Molex 63811-6670 Bedienungsanleitung

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

1797

18 0.80 0.92-1.02 .036-.040 1.93 .076 111.2 25.00

20 0.50 0.91-1.01 .035-.039 1.93 .076 66.7 15.00

22 0.35 0.91-1.01 .035-.039 1.93 .076 53.4 12.00

24 0.20 0.89-0.99 .034-.038 1.93 .076 31.1 7.00

4366

18 0.80 0.92-1.02 .036-.040 1.93 .076 111.2 25.00

20 0.50 0.91-1.01 .035-.039 1.93 .076 66.7 15.00

22 0.35 0.91-1.01 .035-.039 1.93 .076 53.4 12.00

24 0.20 0.89-0.99 .034-.038 1.93 .076 31.1 7.00

1797

24 0.20 0.85-0.95 .033-.037 1.68 .066 31.1 7.00

26 0.12 0.80-0.90 .031-.035 1.68 .066 17.8 4.00

28 0.08 0.78-0.88 .030-.035 1.68 .066 11.1 2.50

30 0.05 0.77-0.87 .030-.034 1.68 .066 6.7 1.50

4573

24 0.20 0.85-0.95 .033-.037 1.68 .066 31.1 7.00

26 0.12 0.80-0.90 .031-.035 1.68 .066 17.8 4.00

28 0.08 0.78-0.88 .030-.035 1.68 .066 11.1 2.50

30 0.05 0.77-0.87 .030-.034 1.68 .066 6.7 1.50

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

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

63816-0250

Battery Power Tool (220 V)

63816-0300 Power Crimp Head

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

M4 X 6mm

LONG BHCS

M4 X 12mm

LONG BHCS

WITH TOOL KIT

LOCATOR ONLY

M4 X 12mm

LONG BHCS

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

M4 by 8 Long

BHCS

M4 by 18 Long

BHCS

M4 by 10 Long

BHCS

POWER HEAD PARTS LIST

Item Order No Engineering No. Description Quantity

63816-0300 63816-0300 Power Crimp Head 1

63811-6670 63811-6670 Tool Kit 1

http://www.molex.com

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