molex 57022 Series User manual

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 Update Instruction Manual No. IS-0117E
Title Straight-Action (Short-Handle Type) Hand Crimp Tool Tool Number
Rev. Issued Description
0 2001/06/01 New creation release.
Prepared by Y. Ishiwata
Checked by T. Yoshida
A 2005/01/13 Changed the form into the bilingual version.
ECN-JM50012 Approved by A. Horino

A–1
<Safety Precautions>
Please read the following before operating the tool.
1. Introduction
Thank you for choosing our Hand Crimp Tool.
This document is prepared so that the tool is properly used.
Please take the time to read this manual, making sure you understand the operating
procedures described herein before attempting to operate the tool.
2. Dangerous operations
1) Don’t insert a part of your body or other foreign materials in the hand crimp tool
(hereinafter referred to as the “tool”) while you’re operating the handle of a tool, as injury
my result.
2) Beware of a handle when it is opened. Releasing a ratchet may cause the handle to open
abruptly, resulting in injury.
3) Only users who have received adequate training on usage and safety from their manager,
and have appropriate knowledge and skills must use the tool. Use by unfamiliar users may
cause injury.
<Caution>
1) Unauthorized reproduction of this document in part or in whole is prohibited.
2) The contents of this document are subject to change without notice.
3) Molex Japan Co., Ltd. assumes no responsibility for losses resulting from use or
misuse of this document.

A–2
<Safety Precautions>
Please read the following before operating the tool.
3. Careful handling
1) Always check the tool number, applicable terminal and wire size, etc. before using 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) Clean the tool regularly if used frequently.
4) Avoid storing the tool in extremes of temperature, or high-humidity environment.
5) Keep the tool in a place out of reach of children in order to prevent accidents.
4. Must not be carried out
1) Use the tool only for the intended purpose. Don’t use it in place of a hammer, pliers, or other
tools. Don’t remodel the tool. Parts damage may result in accident or injury.
2) Don’t use the tool for unspecified terminals. Don’t crimp unspecified wires. Both may cause
parts damage.
3) The ratchet mechanism of the tool is designed based on operation by the grip of the hand.
Note that improper handling such as inserting it into other devices and opening the handle
forcibly may decrease its capabilities and lifespan.

Page 1
1. Description
This tool is a straight-action (short-handle type) hand crimp tool, which is designed for
crimp-connecting wires to crimp terminal of Molex.
Please confirm the tool number, the applicable terminal number, and the size of the
applicable wire marked on the hand crimp tool before attempting to operate this tool.
2. Tool Specification
1) Tool name:
Straight-Action (Short-Handle Type) Hand Crimp Tool
2) Outer dimensions and
weight:
215 (width) x 90 (depth) x 15 (thickness) mm, Approx. 400gf
3) Management method:
Crimp height and crimp strength (Details are described to the crimp specification of a corresponding tool)
4) Part names of tool
Grip
Handle
Ratchet adjustment screw & Fixing nutHead
Crimp section
Link
215 mm
Ratchet part

Page 2
3. Operation Method
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 a “terminal (1)” into the “crimp section (3)” from the “molex logo mark side (2).” Insert
a “terminal (1)” so that the “molex logo mark side (2)” faces the “contact”, and the “terminal
number engraving side (4)” faces the “barrel (5).”
3) Close the handle lightly until the “barrel (5)” of a “terminal (1)” is held by the “insulation
punch (6)” and “anvil (7).” At this time, the tip of a “locator (8)” is placed between the
“conductor barrel (9)” and the “insulation barrel (10)” so that the “terminal (1)” does not
come off.
* Don’t tighten the handle excessively, as doing so may cause deformation of the crimp part
of a terminal and prevent insertion of a wire.
Insulation barrel (10) Conductor barrel (9)
A
nvil (7)
Direction of terminal
insertion
Locator (8)
Insulation punch (6)Conductor punch
Insulation end face (12)
Wire (11)
molex logo mark side Terminal number engraving side
Terminal number engraving side (4)Crimp section (3)
molex logo mark side (2)
Barrel (5)
Terminal (1)

Page 3
3. Operation Method (continued)
4) Insert the stripped “wire (12)” from the “terminal number engraving side (4)” until the
“insulation end face (12)” contacts the “locator (8).”
5) Squeeze the tool handle firmly until the ratchet is released (clicks), while holding the wire in
the same position as in below figure.
6) When the ratchet clicks and is released, the handle is automatically opened by the return
spring, and the terminal is crimped.
7) Holding and pulling the “wire (11)” toward the handle gently removes the crimped terminal.
“Note” Don’t tighten the handle excessively after the ratchet is released, as doing so may
over-crimp the terminal and cause wire breakage of parts damage.
Wire strip length
Insulation crimp height (reference)
Conductor crimp height
Extrude wire length

Page 4
4. Daily Maintenance
4.1. Machinery Inspection and Adjustment
1) Check to confirm that the handle moves smoothly (as heeded).
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 below figure
by attached “exclusive tool”, and rotate the ratchet adjustment 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.
Ratchet adjustment screw
Crimp section
Ratchet part
Fixing nut

Page 5
4.2. Crimp Terminal Inspection
1) Crimp height of conductor wire (Crimp height)
(1) Always check the crimp height of a conductor wire at the beginning and end of daily
operation, and also check it regularly during operation.
(2) Refer to the specification table provided with the tool for crimp height.
(3) When the crimp height of a conductor wire is not in accordance with the specification, the
tool has damaged or reached the end of its lifespan. Please consult our service personnel.
(4) As this tool crimps wires of various sizes using one set teeth, the insulation crimp height is
for reference only.
“Note” We recommend to measure the crimp height of a conductor
wire by using the “crimp height micrometer” (J5830-001) of
Molex.
Wire strip length
Insulation crimp height (reference)
Conductor crimp height
Extrude wire length
Measurement of crimp
height of conductor wire
J5830-001

Page 6
4.2. Crimp Terminal Inspection (continued)
2) Wire pullout strength
(1) Be sure to check the wire pullout strength regularly.
(2) Create a test sample like one the below figure and place it in a pullout force tester or a pull
gauge. Then apply the standard pullout force of 25 mm/min. to it, and measure the value at
the point where the wire is pulled out or fractured.
(3) Remember that the insulation section should not be crimped.
3) Crack or deform of terminal
Always check to confirm that the crimped terminal is not cracked or deformed.
Do not crimp the insulation section. Pull out by the speed of 25 mm/min.
150 mm
20 mm

Page 7
5. Parts List
“Note” Parts are not supplied separately.
No. Parts Name Q’ty 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 Adjust Screw 1
10 Nut 1
11 Pawl 1
12 Torsion Spring 1
13 Spring for Locator 2
14 Pawl Spring 1
15 Stop Pin (phi6) 1
16 Stop Pin (phi5) 4
17 Pin for Pawl 1
18 Rivet for Head 4
19 Rivet for Anvil 2
20 Conductor Punch (1)
21 Conductor Anvil (1)
22 Insulation Punch (1)
23 Insulation Anvil (1)
24 Locator (1)
25 Support (1)
26 C-ring (phi5) 8
27 C-ring (phi6) 2
28 Spring Pin (phi2) 1
29 Spring Pin (phi3) 1
Section A-A

Page 8
6. Straight-Action (Short-Handle Type) Hand Crimp Tool Startup
Checklist
[Applicable Tool] Straight-Action (Short-Handle Type) Hand Crimp Tool
“Note” Please check the following matter before the commencement of work, and start operation
after checking those without a problem.
No. Checkpoint Standard Method/equipment Check result
1 Crimp height of
conductor wire
When you crimp an applicable
terminal for the tool, the crimp
height of a conductor wire should
satisfy the standard.
Check by trial
crimping.
2 Wire pullout
strength
The wire pullout strength of an
applicable terminal should satisfy the
standard.
Check by trial
crimping.
3 Separation of
ratchet When squeeze a tool handle firmly, a ratchet should crick and separate. Check by trial operation.
4 Crack of terminal There are no crack and deformation
by the hand tool in a terminal. Check a crimped terminal visually.
5 Crimp section There are no article and dust in a
crimp section. Cleanup
Wire strip length
Insulation crimp height (reference)
Conductor crimp height
Extrude wire length
Measurement of crimp
height of conductor wire