molex 35477 Series User manual

Tool Kit for Bulb Socket Wedge Crimp Terminals
Doc No: ATS-6 8195 HM Release Date: 01-06-09 UNCONTROLLED COPY Page 1 of 9
Revision: B Revision Date: 10-07-10
CONDUCTOR
BRUSH
STRIP LENGTH
SEAM
CONDUCTOR
CRIMP
CUT-OFF
TAB
BELL MOUTH
BEND UP
TWISTING
ROLLING
BEND
DOWN
WIRE
SEAL INSULATION CRIMP
Application Tooling
Sp cification Sh t
Tool Kit
Ord r No. 63819-5370
Hand Crimp Tool
Ord r No. 63819-5300
FEATURES
% A full cycle ratcheting hand tool ensures complete crimps
% Ergonomically designed soft handles
% Precisely designed crimping profiles with simple contact positioning
% Easy handling due to outstanding force ratio
 Tool kits are easily installed into the Hand Crimp Tool or the 6 816-0 00 Power Crimp Head which is installed
into the 6 816-0200 (110 V) or the 6 816-0250 (220 V) Battery Powered Tool.
 Many different Tool kits can be used with a single Battery Powered Tool.
 This tool is IPC/WHMA-A-620 Class 2 and RoHS compliant.
SCOPE
Products: Bulb Socket Wedge Terminal for 0.50 to 0.85mm² wire used with 590 -0096 Wire Seal.
T rminal S ri s No.
T rminal Ord r No. Wir Siz and Typ
Insulation
Diam t r Strip L ngth
 Availabl in R l Only mm² (AVSS) mm In. mm In.
5477 5477-9002 0.50 to 0.85 2.0 – 2. .079-.091 5.00 – 5.50 .197 - .217
Customer to cut off terminal from reel: 0.15mm (.006”) maximum Cut-off Tab.
DEFINITION OF TERMS
TYPE 2C

Tool Kit for Bulb Socket Wedge Crimp Terminals
Doc No: ATS-6 8195 HM Release Date: 01-06-09 UNCONTROLLED COPY Page 2 of 9
Revision: B Revision Date: 10-07-10
ANVILS
POWER
CRIMP
HEAD
Figur 1
PUNCHES
M4 X 10 LONG
BHCS
M4 X 18 LONG
BHCS
SWING
LOCATOR
OPEN
PRESS DOWN
ON THE BRASS
PIVOT SHAFT
LIFT UP ON
THE LOCATOR
Figur 2
CONDITIONS:
After crimping, the conductor profiles should measure the following (see notes on page 5).
T rminal
S ri s No.
Wir
Siz
Conductor Crimp Insulation Crimp Pull Forc
Minimum 

Profil
H ight (R f.) Width (R f.) H ight (R f.) Width (R f.)
mm2 mm In. mm In. mm In. mm In. N Lb. A B C
5477
0.50 1.25-1. 5 .049-.05 2.00 - 2.10 .079 - .08 4.2 max .165 max 4.5 max .177 max 88.2 19.84 X
0.75 1.40-1.50 .055-.059 2.00 - 2.10 .079 - .08 4.4 max .17 max 4.7 max .185 max 107.8 24.25 X
0.85 1.45-1.55 .057-.061 2.00 - 2.10 .079 - .08 4.4 max .17 max 4.7 max .185 max 127.5 28.66 X
Tool Qualification Notes:
1. Pull Force should be measured with no influence from the insulation crimp.
2. The above specifications are guidelines to an optimum crimp.
Not :
A crimp height chart is provided with this manual as Reference Only. Due to the wide range of wires, strands,
insulation diameters, and durometers, actual crimp height measurements may very slightly. An occasional,
destructive, pull force test should be preformed to check hand tool crimp. Pull Force value must exceed the
minimum pull force specifications listed.
CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects as damage
can occur to the tool or die.
INSTALLATION
To install the Tool Kit into the Power Crimp Head follow the steps below:
Anvils and Punch s Installation
1. Insert the Anvils into the bottom slots of the nest. Install the M4 x 10 long BHCS and tighten in place.
2. Insert the Punches into the top slots of the nest. Install the M4 x 18 long BHCS and tighten in place. See
Figure 1.

Tool Kit for Bulb Socket Wedge Crimp Terminals
Doc No: ATS-6 8195 HM Release Date: 01-06-09 UNCONTROLLED COPY Page of 9
Revision: B Revision Date: 10-07-10
TERMINAL
SWING OPEN
LOCATOR
LOCATOR TERMINAL
IN PLACE
Figur 4
PUSH HERE
TO OPEN
WIRE STOP
Locator Installation and R moval
Follow the steps below to install or replace the locator. See Figure 2.
To install th locator
1. Position the locator with the hole over the brass pivot shaft and snap it
into place.
To r mov th locator
1. Open the crimp hand tool.
2. Swing the existing locator open and away from the hand tool.
. Firmly press down on the brass pivot shaft with your thumb, while pulling
the locator up. Slip the locator off the top of the brass pivot shaft.
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 T rminals
1. Select the desired terminal listed in the preceding charts.
2. Swing the terminal locator away from the crimp tool shown in Figure .
Some terminals with large insulation grips may interfere with the crimp
tooling when swinging the locator into position. The terminal must then
be loaded into the locator in the closed/crimp position.
. When using the locator, press down on the wire stop on the locator as
shown in Figure 4. Insert the terminal into the proper nest opening.
Make sure when choosing the nest opening, it will correspond with the
A, B, or C profile on the hand tool.
4. Return the locator to its original position. Insert the pre-stripped wire
with the seal over the terminal. Gently touch the wire stop with the end
of the wire. See Figure 5..
5. Compress the terminal by squeezing the tool handles until the ratchet
mechanism cycle has been completed. Release handles to open the
jaws.
Figur 3
LOCATOR
JAWS OPEN
LOCATOR
IN PLACE
WIRE STOP
TERMINAL
WIRE AGAINST
STOP Figur 5
WIRE STOP
WIRE

Tool Kit for Bulb Socket Wedge Crimp Terminals
Doc No: ATS-6 8195 HM Release Date: 01-06-09 UNCONTROLLED COPY Page 4 of 9
Revision: B Revision Date: 10-07-10
6. Remove the crimped terminal from the terminal locator by pressing down on the wire stop and gently pulling on
the wire. The terminal locator can be in either position.
7. Visually inspect the crimped terminal for proper crimp location.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
For th Batt ry Pow r Tool:
1. Cycle the Battery Power Tool to crimp the terminal to
the wire.
2. Remove the crimped terminal from the terminal
locator by pressing down on the wire stop and gently
pulling on the wire. The terminal locator can be in
either position.
. Visually inspect the crimped terminal for proper crimp
location.
Locator R plac m nt
See the parts list on the last page of this document for the
proper locator order number. Follow the steps below to
replace the locator.
1. Open the crimp hand tool.
2. Swing the existing locator open and away from the hand tool.
. Firmly press down on the brass pivot shaft with your thumb, while pulling the locator up. Slip the locator off the
top of the brass pivot shaft. See Figure 6.
4. Replace it with the proper locator by putting over the brass pivot shaft and snapping it into place.
Maint nanc
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.
. Make certain all pins; pivot points and
bearing surfaces are protected with a thin
coat of high quality machine oil. Do not oil
excessively. The tool was engineered for
durability but like any fine piece of
equipment it needs cleaning and lubrication for a maximum service life of trouble free crimping. Use a 0
weight automotive (light) oil used at the oil points, every 5,000 crimps or months, shown in Figure 7A or 7B
will significantly enhance the tool life.
4. Wipe excess oil from hand tool, particularly from crimping area. Oil transferred from the crimping area onto
certain terminations may affect the electrical characteristics of an application.
Figur 7B
LUBRICATION
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY MONTH
OR
5,000 CRIMPS)
Figur 7A
SWING
LOCATOR
OPEN
PRESS DOWN ON
BRASS PIVOT SHAFT
LIFT UP LOCATOR
JAWS OPEN
Figur 6

Tool Kit for Bulb Socket Wedge Crimp Terminals
Doc No: ATS-6 8195 HM Release Date: 01-06-09 UNCONTROLLED COPY Page 5 of 9
Revision: B Revision Date: 10-07-10
5. 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 pressing the ratchet release lever. See Figure 8.
How to Adjust Tool Pr load
(S Figur 8)
This hand tool is factory preset to 25-45 LBS.
preload. It may be necessary over the life of the
tool to adjust tool handle preload force. Listed
below are the steps required to adjust the crimping
force of the hand tool to obtain proper crimp
conditions:
1. Remove or fold back the handle grip from the
handle to expose the eccentric axle and setting
wheel.
2. Remove the locking screw with a 2mm hex
wrench. The wrench set (6 810-0101), is not
supplied. It is sold separately from the hand
tool.
. Turn the eccentric axle and setting wheel with the wrench or pliers Counter-clockwise (CCW) to increase
handle force.
4. Replace the locking screw, aligning the nearest notch in the setting wheel to locking screw.
5. Replace the handle grip.
6. Check the crimp specifications or conduct a pull test after tool handle preload 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 0
days. Should such a defect occur, we will repair or exchange the tool free of charge. This repair or exchange 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.
CAUTION: Molex crimp specifications are valid only when used with Molex terminals and tooling.
CAUTIONS
1. Manually powered hand tools are intended for low volume or field repair. This tool is NOT intended for
production use. Repetitive use of this tool should be avoided.
2. Insulated rubber handles are not protection against electrical shock.
. Wear eye protection at all times.
4. Use only the Molex terminals specified for crimping with this tool.
RATCHET
RELEASE LEVER
Figur 8
HANDLE
GRIP
REMOVED
ECCENTRIC AXLE
HANDLE
GRIP
LOCKING
SCREW
WRENCH SET
(SOLD
SEPERATELY)
PRELOAD
CHECK POINT
25.4MM
SETTING WHEEL

Tool Kit for Bulb Socket Wedge Crimp Terminals
Doc No: ATS-6 8195 HM Release Date: 01-06-09 UNCONTROLLED COPY Page 6 of 9
Revision: B Revision Date: 10-07-10
C rtification
Molex does not certify or re-certify commercial grade hand tools but rather supplies the following guidelines for
customers to re-certify hand tools.
% This tool is qualified to pull force only. To re-certify, crimp a terminal to a wire, which has been stripped
12.7mm (1/2”) long, so there is no crimping of the insulation. Pull the terminal and wire at a rate no faster than
25mm (1.00”) per minute. See the Molex web site for the Quality Crimp Handbook for more information on pull
testing.
% If the tool does not meet minimum pull force values, handle preload should be increased and the pull test
rerun, (See How to Adjust Preload).
% When the hand tool is no longer capable of achieving minimum pull force, it should be taken out of service and
replaced.

Tool Kit for Bulb Socket Wedge Crimp Terminals
Doc No: ATS-6 8195 HM Release Date: 01-06-09 UNCONTROLLED COPY Page 7 of 9
Revision: B Revision Date: 10-07-10
The chart below shows all applications for this Tool Kit.
Tool Kit
Ord r No.
Tool
Ord r no.
Tool
D scription
Pow r H ad
Ord r No.
Adapt r
D scription
Figur
No.
6 819-5 70
6 810-0100 Hand Crimp Frame (Short) N/A N/A 9
6 810-0400 Hand Crimp Frame (Long) N/A N/A 9
6 816-0200 Battery Power Tool (110 V) 6 816-0 00 Power Crimp Head 10
6 816-0250 Battery Power Tool (220 V) 6 816-0 00 Power Crimp Head 10
Applications for th Tool Kit
Hand Crimp Tool Batt ry Pow r d Tool
Figur 9 Figur 10
WARNING: NEVER operate service, install tool kits, or adjust the Power Crimp Head without proper
instruction and without first reading and understanding the instructions in the proper Manual or
Specification Sheet. See Chart above for the correct Manual or Specification Sheet.
WARNING: NEVER install tooling or service this tool while it is into any power source. Make sure the
power is turned off.
CAUTION: Keep fingers away from the crimping area when operating this tool. It may cause severe injury.
CAUTION: Wear safety glasses when operating or serving this tool.
POWER
CRIMP
HEAD
LOCKING PINS
BATTERY
POWERED
TOOL
TOOLING KIT
HAND CRIMP
FRAME LONG
AND SHORT
TOOLING
KIT

Tool Kit for Bulb Socket Wedge Crimp Terminals
Doc No: ATS-6 8195 HM Release Date: 01-06-09 UNCONTROLLED COPY Page 8 of 9
Revision: B Revision Date: 10-07-10
RATCHET
RELEASE SCREW
Figur 11
1
6
M4 X 6mm
LONG BHCS
M4 X 12mm
LONG BHCS
5
3
WITH TOOL KIT
LOCATOR ONLY
M4 X 12mm
LONG BHCS
4
4
2
5
HAND TOOL PARTS LIST
It m Numb r Ord r Numb r D scription Quantity
1 6 810-0100 Hand Crimp Frame (Short) 1
2 6 810-0101 Wrench Set (Not included) 0
6 810-0102 Locator Base 1
4 6 810-010 Repair Kit (Not included) 0
5 6 819-5 70 Tool Kit with Locator 1
6 6 819-5 75 Locator (only) REF

Tool Kit for Bulb Socket Wedge Crimp Terminals
Doc No: ATS-6 8195 HM Release Date: 01-06-09 UNCONTROLLED COPY Page 9 of 9
Revision: B Revision Date: 10-07-10
Figur 12
1
2
2
M4 by 8 Long
BHCS
M4 by 18 Long
BHCS
M4 by 10 Long
BHCS
1
POWER HEAD PARTS LIST
It m Ord r No Engin ring No. D scription Quantity
1
6 816-0 00 6 816-0 00 Power Crimp Head 1
2
6 819-5 70 6 819-5 70 Tool Kit 1
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