molex 50837 Manual de usuario
Hand Crimp Tool for Mini-Lock™ Wire-to-Board Terminals
Doc No: ATS-6 82 400 Release Date: 04-09-10 UNCONTROLLED COPY Page 1 of 8
Revision: A Revision Date: 04-09-10
HAND CRIMP TOOL
Specification Sheet
Order No. 6 82 - 400
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 WHMA-IPCA620 Class 2 compliant as indicated
This tool is RoHS compliant, however RoHS compliant is not required
SCOPE
Products: Mini-Lock™ 2.50mm (.098") Pitch Wire-to-Board Terminals, 22 – 28 AWG
Terminal Order No. Wire Size Insulation Diameter Strip Length
Terminal Series No.
Loose Piece
Reel AWG
mm² mm In. mm In.
508 7 508 7-8100 508 7-8000
22-28
0, 2-0,08
1-15 – 1.8
.045-.070
2, -2,8
.090-.110
Customer to cut off terminal from reel: 0,.2mm (.008”) 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.
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
BELL MOUTH
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
TYPE 4D
Hand Crimp Tool for Mini-Lock™ Wire-to-Board Terminals
Doc No: ATS-6 82 400 Release Date: 04-09-10 UNCONTROLLED COPY Page 2 of 8
Revision: A Revision Date: 04-09-10
CONDITIONS:
After crimping, the conductor profiles should measure the following.
Conductor Crimp
Wire Size Height (Ref.) Width (Ref.) Profile
Terminal Series No
AWG
mm2
mm In. mm In. 26
22
24
28
22 0, 2 0,84 – 0,89
.0 -.0 5 1,1 – 1,
.04 -.051
X
24 0,20 0,76 – 0,81
.0 0-..0 2
1,1 – 1,
.04 -.051
X
26 0,12 0,71 – 0,76
.028-.0 0 1,1 – 1,
.04 -.051
X
508 7
28 0,08 0,67 – 0,72
.026-.028 1,1 – 1,
.04 -.051
X
Insulation Crimp
Wire Size Max Height (Ref.)
Max Width (Ref.)
Pull Force
Minimum
Terminal Series No
AWG
mm2
mm In. mm In. N Lb.
22 0, 2 1,8 .071 1,9 .075 9.2 8.8
24 0,20 1,8 .071 1,9 .075 29.4 6.6
26 0,12 1,8 .071 1,9 .075 19.6 4.4
508 7
28 0,08 1,8 .071 1,9 .075 9.8 2.2
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 together. At the end of the closing stroke, the ratchet mechanism will
release the handles and the hand tool will spring open. See Figure 1.
Crimping Terminals
1. Select the desired terminal listed
from the preceding charts. Then
install it in the proper locator (See
chart above and see Locator
Installation on page 5).
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 the
locator forward through the tooling.
See Figure 2.
SQUEEZE
HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Figure 1
LOCATOR
IN DOWN
POSTION
PUSH ON THE
LOCATOR BUTTON
Figure 2
Hand Crimp Tool for Mini-Lock™ Wire-to-Board Terminals
Doc No: ATS-6 82 400 Release Date: 04-09-10 UNCONTROLLED COPY Page of 8
Revision: A Revision Date: 04-09-10
RELEASE
LOCATOR BUTTON
TERMINAL Figure
LOCATOR
PUSHED THRU
TOOLING
TERMINAL
LOCATOR
BUTTON
PUSHED IN
LOCATOR
Figure 5
TERMINAL
WIRE AGAINST THE
WIRE STOP
WIRE
WIRE STOP IS PART
OF THE LOCATOR
PRE-STRIPPED
WIRE
TERMINAL
. While holding in the locator button, load the terminal into the proper
nest opening in the locator, based on the wire gauge or terminal type
markings on the hand tooling. See Figure .
4. Release the locator button, allowing the locator to return to the
crimping position.
5. Close the tool handle until the first ratchet position engages. See
Figure 4.
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 bee n completed. Release the handles to open
the jaws.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
8. Remove the crimped terminal from the terminal locator by pulling on the wire.
9. Visually inspect the crimped terminal for proper crimp location.
10. On some large O.D. wires, it may not be possible to insert the wire with the tool partially closed. Those wires
should be inserted with the hand tool in the open position. Insert the wire above the terminal in the punch and
against the wire stop then close the tool. See Figure 6.
PARTIALLY
CLOSE HANDLE
TOOLING
PARTIALLY
CLOSED
Figure 4
FIRST RATCHET
POSITION
OPEN
POSITION
Hand Crimp Tool for Mini-Lock™ Wire-to-Board Terminals
Doc No: ATS-6 82 400 Release Date: 04-09-10 UNCONTROLLED COPY Page 4 of 8
Revision: A Revision Date: 04-09-10
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
available, actual crimp height measurements may
very slightly. An occasional, destructive, pull force
test should be preformed to check hand tool crimp.
Pull Force value Must exceed the Minimum pull force
specifications listed.
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. Squeeze gently on the lower area shown in Figure 7A with your thumb and index finger. The lower tabs of the
locator should disengage from the hand tool.
. Lift and pull away from the hand tool. The top locator hooks should slip out of the top slots easily. See Figure
7A.
4. To reinstall the new locator, make sure the hand tool is in the open position.
5. Press the red insert down as far as it will go as shown in Figure 7B.
6. Holding onto the lower part of the locator with your thumb and index finger, insert the locator top 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 the
locator into place, the lower tabs must snap into place on the hand tool frame.
TERMINAL
Figure 6
WIRE
WIRE STOP
SQUEEZE
HERE
SQUEEZE
HERE
LOCATOR
Figure 7A
TOP HOOKS
TOP SLOTS OF
HANDTOOL
LOWER TABS
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
Figure 7B
Figure 8
PUSH ON
HANDLE
JAWS OPEN
PULL OPEN
TOOLING TOOLING
M BHCS
Hand Crimp Tool for Mini-Lock™ Wire-to-Board Terminals
Doc No: ATS-6 82 400 Release Date: 04-09-10 UNCONTROLLED COPY Page 5 of 8
Revision: A Revision Date: 04-09-10
Figure 12
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
SETTING
WHEEL
RATCHET
RELEASE LEVER
Right or Left Hand Operation
This hand tool has an added feature that can be converted
from a right handed application to a left handed application.
It is necessary to reverse the tooling along with the locator if
using the left handed application. Follow the steps below:
1. The locator must be removed before reversing the
tooling.
2. Remove the M BHCS which is
holding the upper tooling.
. Flip the upper tooling to the
opposite side and replace the M
BHCS Make sure the small
markings on the front and back of
the hand tool frame match up and
are on the outside of the hand
tool frame. See Figure 8 and 9.
4. Do the same thing with the lower
tooling and tighten the M
screws. Be sure the small
markings line up.
5. Reinstall the locator by following the Instructions in the locator replacement section.
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.
. Make 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 other equipment it needs cleaning and lubrication for a maximum service
life of trouble free crimping. Light oil (such as 0 weight automotive oil) used at the oil points, every 5,000
crimps or months, will significantly enhance the tool life.
RATCHET RELEASE
LEVER
Figure 11
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY MONTHS OR
5,000 CRIMPS)
Figure 10
MATCH
UP MARKS
FRONT BACK
Figure 9
Hand Crimp Tool for Mini-Lock™ Wire-to-Board Terminals
Doc No: ATS-6 82 400 Release Date: 04-09-10 UNCONTROLLED COPY Page 6 of 8
Revision: A Revision Date: 04-09-10
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 up on the ratchet release lever in the movable handle. See Figure 11
How to Adjust Tool Preload
(See Figure 12)
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. Hold the hand tool in the palm of your hand as shown in Figure 12. Using the index finger squeeze the link
towards 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).
. 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.
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 0
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: 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 for
production use. Repetitive use of this tool should be avoided.
2. Insulated rubber handles are not protection against electrical shock.
. Wear eye protection at all times.
4. Use only the Molex terminals specified for crimping with this tool.
Hand Crimp Tool for Mini-Lock™ Wire-to-Board Terminals
Doc No: ATS-6 82 400 Release Date: 04-09-10 UNCONTROLLED COPY Page 7 of 8
Revision: A Revision Date: 04-09-10
Certification
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. 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 Molex 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.
Hand Crimp Tool for Mini-Lock™ Wire-to-Board Terminals
Doc No: ATS-6 82 400 Release Date: 04-09-10 UNCONTROLLED COPY Page 8 of 8
Revision: A Revision Date: 04-09-10
RATCHET
RELEASE LEVER
2
Figure 1
1
PARTS LIST
Item Number Order Number Description Quantity
REF 6 82 - 400 Hand Crimp Tool Figure 1
1 6 82 - 475 Locator Assembly (Red) 1
2 6 810-0104 Spring, Return 1
6 810-0105 Spring, Ratchet 1
Americas Headquarters
Lisle, Illinois 605 2 U.S.A.
1-800-78MOLEX
Far East North Headquarters
Yamato, Kanagawa, Japan
81-462-65-2 24
Far East South Headquarters
Jurong, Singapore
65-6-268-6868
European Headquarters
Munich, Germany
49-89-41 092-0
Corporate Headquarters
2222 Wellington Ct.
Lisle, IL 605 2 U.S.A.
6 0-969-4550
Fax: 6 0-969-1 52
Visit our Web site at http://www.molex.com
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