molex 63811-8200 Specification Sheet
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molex 63811-8200 Specification Sheet

Hand crimp tool
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Hand Crimp Tool For 2.54mm (.100) KK® Crimp Terminals
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 RoHS compliant, however RoHS compliant is not required
SCOPE
Products: 2.54mm (.100) KK® Crimp Terminals, 22-30 AWG.
Terminal
Series No.
2759
4809
5159
6459
8088
40445
41572
Terminals in this chart have a center cut-off tab. They cannot be removed from the reel by manual cutting them.
An applicator must be used when using reel terminals or the terminals will not function properly.
Doc No: ATS-638118200
Revision: D
HAND CRIMP TOOL
Specification Sheet
Order No. 63811-8200
Terminal Order No.
Loose Piece Only
AWG
08-50-0114
39-00-0033
08-50-0124
39-00-0107
08-50-0160
39-00-0373
08-50-0275
39-00-0375
22-30
08-51-0102
39-00-0377
08-55-0102
39-00-0379
08-55-0131
39-00-0381
08-56-0110
50-29-1638
08-50-0032
40-01-0830
08-50-0136
97-00-0451
22-30
08-55-0111
97-00-0453
08-56-0115
08-70-0049
08-70-0069
22-28
08-52-0122
08-65-0814
22-30
08-52-0123
08-65-0816
08-65-0812
08-65-0818
08-52-0104
40-07-0813
22-30
08-52-0108
97-00-0226
08-65-0106
97-00-0228
08-50-0322
97-00-0445
22-30
97-00-0921
08-65-0805
22-30
All these terminals are loose piece only.
Release Date: 10-26-07
Revision Date: 08-27-08
Wire Size
Insulation Diameter
mm²
mm
0.35-0.05
1.09-1.57
0.35-0.05
1.02-1.57
0.35-0.08
1.20-1.70
0.35-0.05
1.02-1.57
0.35-0.05
1.02-1.57
0.35-0.05
1.02-1.57
0.20-0.05
1.02-2.29
UNCONTROLLED COPY
Strip Length
In.
mm
In.
.040-.062
2.54-3.17
.100-.125
.040-.062
2.54-3.17
.100-.125
.040-.090
2.54-3.17
.100-.125
.040-.062
2.54-3.17
.100-.125
.040-.062
2.54-3.17
.100-.125
.040-.062
2.54-3.17
.100-.125
.040-.090
3.17-3.96
.125-.156
TYPE 4D
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Summary of Contents for molex 63811-8200

  • Page 1 Hand Crimp Tool For 2.54mm (.100) KK® Crimp Terminals HAND CRIMP TOOL Specification Sheet Order No. 63811-8200 TYPE 4D 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...

  • Page 2: Definition Of Terms

    Hand Crimp Tool For 2.54mm (.100) KK® Crimp Terminals DEFINITION OF TERMS CONDUCTOR CRIMP INSULATION CRIMP LOCKING TANG HEIGHT BEND UP BRUSH SEAM ROLLING BELL MOUTH TWISTING CUT-OFF BEND DOWN STRIP LENGTH CRIMP HEIGHT CONDITIONS: After crimping, the conductor profiles should measure the following. Conductor Crimp Insulation Crimp Wire Size...
  • Page 3 Hand Crimp Tool For 2.54mm (.100) KK® Crimp Terminals Conductor Crimp Insulation Crimp Wire Size Terminal Height (Ref.) Width (Ref.) Height (Ref.) Width (Ref.) Series No AWG mm 0.35 0.71-0.81 .028-.032 1.40 .055 1.42 .056 1.64 .065 0.20 0.71-0.81 .028-.032 1.40 .055 1.39 .054...

  • Page 4: Operation

    Hand Crimp Tool For 2.54mm (.100) KK® Crimp Terminals 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 LOCATOR together.
  • Page 5 Hand Crimp Tool For 2.54mm (.100) KK® Crimp Terminals 6. 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.
  • Page 6 Hand Crimp Tool For 2.54mm (.100) KK® Crimp Terminals LOCATOR Locator Replacement SQUEEZE See the parts list on the last page of this document HERE for the proper locator order number. Follow the MAKE SURE steps below to replace the locator. CENTER OF LOCATOR SQUEEZE IS IN THE...

  • Page 7: Maintenance

    Hand Crimp Tool For 2.54mm (.100) KK® Crimp Terminals Maintenance MATCH UP MARKS It is recommended that each operator of the tool be made aware of, and responsible for, the following maintenance steps: Figure 9 1. Remove dust, moisture, and other contaminants with a clean brush, or soft, lint free cloth.

  • Page 8: Warranty

    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. See the Molex web site for the Quality Crimp Handbook for more information on pull testing.

  • Page 9: Parts List

    2222 Wellington Ct. 1-800-78MOLEX 81-462-65-2324 65-6-268-6868 49-89-413092-0 Lisle, IL 60532 U.S.A. amerinfo@molex.com feninfo@molex.com fesinfo@molex.com eurinfo@molex.com 630-969-4550 Fax: 630-969-1352 Visit our Web site at http://www.molex.com UNCONTROLLED COPY Doc No: ATS-638118200 Release Date: 10-26-07 Page 9 of 9 Revision: D Revision Date: 08-27-08...

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