Hand Crimp Tool for .100 KK
HAND CRIMP TOOL
SPECIFICATION SHEET
Order No. 11-01-0185
(CR2262C)
FEATURES
SCOPE
Terminal
Series No.
1854
1855
2189
2190
2717
2759
2951
40445
41572
4548
4559
4809
5159
6459
6796
7879
8088
Wire Size
AWG
mm²
24-30 0.20-0.05
24-30 0.20-0.05
24-30 0.20-0.05
24-30 0.20-0.05
24-30 0.20-0.05
22-30 0.35-0.05
24-30 0.20-0.05
22-30 0.35-0.05
22-30 0.20-0.05
24-30 0.20-0.05
24-30 0.20-0.05
22-30 0.35-0.05
24-30 0.20-0.05
22-30 0.35-0.05
24-30 0.20-0.05
22-30 0.35-0.05
22-30 0.35-0.05
Insulation Diameter
mm
In.
1.02-2.29 .040-.090
1.02-2.29 .040-.090
1.02-2.29 .040-.090
1.02-2.29 .040-.090
1.02-2.29 .040-.090
1.02-1.57 .040-.062
1.02-2.29 .040-.090
1.02-1.57 .040-.062
1.02-2.29 .040-.090
1.02-2.29 .040-.090
1.02-2.29 .040-.090
1.02-1.57 .040-.062
1.02-2.29 .040-.090
1.02-1.57 .040-.062
1.02-2.29 .040-.090
1.02-1.57 .040-.062
1.02-1.57 .040-.062
Strip Length
mm
In.
3.17-3.96 .125-.156
3.17-3.96 .125-.156
3.17-3.96 .125-.156
3.17-3.96 .125-.156
3.17-3.96 .125-.156
2.54-3.17 .100-.125
3.17-3.96 .125-.156
2.54-3.17 .100-.125
3.17-3.96 .125-.156
3.17-3.96 .125-.156
3.17-3.96 .125-.156
2.54-3.17 .100-.125
3.17-3.96 .125-.156
2.54-3.17 .100-.125
3.17-3.96 .125-.156
2.54-3.17 .100-.125
2.54-3.17 .100-.125
BEND UP
ROLLING
BRUSH
BELL MOUTH
INSULATION
CRIMP
CONDUCTOR
CRIMP
Small handle spread which make this style tool ideally suited for end users
Ratchet with safety release that ensures consistent performance
A precision user-friendly terminal locator wire stop holds terminals in the proper crimping position
DEFINITION OF TERMS
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. 11-01-0185
Revision: E
Release Date: 10-07-03
Revision Date: 08-11-04
UNCONTROLLED COPY
Page 1 of 6
Hand Crimp Tool for .100 KK
CONDITIONS:
After crimping, the conductor profiles should measure the following (see notes on page 5).
Terminal Wire Size Cond. Crimp Height (REF)
Series No.
AWG
mm
2
mm
In.
1854
24 0.20 0.76-0.86
.030-.034
1854
26 0.12 0.71-0.81
.028-.032
1854
28 0.08 0.69-0.79
.027-.031
1854
30 0.05 0.69-0.79
.027-.031
1855
1855
1855
1855
2189
2189
2189
2189
2190
2190
2190
2190
2717
2717
2717
2717
2759
2759
2759
2759
2759
2951
2951
2951
2951
40445
40445
40445
40445
40445
24
26
28
30
24
26
28
30
24
26
28
30
24
26
28
30
22
24
26
28
30
24
26
28
30
22
24
26
28
30
0.20
0.12
0.08
0.05
0.20
0.12
0.08
0.05
0.20
0.12
0.08
0.05
0.20
0.12
0.08
0.05
0.35
0.20
0.12
0.08
0.05
0.20
0.12
0.08
0.05
0.35
0.20
0.12
0.08
0.05
0.76-0.86
0.71-0.81
0.69-0.79
0.69-0.79
0.76-0.86
0.71-0.81
0.69-0.79
0.69-0.79
0.76-0.86
0.71-0.81
0.69-0.79
0.69-0.79
0.76-0.86
0.71-0.81
0.69-0.79
0.69-0.79
0.76-0.86
0.76-0.86
0.71-0.81
0.69-0.79
0.69-0.79
0.76-0.86
0.71-0.81
0.69-0.79
0.69-0.79
0.76-0.86
0.76-0.86
0.71-0.81
0.69-0.79
0.69-0.79
.030-.034
.028-.032
.027-.031
.027-.031
.030-.034
.028-.032
.027-.031
.027-.031
.030-.034
.028-.032
.027-.031
.027-.031
.030-.034
.028-.032
.027-.031
.027-.031
.030-.034
.030-.034
.028-.032
.027-.031
.027-.031
.030-.034
.028-.032
.027-.031
.027-.031
.030-.034
.030-.034
.028-.032
.027-.031
.027-.031
Cond. Crimp Width
mm
In.
1.40
.055
1.40
.055
1.40
.055
1.40
.055
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
Pull Force Min.
N
Lb.
28.9
6.50
17.8
4.00
11.1
2.50
6.7
1.50
28.9
17.8
11.1
6.7
28.9
17.8
11.1
6.7
28.9
17.8
11.1
6.7
28.9
17.8
11.1
6.7
44.8
28.9
17.8
11.1
6.7
28.9
17.8
11.1
6.7
44.8
28.9
17.8
11.1
6.7
6.50
4.00
2.50
1.50
6.50
4.00
2.50
1.50
6.50
4.00
2.50
1.50
6.50
4.00
2.50
1.50
10.00
6.50
4.00
2.50
1.50
6.50
4.00
2.50
1.50
10.00
6.50
4.00
2.50
1.50
Profile
A
B
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Doc No. 11-01-0185
Revision: E
Release Date: 10-07-03
Revision Date: 08-11-04
UNCONTROLLED COPY
Page 2 of 6
Hand Crimp Tool for .100 KK
CONDITIONS: (Continued)
Terminal
Wire Size Cond. Crimp Height (REF)
Series No. AWG mm
2
mm
In.
41572
22 0.35 0.76-0.86
.030-.034
41572
24 0.20 0.76-0.86
.030-.034
41572
26 0.12 0.71-0.81
.028-.032
41572
28 0.08 0.69-0.79
.027-.031
41572
30 0.05 0.69-0.79
.027-.031
4548
4548
4548
4548
4559
4559
4559
4559
4809
4809
4809
4809
4809
5159
5159
5159
5159
6459
6459
6459
6459
6459
6796
6796
6796
6796
7879
7879
7879
7879
7879
8088
8088
8088
8088
8088
24
26
28
30
24
26
28
30
22
24
26
28
30
24
26
28
30
22
24
26
28
30
24
26
28
30
22
24
26
28
30
22
24
26
28
30
0.20
0.12
0.08
0.05
0.20
0.12
0.08
0.05
0.35
0.20
0.12
0.08
0.05
0.20
0.12
0.08
0.05
0.35
0.20
0.12
0.08
0.05
0.20
0.12
0.08
0.05
0.35
0.20
0.12
0.08
0.05
0.35
0.20
0.12
0.08
0.05
0.76-0.86
0.71-0.81
0.69-0.79
0.69-0.79
0.76-0.86
0.71-0.81
0.69-0.79
0.69-0.79
0.76-0.86
0.76-0.86
0.71-0.81
0.69-0.79
0.69-0.79
0.76-0.86
0.71-0.81
0.69-0.79
0.69-0.79
0.76-0.86
0.76-0.86
0.71-0.81
0.69-0.79
0.69-0.79
0.76-0.86
0.71-0.81
0.69-0.79
0.69-0.79
0.76-0.86
0.76-0.86
0.71-0.81
0.69-0.79
0.69-0.79
0.76-0.86
0.76-0.86
0.71-0.81
0.69-0.79
0.69-0.79
.030-.034
.028-.032
.027-.031
.027-.031
.030-.034
.028-.032
.027-.031
.027-.031
.030-.034
.030-.034
.028-.032
.027-.031
.027-.031
.030-.034
.028-.032
.027-.031
.027-.031
.030-.034
.030-.034
.028-.032
.027-.031
.027-.031
.030-.034
.028-.032
.027-.031
.027-.031
.030-.034
.030-.034
.028-.032
.027-.031
.027-.031
.030-.034
.030-.034
.028-.032
.027-.031
.027-.031
Cond. Crimp Width
mm
In.
1.40
.055
1.40
.055
1.40
.055
1.40
.055
1.40
.055
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
.055
Pull Force Min.
N
Lb.
44.8
10.00
28.9
6.50
17.8
4.00
11.1
2.50
6.7
1.50
28.9
17.8
11.1
6.7
28.9
17.8
11.1
6.7
44.8
28.9
17.8
11.1
6.7
28.9
17.8
11.1
6.7
44.8
28.9
17.8
11.1
6.7
28.9
17.8
11.1
6.7
44.8
28.9
17.8
11.1
6.7
44.8
28.9
17.8
11.1
6.7
6.50
4.00
2.50
1.50
6.50
4.00
2.50
1.50
10.00
6.50
4.00
2.50
1.50
6.50
4.00
2.50
1.50
10.00
6.50
4.00
2.50
1.50
6.50
4.00
2.50
1.50
10.00
6.50
4.00
2.50
1.50
10.00
6.50
4.00
2.50
1.50
Profile
A B
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Doc No. 11-01-0185
Revision: E
Release Date: 10-07-03
Revision Date: 08-11-04
UNCONTROLLED COPY
Page 3 of 6
Hand Crimp Tool for .100 KK
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.
Crimping Terminals
1. Lift the locator blade and place the terminal into the correct die
profile (A or B), release the locator blade. Not all tools are
equipped with a locator or locator blade.
Figure 1
2. Partially close the tool until the terminal is
held in place, (See Figure 2).
3. Place a wire into the terminal and up against the
locator blade, (See Figure 3). On tools without
locators line the wire up with the conductor and
insulation grips visually.
4. Close the tool until the ratchet releases,
(See Figure 4).
5. Lift the locator blade or wire stop up.
6. Carefully remove the crimped terminal.
Figure 2
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
Figure 3
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.
4. 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 lifting the ratchet release lever (See Figure 4).
Doc No. 11-01-0185
Revision: E
Release Date: 10-07-03
Revision Date: 08-11-04
UNCONTROLLED COPY
Page 4 of 6
Hand Crimp Tool for .100 KK
How To Adjust Tool Crimp Force
(See Figure 4)
It may be necessary over the life of the tool to adjust tool-crimping force. Listed below are the steps required to
adjust the crimping force of the hand tool to obtain proper crimp conditions:
1. Remove the screw and washer. Located over the adjustment ring.
2. Lift the adjusting ring slightly, off of the locating pin.
3. Turn the adjusting ring in the desired direction (L= less force, T= more force) to increase or decrease crimp
pressure.
4. Press the adjusting wheel flat against the tool and engage the locking pin.
5. Replace the washer and screw.
6. Check the crimp specifications after tool crimp 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 would exchange the tool free of charge. This 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.
Hand held crimping tools are intended for low volume, prototyping, or repair requirements only.
Caution:
Repetitive use of this tool should be
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 is 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, applicators and
Doc No. 11-01-0185
Revision: E
Release Date: 10-07-03
Revision Date: 08-11-04
UNCONTROLLED COPY
Page 5 of 6
