Hand Crimp Tool (Straight-Action Short-Handle Type) Instruction Manual

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1 Instruction Manual No. IS-0117J ISSUED Jun. 1, 2001 REVISED REV. 0 Hand Crimp Tool (Straight-Action Short-Handle Type) Instruction Manual MOLEX JAPAN CO., LTD.

2 Thank you for purchasing a Molex product. Introduction This manual describes the procedures for proper use and maintenance of the hand crimper. Read thoroughly prior to use. Read the instructions below before using the tool. Safety Notices After reading, make a copy of this manual, and keep the original in a safe place. Make sure the copy is easily accessible to users of the tool. Caution 1. Always check the tool number, applicable terminal number and wire size, and the like before using the hand tool (hereinafter referred to as the tool ) in the crimping process. 2. Check the tool for any damage, and repair prior to use. Defective crimping may result in fire. 3. Take care not to catch your hand or fingers in the teeth and handles of the tool, as injury may result. 4. Beware of the handle when it is opened. Releasing the ratchet may cause the handle to open abruptly, resulting in injury. 5. Use the tool only for the intended purposes. Do not use it in place of a hammer, pliers, or other tools. Do not remodel the tool. Parts damage may result in accident or injury. 6. Do not use the tool in an awkward position, as this may cause overturning or injury. 7. Keep the tool in a dry place out of reach of children in order to prevent accidents. 8. Be careful not to drop the tool or trap foreign matter between the teeth during the crimping process. These may result in defective crimping possibly causing fire, or parts damage. 9. Do not use the tool for unspecified terminals. Do not crimp unspecified wires. Both may cause parts damage. 10. The crimping controller (ratchet mechanism) of the tool is designed to be operated by hand. Note that improper handling such as inserting it into other devices and opening the handle forcibly may damage the ratchet, link, plate pin, or the like, and decrease its capabilities and lifespan. 11. Clean the tool regularly if used frequently. 12. Avoid storing the tool in extremes of temperature, or in high-humidity environments. In addition, avoid storing it where it may drop, resulting in parts damage or injury. 13. The tool must be used only by users who have received adequate training on usage and safety from their employer, and have appropriate knowledge and skills. Use by unfamiliar users may cause parts damage or injury. (1)

3 Contents 1. Overview Tool Part Names Operation Procedure (Figures 2 & 3) Daily Inspection & Adjustment... 4,5 5. Part Names Overview This hand crimper is a straight-action (short-handle) type hand tool designed for crimp-connecting wires to Molex crimp terminals. 2. Tool Part Names Crimp area Head Ratchet adjustment screw Fixing nut Grip Link Ratchet Handle (Figure 1) (2)

4 3. Operation Procedure (Figures 2 & 3) (1) Hold the tool handle, and squeeze it until the ratchet is released. Then, unclench your hand. The handle will be opened by the return spring. (2) Insert the terminal into the teeth from the molex logo side of the tool. Insert the terminal so that its logo side faces the contact, and its terminal number engraving side faces the crimp barrel. Crimp area Terminal number engraving side molex logo side Crimp barrel Terminal (Figure 2) (3) Close the handle lightly until the terminal barrel is held by the tool punch and anvil. Place the locator tip between the conductor wire barrel and the insulation barrel so that the terminal does not come off. Do not tighten the handle excessively, as doing so may cause deformation of the crimped terminal and prevent insertion of the wire. molex logo side Conductor punch Insulation punch Terminal number engraving side Support Locator Coated end face Direction in which the terminal is inserted Conductor barrel Insulation barrel Wire Anvil (Figure 3) (4) Insert the stripped wire from the terminal number engraving side until the insulation end face contacts the locator. (5) Close the tool handle firmly until the ratchet is released (clicks), while holding the wire in the same position as in (4). Do not tighten the handle excessively after the ratchet is released, as doing so may over-crimp the terminal and cause wire breakage or parts damage. (6) When the ratchet clicks and is released, the handle is automatically opened by the return spring mounted in it, and the terminal is crimped. Pulling the wire toward the handle gently removes the crimped terminal. (3)

5 4. Daily Inspection & Adjustment 4.1 Machinery Inspection & Adjustment (1) Check to confirm that the handle moves smoothly (as needed). (2) After using the tool, always apply machine oil or commercial anti-corrosive oil to the crimp section, the link, the ratchet, and other moving parts prior to storage (as needed). (3) Loosen the fixing nut for ratchet adjustment screw (eccentric shaft) shown in Figure 1, and rotate the screw to change the position at which the ratchet is released. Always adjust the position when the crimp section cannot be fully closed due to parts wear or the like. Be sure to retighten the fixing nut after completion of adjustment. 4.2 Crimped Terminal Inspection (1) Always check the crimp height of the conductor wire at the beginning and end of daily operation, and also check it regularly during operation. Refer to the specification table provided with the tool for the crimp height. If the crimp height of the conductor wire is not in accordance with the specification, check whether the crimp punch are fully closed. If they are not, adjust the ratchet. When the crimp height of the conductor wire is not in accordance with the specification despite the crimp section being fully closed, the tool has reached the end of its lifespan. Please consult our service personnel. As this tool crimps wires of various sizes using one set of teeth, the crimp height of the insulation height is for reference only. Be sure to refer to the specification table provided with the tool for the crimp height of the tool. Wire strip length Extruded wire length Conductor crimp height Insulation crimp height (For reference) Description in the specification table (Figure 4) (4)

6 (2) Be sure to check the wire pull-out force regularly (Figure 5). Create a test sample like the one below and place it in a pull-out force tester or a pull gauge. Then apply the standard pull-out force of 25 mm/min. to it, and measure the value at the point where the wire is pulled out or fractured. Remember that the insulation section should not be crimped. * Do not crimp the coating of the sample to be measured. Do not crimp the insulation section. 25 mm/min. (Figure 5) (3) Always check to confirm that the crimped terminal is not scratched or deformed. If you have any questions regarding tool handling, please consult the Machine Maintenance Service Department or sales office service personnel. Please request the Machine Maintenance Service Department to repair any broken parts. (Parts are not supplied separately.) Contact: Machine Maintenance Service Department, MOLEX JAPAN CO., LTD , Fukami-Higashi, Yamato City, Kanagawa, TEL: (direct line) (5)

7 5. Part Names Item No. Name Req. No. Remarks 1 U HEAD 1 2 FRONT PLATE 1 3 REAR PLATE 1 4 LINK 4 5 HANDLE A 1 6 HANDLE B 1 7 GRIP 2 8 RATCHET 1 9 ADJUSTMENT SCREW 1 10 NUT 1 11 PAWL 1 12 TORSION SPRING 1 13 SPRING FOR LOCATOR 2 14 PAWL SPRING 1 15 STOP PIN φ STOP PIN φ PIN FOR PAWL 1 18 RIVET FOR HEAD 4 19 RIVET FOR ANVIL 2 20 COND PUNCH (core wire punch) 1 21 COND ANVIL (core wire anvil) 1 22 INS PUNCH (coated punch) 1 23 INS ANVIL (coated punch) 1 24 LOCATOR 1 25 SUPPORT 1 26 C RING φ C RING φ SPRING PIN φ SPRING PIN φ (6)

STRAIGHT-ACTION (SHORT-HANDLE TYPE) HAND CRIMP TOOL

INSTRUCTION MANUAL NO. IS-0117E ISSUED 2001-06-01 REVISED 2005-01-13 REV. A STRAIGHT-ACTION (SHORT-HANDLE TYPE) HAND CRIMP TOOL OPERATING MANUAL Molex Japan Co., Ltd. Molex Japan Co., Ltd. Contents of