Molex 50837 User manual

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 0, 2 0,84 – 0,89

.0 -.0 5 1,1 – 1,

.04 -.051

24 0,20 0,76 – 0,81

.0 0-..0 2

1,1 – 1,

.04 -.051

26 0,12 0,71 – 0,76

.028-.0 0 1,1 – 1,

.04 -.051

508 7

28 0,08 0,67 – 0,72

.026-.028 1,1 – 1,

.04 -.051

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

Figure 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

[email protected]

Far East North Headquarters

Yamato, Kanagawa, Japan

81-462-65-2 24

[email protected]

Far East South Headquarters

Jurong, Singapore

65-6-268-6868

[email protected]

European Headquarters

Munich, Germany

49-89-41 092-0

[email protected]

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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