
RELEASE LEVER
2
Figure 1
1
PARTS LIST
Item Number Order Number Description Quantity
REF 63811-8200 Hand Crimp Tool Figure 13
1 63811-8275 Locator Assembly 1
2 63810-0104 pring, Return 1
3 63810-0105 pring, Ratchet 1
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[email protected]
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Yamato, Kanagawa, Japan
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Corporate Headquarters
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Lisle, IL 60532 U. .A.
630-969-4550
Fax: [phone]
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