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Hand Crimp Tool For 2.54mm (.100) KK Crimp TerminalsHAND CRIMPTOOLApplication ToolingSpecification SheetTYPE 4DOrder No. 63811-8200FEATURES 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 RoHS compliant, however RoHS compliant is not requiredSCOPEProducts: 2.54mm (.100) KK Crimp Terminals, 22-30 AWG.Terminal Order No.Wire SizeInsulation DiameterStrip LengthLoose Piece Only AWGmm²mmIn.mmIn.08-50-0114 39-00-003308-50-0124 39-00-010708-50-0160 39-00-037308-50-0275 39-00-0375275922-30 0.35-0.05 1.09-1.57 .040-.062 2.54-3.17 .100-.12508-51-0102 39-00-037708-55-0102 39-00-037908-55-0131 39-00-038108-56-0110 50-29-163808-50-0032 40-01-083008-50-0136 97-00-0451480922-30 0.35-0.05 1.02-1.57 .040-.062 2.54-3.17 .100-.12508-55-0111 97-00-045308-56-0115515908-70-0049 08-70-0069 22-28 0.35-0.08 1.20-1.70 .040-.067 2.54-3.17 .100-.12508-52-0122 08-65-0814645908-52-0123 08-65-0816 22-30 0.35-0.05 1.02-1.57 .040-.062 2.54-3.17 .100-.12508-65-0812 08-65-081808-52-0104 08-65-022808-52-0106 40-07-0813808808-52-0108 97-00-0226 22-30 0.35-0.05 1.02-1.57 .040-.062 2.54-3.17 .100-.12508-65-0106 97-00-022808-65-022608-50-0322 97-00-04454044522-30 0.35-0.05 1.02-1.57 .040-.062 2.54-3.17 .100-.12597-00-09214157208-65-080522-30 0.20-0.05 1.02-1.57 .040-.062 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.TerminalSeries No.Doc No: ATS-638118200Revision: FRelease Date: 10-26-07Revision Date: 02-04-11UNCONTROLLED COPYPage 1 of 9

Hand Crimp Tool For 2.54mm (.100) KK Crimp TerminalsDEFINITION OF TERMSCONDUCTOR CRIMPINSULATION CRIMPLOCKING TANGHEIGHTBEND UPBRUSHSEAMROLLINGBELLMOUTHTWISTINGSTRIP LENGTHCUT-OFFTABBENDDOWNCRIMP HEIGHTCONDITIONS:After crimping, the conductor profiles should measure the following.TerminalSeries No27594809515964598088Doc No: ATS-638118200Revision: FWire 0.05Conductor CrimpInsulation CrimpHeight (Ref.)Width (Ref.) Height (Ref.) Width (Ref.)mmIn.mmIn.mmIn.mmIn.0.71-0.81 .028-.032 1.40 .055 1.42 .056 1.64 .0650.71-0.81 .028-.032 1.40 .055 1.39 .054 1.64 .0650.63-0.73 .025-.029 1.37 .054 1.33 .052 1.42 .0560.63-0.73 .025-.029 1.37 .054 1.33 .052 1.42 .0560.63-0.73 .025-.029 1.37 .054 1.33 .052 1.42 .0560.71-0.81 .028-.032 1.40 .055 1.42 .056 1.64 .0650.71-0.81 .028-.032 1.40 .055 1.39 .054 1.64 .0650.63-0.73 .025-.029 1.37 .054 1.33 .052 1.42 .0560.63-0.73 .025-.029 1.37 .054 1.33 .052 1.42 .0560.63-0.73 .025-.029 1.37 .054 1.33 .052 1.42 .0560.71-0.81 .028-.032 1.40 .055 1.42 .056 1.64 .0650.71-0.81 .028-.032 1.40 .055 1.39 .054 1.64 .0650.63-0.73 .025-.029 1.37 .054 1.33 .052 1.42 .0560.63-0.73 .025-.029 1.37 .054 1.33 .052 1.42 .0560.76-0.86 .030-.034 1.42 .056 1.45 .057 1.64 .0650.73-0.83 .029-.033 1.42 .056 1.40 .055 1.61 .0630.69-0.79 .027-.031 1.37 .054 1.38 .054 1.40 .0550.69-0.79 .027-.031 1.37 .054 1.38 .054 1.40 .0550.69-0.79 .027-.031 1.37 .054 1.38 .054 1.40 .0550.76-0.86 .030-.034 1.42 .056 1.45 .057 1.64 .0650.73-0.83 .029-.033 1.42 .056 1.40 .055 1.61 .0630.69-0.79 .027-.031 1.37 .054 1.38 .054 1.40 .0550.69-0.79 .027-.031 1.37 .054 1.38 .054 1.40 .0550.69-0.79 .027-.031 1.37 .054 1.38 .054 1.40 .055Release Date: 10-26-07Revision Date: 02-04-11UNCONTROLLED COPYPage 2 of 9

Hand Crimp Tool For 2.54mm (.100) KK Crimp TerminalsTerminalSeries No4044541572Wire 0.350.200.120.080.05TerminalSeries No275948095159645980884044541572Doc No: ATS-638118200Revision: FConductor CrimpInsulation CrimpHeight (Ref.)Width (Ref.) Height (Ref.) Width (Ref.)mmIn.mmIn.mmIn.mmIn.0.71-0.81 .028-.032 1.40 .055 1.42 .056 1.64 .0650.71-0.81 .028-.032 1.40 .055 1.39 .054 1.64 .0650.63-0.73 .025-.029 1.37 .054 1.33 .052 1.42 .0560.63-0.73 .025-.029 1.37 .054 1.33 .052 1.42 .0560.63-0.73 .025-.029 1.37 .054 1.33 .052 1.42 .0560.76-0.86 .030-.034 1.42 .056 1.45 .057 1.64 .0650.73-0.83 .029-.033 1.42 .056 1.40 .055 1.61 .0630.69-0.79 .027-.031 1.37 .054 1.38 .054 1.40 .0550.69-0.79 .027-.031 1.37 .054 1.38 .054 1.40 .0550.69-0.79 .027-.031 1.37 .054 1.38 .054 1.40 .055Wire 200.120.080.05Release Date: 10-26-07Revision Date: 02-04-11ProfilePull ForceMinimumABCDNLb. 26-30 22-24 22-24 26-3044.8 10.00X28.9 6.50X17.8 4.00X11.1 2.50X6.7 1.50X44.8 10.00X28.9 6.50X17.8 4.00X11.1 2.50X6.7 1.50X39.2 8.00X28.9 6.50X17.8 4.00X11.1 2.50X44.8 10.00X28.9 6.50X17.8 4.00X11.1 2.50X6.7 1.50X44.8 10.00X28.9 6.50X17.8 4.00X11.1 2.50X6.7 1.50X44.8 10.00X28.9 6.50X17.8 4.00X11.1 2.50X6.7 1.50X44.8 10.00X28.9 6.50X17.8 4.00X11.1 2.50X6.7 1.50XUNCONTROLLED COPYPage 3 of 9

Hand Crimp Tool For 2.54mm (.100) KK Crimp TerminalsOPERATIONCAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects as damage canoccur to the tool or die.Open the tool by squeezing the handlestogether. At the end of the closing stroke,the ratchet mechanism will release thehandles and the hand tool will spring open.See Figure 1.LOCATORIN DOWNPOSTIONHANDLE WILLSPRING OPENCrimping Terminals1. Select the desired terminal listed in thepreceding charts.2. Make sure the center of the locator is inthe down position. With the locatorattached, push the locator button onthe back of the hand tool to bring thelocator forward through the tooling.See Figure 2.LOCATORPUSHED THRUTOOLINGFigure 2SQUEEZEHANDLESTOGETHERFigure 1RELEASELOCATOR BUTTONLOCATORLOCATORBUTTONPUSHED INTERMINALFigure 3TOOLINGPARTIALLYCLOSEDTERMINAL3. While holding the locator button in, load the terminal into the propernest opening in the locator based on the wire gauge or terminal typemarkings on the hand tooling. See Figure 3.4. Release the locator button, allowing the locator to return to thecrimping position.5. Close the tool handle until the first ratchet position engages. SeeFigure 4.Doc No: ATS-638118200Revision: FPUSH ON THELOCATOR BUTTONRelease Date: 10-26-07Revision Date: 02-04-11PARTIALLYCLOSE HANDLEOPENPOSITIONFIRST RATCHETPOSITIONFigure 4UNCONTROLLED COPYPage 4 of 9

Hand Crimp Tool For 2.54mm (.100) KK Crimp Terminals6. Insert the properly stripped wire through the terminal and against the wire stop. See 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.TERMINALWIRE AGAINST THEWIRE STOPWIRE STOP IS PARTOF THE LOCATORPRE-STRIPPEDWIREFigure 5TERMINALWIRENote: The tamper proof ratchet action will not release the tool until it has been fully closed.WIRE8. Remove the crimped terminal from the terminallocator by pulling on the wire.9. Visually inspect the crimped terminal for propercrimp location.10. On some large O.D. wires, it may not be possibleto insert the wire with the tool partially closed.Those wires should be inserted with the handtool in the open position. Insert the wire abovethe terminal in the punch and against the wirestop then close the tool. See Figure 6.WIRE STOPFigure 6TERMINALNote: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. Anoccasional, destructive, pull force test should be performed to check hand tool crimp. Pull Force value Must exceedthe Minimum pull force specifications listed.Doc No: ATS-638118200Revision: FRelease Date: 10-26-07Revision Date: 02-04-11UNCONTROLLED COPYPage 5 of 9

Hand Crimp Tool For 2.54mm (.100) KK Crimp TerminalsLOCATORLocator ReplacementSee the parts list on the last page of this documentfor the proper locator order number. Follow thesteps below to replace the locator.SQUEEZEHEREMAKE SURECENTER OF LOCATORIS IN THEDOWN POSITIONSQUEEZEHERE1. Open the crimp hand tool.Figure 7A2. Squeeze gently on the lower area shown inTOP SLOTS OFFigure 7A with your thumb and index finger.HANDTOOLThe lower tabs of the locator should disengagefrom the hand tool.TOP HOOKS3. Lift and pull away from the hand tool. The toplocator hooks should slip out of the top slotseasily. See Figure 7A.4. To reinstall the new locator, make sure thehand tool is in the open position.Figure 7B5. Press the red insert down as far as it will go asshown in Figure 7B.6. Holding onto the lower part of the locator withLOWER TABSyour thumb and index finger, insert the locatorstop 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 thelocator into place, the lower tabs must snap into place on the hand tool frame.Right or Left Hand OperationThis hand tool has an added feature that can beconverted from a right handed application to aleft handed application. It is necessary toreverse the tooling if using the left handedapplication along with the locator. Follow thesteps below:JAWS OPENPULL OPENTOOLINGTOOLINGM3 BHCS1. The locator must be removed beforereversing the tooling.2. Remove the M3 BHCS which is holding theFigure 8upper tooling.3. Flip the upper tooling to the opposite sideand replace the M3 BHCS. Make sure thePUSH ONHANDLEsmall markings on the front and back of thehand tool frame match up and are on theoutside of the hand tool frame. See 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.Doc No: ATS-638118200Revision: FRelease Date: 10-26-07Revision Date: 02-04-11UNCONTROLLED COPYPage 6 of 9

Hand Crimp Tool For 2.54mm (.100) KK Crimp TerminalsMaintenanceMATCHUP MARKSIt is recommended that each operator of the tool bemade aware of, and responsible for, the followingmaintenance steps:Figure 91. Remove dust, moisture, and other contaminantswith a clean brush, or soft, lint free cloth.BACKFRONT2. Do not use any abrasive materials that coulddamage the tool.3. Make certain all pins; pivot points and bearing surfaces are protected with a thin coat of high quality machineoil. Do not oil excessively. The tool was engineered for durability but like any other equipment it needscleaning and lubrication for a maximum service life of trouble free crimping. Light oil (such as 30 weightautomotive 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. OilRATCHET RELEASEtransferred from the crimping areaLEVERonto certain terminations may affectthe electrical characteristics of anapplication.5. When tool is not in use, keep thehandles closed to prevent objectsfrom becoming lodged in the crimpingdies, and store the tool in a clean, dry LUBRICATION POINTSarea.(BOTH SIDES) LIGHT OILFigure 11(EVERY 3 MONTHS OR5,000 CRIMPS)Miscrimps or JamsShould this tool ever become stuck orjammed in a partially closed position, DoNot force the handles open or closed. Thetool will open easily by pressing up on theratchet release lever in the movablehandle. See Figure 11.Figure 10RATCHETRELEASE LEVERSQUEEZETHE LINK INTHE HANDLEHOLD THE HANDTOOL IN POSITIONHow to Adjust Tool Preload(See Figure 12)This hand tool is factory preset to 25-45LBS. preload. It may be necessary overthe life of the tool to adjust tool handlepreload force. Listed below are the stepsrequired to adjust the crimping force of thehand tool to obtain proper crimp conditions:Doc No: ATS-638118200Revision: FFigure 12SETTINGWHEELRelease Date: 10-26-07Revision Date: 02-04-11UNCONTROLLED COPYPage 7 of 9

Hand Crimp Tool For 2.54mm (.100) KK Crimp Terminals1. Hold the hand tool in the palm of your hand as shown in Figure 10. Using the index finger squeeze the linktowards 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.WarrantyThis tool is for electrical terminal crimping purposes only. This tool is made of the best quality materials. All vitalcomponents are long life tested. All tools are warranted to be free of manufacturing defects for a period of 30days. Should such a defect occur, we will repair or exchange the tool free of charge. This repair or exchange willnot 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 forproduction 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.CertificationMolex does not certify or re-certify hand tools but rather supplies the following guidelines for customers to re-certifyhand tools.% This tool is qualified to pull force only. See the Molex web site for the Quality Crimp Handbook for moreinformation on pull testing.% If the tool does not meet minimum pull force values, handle preload should be increased and the pull testrerun, (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 andreplaced.Doc No: ATS-638118200Revision: FRelease Date: 10-26-07Revision Date: 02-04-11UNCONTROLLED COPYPage 8 of 9

Hand Crimp Tool For 2.54mm (.100) KK Crimp TerminalsPARTS LISTItem NumberREF123Order riptionHand Crimp ToolLocator AssemblySpring, ReturnSpring, RatchetQuantityFigure 1311121RATCHETRELEASE LEVERFigure 133http://www.molex.comDoc No: ATS-638118200Revision: FRelease Date: 10-26-07Revision Date: 02-04-11UNCONTROLLED COPYPage 9 of 9

Crimping Terminals 1. Select 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