molex CR5904 User manual

CR5904 Hand Crimp Tool for “SPOX” .156 Cent.
Doc No. 11-01-0193 Release Date: 04-13-93 UNCONTROLLED COPY Page 1 of 4
Revision: E Revision Date: 07-28-04
INSULATION
CRIMP
BRUSH
STRIP
LEN
BELL MOUTH
CRIMP HEIG
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
HAND CRIMP TOOL
Operating Instruction and
Specification Sheet
Order No. 11-01-0193 (CR5904)
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
Wire Size Insulation Diameter Strip LengthTerminal
Series No. AWG mm² mm In. mm In.
5194 18 - 24 0.80-0.20 1.30-3.00 .051-.118 3.00-3.50 .118-.138
DEFINITION OF TERMS
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the scope.
CONDITIONS:
After crimping, the conductor profiles should measure the following (see notes on page 3).
Punch Width (Ref)
Wire Size Cond. Crimp
Height (Ref) Cond. Ins.
Pull Force Min. Profile
Terminal
Series No. AWG mm2mm In. mm In. mm In. N Lb. A B
5194 18 0.80 1.16-1.26 .046-.050 1.70 .067 2.80 .110 89.0 20.00 X
5194 20 0.50 0.99-1.09 .039-.043 1.70 .067 2.80 .110 57.8 13.00 X
5194 22 0.35 0.98-1.08 .039-.043 1.70 .067 2.80 .110 40.0 9.00 X
5194 24 0.20 0.95-1.05 .037-.041 1.70 .067 2.80 .110 28.5 6.40 X

CR5904 Hand Crimp Tool for “SPOX”.156 Cent.
Doc No. 11-01-0193 Release Date: 04-13-93 UNCONTROLLED COPY Page 2 of 4
Revision: E Revision Date: 07-28-04
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 2).
3. Place a wire into the terminal and up against the locator
blade, (See Figure 3). On tools without locators line the
wire up with the conductor and insulation grips visually.
4. Close the tool until the ratchet releases, (See
Figure 4).
5. Lift the locator blade or wire stop up.
6. Carefully remove the crimped terminal.
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).
Figure 2
Figure 3
TERMINAL
PRE-STRIPPED WIRE
Figure 1

CR5904 Hand Crimp Tool for “SPOX”.156 Cent.
Doc No. 11-01-0193 Release Date: 04-13-93 UNCONTROLLED COPY Page 3 of 4
Revision: E Revision Date: 07-28-04
CAUTION: Molex crimp specifications are valid only when used with Molex terminals, applicators and tooling.
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.
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: Repetitive use of this tool should be avoided.

CR5904 Hand Crimp Tool for “SPOX”.156 Cent.
Doc No. 11-01-0193 Release Date: 04-13-93 UNCONTROLLED COPY Page 4 of 4
Revision: E Revision Date: 07-28-04
PARTS LIST
Item Number Order Number Description Quantity
1 11-11-0339 Locator Assembly** 1
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.
Molex Application Tooling Group
1150 E. Diehl Road
Naperville, IL, 60563
Tel: [phone]
Fax: [phone]
Visit our Web site at http://www.molex.com
M4 NUT
RATCHET
RELEASE LEVER
ADJUSTMENT
RING
LOCATOR
BLADE
2
Figure 4
1
M4 X 18LG BHCS
3