molex CR60927A User manual

Hand Crimp Tool for Milli-Grid™ Crimp Terminal
Doc No: ATS-011010204 Release Date: 03-02-93 UNCONTROLLED COPY Page 1 of 5
Revision: E Revision Date: 04-14-08
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
BELL MOUTH
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
HAND CRIMP TOOL
SPECIFICATION SHEET
Order No. 11-01-0204
Engineering No. CR60927A
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: Milli-Grid™ Crimp Terminal for 24-30 AWG.
Terminal Order No. Wire Size Insulation Diameter Strip LengthTerminal
Series No.
Loose Piece  Reel AWG mm² mm In. mm In.
50394-8100 50394-8400 50394-8051 50394-8054
50394 50394-8200
50394-8052 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 Milli-Grid™ Crimp Terminal
Doc No: ATS-011010204 Release Date: 03-02-93 UNCONTROLLED COPY Page 2 of 5
Revision: E Revision Date: 04-14-08
CONDITIONS:
After crimping, the conductor profiles should measure the following (see notes on page 3).
Conductor Crimp Insulation Crimp
Wire Size Height (Ref) Width (Ref)
Width (Ref)
Pull Force
Minimum Profile
Terminal Series No.
AWG
mm
2mm In. mm In. mm In. N Lb. A
B
24 0.20 0.55-0.65 .022-.026 1.00 .039 1.40 .055 29.4 6.60 X
26 0.13 0.53-0.63 .021-.025 1.00 .039 1.40 .055 19.6 4.40 X
28 0.08 0.52-0.62 .020-.024 1.00 .039 1.40 .055 9.8 2.20 X
50394
30 0.05 0.51-0.61 .020-.024 1.00 .039 1.40 .055 4.9 1.10 X
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.
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.
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.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
TERMINAL
PRE
-
STRIPPED WIRE
Figure 1
TERMINAL
Figure 2
LOCATOR
BLADE
CONDUCTOR
GRIPS
INSULATION
GRIPS
WIRE
LOCATOR

Hand Crimp Tool for Milli-Grid™ Crimp Terminal
Doc No: ATS-011010204 Release Date: 03-02-93 UNCONTROLLED COPY Page 3 of 5
Revision: E Revision Date: 04-14-08
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 3.
How to Adjust Tool Crimp Force
See Figure 3
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 Milli-Grid™ Crimp Terminal
Doc No: ATS-011010204 Release Date: 03-02-93 UNCONTROLLED COPY Page 4 of 5
Revision: E Revision Date: 04-14-08
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, and 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 Milli-Grid™ Crimp Terminal
Doc No: ATS-011010204 Release Date: 03-02-93 UNCONTROLLED COPY Page 5 of 5
Revision: E Revision Date: 04-14-08
M4 NUT
RATCHET
RELEASE LEVER
ADJUSTMENT
RING
LOCATOR
BLADE
2
Figu
re 3
1
M4 X 18LG BHCS
3
PARTS LIST
Item Number Order Number Description Quantity
1 11-11-0381 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.
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