Hand Crimp Tool for Mini KK Crimp Terminals
Hand Crimp Tool
Application Tooling
Specification Sheet
TYPE 4A
Order No. 63823-6900
FEATURES
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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
A-620 Class 3 compliant and RoHS compliant
Modular Crimp Head is removable and can be used in the Air Powered Tool Order No. 63816-0100,
accompanied by Air Powered Crimp Adapter (Order No. 63816-0700).
Can also be used in the Battery Powered Tool Order No. 63816-0200 (110 V) or 63816-0250 (220 V),
accompanied by Battery Powered Crimp Adapter (Order No. 63816-0600).
SCOPE
Products: Mini KK Crimp Terminal, 22-28 AWG.
Terminal
Series No.
5659
Terminal Order No.
Reel
Loose
Wire Size
AWG
mm²
Insulation Diameter
mm
In.
1.20-1.70
.047-.067
Strip Length
mm
In.
2.50-3.00 .098-.118
08-70-0038 08-70-0039 22-28 0.35-0.08
Customer to cut off terminal from reel: 0.50mm (.020”) maximum Cut-off Tab.
See Conditions on page 2.
DEFINITION OF TERMS
BRUSH
BELL MOUTH
INSULATION
CRIMP
CONDUCTOR
CRIMP
BEND UP
ROLLING
TWISTING
STRIP
LENGTH
BEND
DOWN
CRIMP HEIGHT
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the scope.
Doc No: ATS-6382369HM
Revision: B
Release Date: 02-24-11
Revision Date: 08-10-17
UNCONTROLLED COPY
Page 1 of 7
Hand Crimp Tool for Mini KK Crimp Terminals
▲Insulation
Crimp Note
Due to the terminal’s insulation grip design or
insulation diameter range, this tool uses overlap form
geometry in the insulation punch. This produces an
overlap insulation crimp (A620-compliant). Although
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.)
OVERLAP FORM GEOMETRY
PUNCH
OVERLAP
INSULATION
CRIMP
CRIMP SPECIFICATION
After crimping, the crimp profiles should measure the
following (see notes on page 4):
Terminal
Series No.
Wire Size
AWG
22
24
26
28
Wire Size
AWG
22
24
26
28
mm
2
0.35
0.20
0.12
0.08
mm
2
0.35
0.20
0.12
0.08
ANVIL
WIRE
5659
Conductor Crimp
Height
Width (Ref.)
mm
In.
mm
In.
0.82-0.87 .032-.034 1.40 .055
0.75-0.80 .030-.032 1.40 .055
0.70-0.75 .028-.030 1.40 .055
0.66-0.71 .026-.028 1.40 .055
Profile
22
X
24
X
X
X
Pull Force
Minimum
N
Lb.
39.23 8.8
29.42 6.6
19.61 4.4
9.81 2.2
26
28
Terminal
Series No.
Insulation Diameter
mm
1.60-1.70
1.40-1.50
1.30-1.45
1.20-1.30
In.
.063-.067
.055-.059
.051-.057
.047-.051
5659
Insulation Crimp
Height (Ref.) Width (Ref.)
mm
In.
mm
In.
1.70 .067 1.85 .073
1.65 .065 1.85 .073
1.50 .059 1.75 .069
1.50 .059 1.75 .069
Tool Qualification Notes
1. Pull force should be measured with no
influence from the insulation crimp.
2. The above specifications are guidelines to
an optimal crimp.
HAND TOOL
OPEN
SWING
LOCATOR
OPEN
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.
1. With the hand tool in the open position,
pivot the terminal locator open by pulling up
on the locator knob, and lift the wire stop
blade. See Figure 1.
TERMINAL
SEATED IN
LOCATOR
WIRE
STOP BLADE
Figure 1
Doc No: ATS-6382369HM
Revision: B
Release Date: 02-24-11
Revision Date: 08-10-17
UNCONTROLLED COPY
Page 2 of 7
Hand Crimp Tool for Mini KK Crimp Terminals
2. Insert the terminal into the correct profile until the terminal is fully seated and stops. Make sure the wire
stop blade is fully seated on the terminal behind the conductor grip section.
3. Gently pivot the locator closed.
4. Bring down the wire stop blade.
5. Slide the pre-stripped wire into the terminal. Make sure to aim the wire brush toward the tip point on the
wire stop blade. See Figure 2. Align the wire so that it is parallel and sitting into the terminal. Maintain a
light and constant pressure on the wire that is seated in the terminal at all times. (Do not let go of the
wire.) Be sure to hold the wire and terminal in place until the terminal is fully crimped. See Figure 3.
6. Close the tool until the ratchet releases.
7. Lift up on the wire stop blade.
8. Carefully remove the crimped terminal.
WIRE STOP
BLADE
TERMINAL
CONDUCTOR
PUNCH
WIRE STOP
BLADE
LOCATOR
WIRE
CONDUCTOR
PUNCH
INSULATION
PUNCH
TERMINAL
WIRE
Figure 2
Figure 3
CONDUCTOR
ANVIL
INSULATION
ANVIL
Note:
The tamper-proof ratchet action will not release the tool until it has been fully closed.
Note:
To maintain good brush control and a consistent bell mouth, the crimping instructions must be followed.
Terminal Locator Replacement
This section describes the procedure for changing locators.
Removal
1. With the tool in the open position, pivot the terminal locator outward.
2. Remove the M4 BHCS. See Figure 4.
Installation
1. Place the proper locator (see chart on page 2) on the hand tool.
Install the M4 BHCS. See Figure 4.
2. Tighten the screw enough to hold the locator. Make sure the locator
can still float freely with hand pressure.
M4 BHCS
PIVOT LOCATOR
Figure 4
Doc No: ATS-6382369HM
Revision: B
Release Date: 02-24-11
Revision Date: 08-10-17
UNCONTROLLED COPY
Page 3 of 7
Hand Crimp Tool for Mini KK Crimp Terminals
3. Insert the proper terminal fully into the correct profile slot until the terminal is fully seated and stops. Then,
gently pivot the locator closed.
4. With hand pressure, slowly slide the locator to the correct position. See Figure 5.
5. Gently pivot the locator open without disturbing the location.
6. Hold the locator firmly in place, and slowly tighten the M4 BHCS.
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 a soft, lint-free cloth.
2. Do not use any abrasive materials that could damage the
tool.
INCORRECT
CORRECT
INCORRECT
3. Make certain all pins, pivot points and bearing surfaces
are protected with a thin coat of high-quality machine oil.
Figure 5
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 the hand tool, particularly from the crimping area. Oil transferred from the crimping area
onto certain terminations may affect the electrical characteristics of an application.
5. When the 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 lifting the ratchet release lever. See Figure 9.
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, Molex 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:
Repetitive use of this tool should be avoided.
CAUTIONS:
1. Manually powered hand tools are intended for low-volume use 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.
Doc No: ATS-6382369HM
Revision: B
Release Date: 02-24-11
Revision Date: 08-10-17
UNCONTROLLED COPY
Page 4 of 7
Hand Crimp Tool for Mini KK Crimp Terminals
Notes
1. This tool should only be used for the terminals and wire gauges specified on this sheet.
2. This tool is not adjustable for crimp height; however, crimp force is adjustable (See instructions above).
Variations in tools, terminals, wire stranding and insulation types may affect crimp height.
3. This tool is intended for standard conductor sizes. It may not give a good insulation crimp support for all
insulation sizes.
4. Molex does not repair hand tools (see warranty above). The replacement parts listed are the only parts
available for repair. If the handles or crimp tooling are damaged or worn, a new tool must be purchased.
5. Pull force should be used as the final criteria for an acceptable crimp. Pull force is measured with no
influence from the insulation crimp. The insulation should be stripped long (1/2 in.) so the insulation grips
on the terminal do not grip the wire insulation or the conductor. Refer to Molex Quality Crimping
Handbook 63800-0029 for additional information on crimping and crimp testing.
6. Molex does not certify crimp hand tools.
CAUTION:
Molex crimp specifications are valid only when used with Molex terminals and tooling.
Applications for the Modular Crimp Head
WARNING:
NEVER
operate, service, install or adjust this modular crimp head without proper instruction
and without first reading and understanding the instructions in the proper manual or specification sheet.
See chart below for the correct manual or specification sheet.
WARNING:
NEVER
install tooling or service this tool while it is into any power source. Disconnect the
power by unplugging, or turn off the actuator from its power source.
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.
Doc No: ATS-6382369HM
Revision: B
Release Date: 02-24-11
Revision Date: 08-10-17
UNCONTROLLED COPY
Page 5 of 7
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