Molex 59354 User manual

Hand Crimp Tool for 2.00mm (.079") Pitch Crimp Terminals

Doc No: ATS- 638111200 Release Date: 03-06-98 UNCONTROLLED COPY Page 1 of 5

Revision: G Revision Date: 04-15-08

INSULATION

CRIMP

BRUSH

STRIP

LENGTH

BELL MOUTH

CRIMP HEIGHT

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP

TWISTING

HAND CRIMP TOOL

Operating Instruction and

Specification Sheet

Order No. 63811-1200

FEATURES



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

SCOPE

Products: 2.00mm (.079") Pitch Crimp Terminals, 24-30 AWG.

Terminal Order No. Wire Size Insulation Diameter

Strip Length

Terminal Series No.

Loose Piece



Reel AWG

mm² mm In. mm In.

50212 50212-8100

39-00-0424

50212-8000

24-30

0.20-0.05

0.80-1.40

.031-055

1.30-1.80

.051-.071

59354-8181

59354-8081

59354 59354-8099

24-30

0.20-0.05

0.80-1.40

.031-055

1.30-1.80

.051-.071



Customer to cut off terminal from reel: 0.20mm (.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.

Hand Crimp Tool for 2.00mm (.079") Pitch Crimp Terminals

Doc No: ATS- 638111200 Release Date: 03-06-98 UNCONTROLLED COPY Page 2 of 5

Revision: G Revision Date: 04-15-08

Figure 3

LOCATOR

Figure 2

INSULATION

GRIPS

CONDUCTOR

GRIPS

WIRE

TERMINAL

LOCATOR

BLADE

CONDITIONS:

After crimping, the conductor profiles should measure the following (see notes on page 3).

Conductor Crimp Punch

Wire Size Height (Ref) Width (Ref)

Pull Force

Minimum Profile

Terminal Series No.

AWG

2mm In. mm In. N Lb. A

24 0.20 0.55-0.65 .022-.026 1.34 .053 29.4 6.60

26 0.12 0.53-0.64 .021-.025 1.34 .053 19.6 4.40

28 0.08 0.53-0.64 .021-.025 1.34 .053 9.8 2.20

50212

30 0.05 0.51-0.61 .020-.024 1.34 .053 4.9 1.10

24 0.20 0.55-0.65 .022-.026 1.34 .053 29.4 6.60

26 0.12 0.53-0.64 .021-.025 1.34 .053 19.6 4.40

28 0.08 0.53-0.64 .021-.025 1.34 .053 9.8 2.20

59354

30 0.05 0.51-0.61 .020-.024 1.34 .053 4.9 1.10

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.

2. Partially close the tool until the terminal is held in place. See Figure 1. If the insulation diameter is too large to

do this, then place the insulation down into the terminal before closing the tool.

3. Place a wire into the terminal and up against the locator blade. See Figure 2. On tools without locators line the

wire up with the conductor and insulation grips visually.

4. Close the tool until the ratchet releases.

5. Lift the locator blade or wire stop up.

6. Carefully remove the crimped terminal.

TERMINAL

PRE

STRIPPED WIRE

Figure 1

Hand Crimp Tool for 2.00mm (.079") Pitch Crimp Terminals

Doc No: ATS- 638111200 Release Date: 03-06-98 UNCONTROLLED COPY Page 3 of 5

Revision: G Revision Date: 04-15-08

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.

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.

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 avoided.

Hand Crimp Tool for 2.00mm (.079") Pitch Crimp Terminals

Doc No: ATS- 638111200 Release Date: 03-06-98 UNCONTROLLED COPY Page 4 of 5

Revision: G Revision Date: 04-15-08

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

tooling.

Hand Crimp Tool for 2.00mm (.079") Pitch Crimp Terminals

Doc No: ATS- 638111200 Release Date: 03-06-98 UNCONTROLLED COPY Page 5 of 5

Revision: G Revision Date: 04-15-08

M4 NUT

RATCHET

RELEASE LEVER

ADJUSTMENT

RING

LOCATOR

BLADE

Figure 4

M4 X 18LG BHCS

PARTS LIST

Item Number

Order Number

Description Quantity

1 63811-1275 Locator Assembly**

2 11-11-0324 Spring (Main) 1

3 11-11-0320 Spring (Ratchet) 1

** Not all tools are equipped with a locator or locator blade.

Americas Headquarters

Lisle, Illinois 60532 U.S.A.

1-800-78MOLEX

[email protected]

Far East North Headquarters

Yamato, Kanagawa, Japan

81-462-65-2324

[email protected]

Far East South Headquarters

Jurong, Singapore

65-6-268-6868

[email protected]

European Headquarters

Munich, Germany

49-89-413092-0

[email protected]

Corporate Headquarters

2222 Wellington Ct.

Lisle, IL 60532 U.S.A.

630-969-4550

Fax: 630-969-1352

Visit our Web site at http://www.molex.com

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