0640160044

Hand Termination Tool for Modular Plugs ServiceGrade  Hand Termination Tool Application Tooling Specification Sheet Order No. 64016-0044 FEATURES A full cycle ratcheting hand tool ensures complete termination Ergonomic soft grip handles for comfortable operation Termination, stripping and cutting all in one tool Small handle spread – ideal for all users For terminations conforming to industry standards please use the 62202-0500 Premium Grade™ hand tool for the Molex modular plugs SCOPE Products: Crimps RJ-22 (4 position), RJ-11 (6 position) and RJ-45 (8 position) modular plugs. OPERATION WARNING: Make sure that the cable is DISCONNECTED from any power supply. TOOL NESTS CAUTION: Sharp edges; always keep hands and fingers out of the cutting and crimping area! Make sure work area is clean and dry and wear approved eye protection. Preparing the Cable 1. Strip the outer jacket of the cable to the strip length needed for the plug used. 2. Separate the pairs of wires if necessary. 3. Straighten the wires into individual leads necessary. 4. Using the cutter in the middle of the hand tool trim the ends of the wires so all wires ends are even. WIRE STRIPPER AREA WIRE CUTTING AREA Crimping the Modular Plugs Figure 1 1. Open tool by squeezing handles together. 2. Select appropriate Molex plug. 3. Insert the stripped cable into the plug and make sure the wires are in the proper order and the wire leads are bottomed in the plug. 4. Insert modular plug with the wires into proper tool nest. 5. Hold wires in place with one hand and gently squeeze the handles together. Miscrimps or Jams If the tool ever becomes jammed in a partially closed position, DO NOT force the handles open or closed. The tool will open by pushing the ratchet release lever. See Figure 2. Doc No: ATS-640160044 Revision: A Release Date: 07-12-12 Revision Date: 07-12-12 Figure 2 UNCONTROLLED COPY RATCHET RELEASE LEVER Page 1 of 2 Hand Termination Tool for Modular Plugs 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. Light oil (such as SAE30W oil) applied at the oil points, shown in Figure 3, every 5,000 crimps or 3 months, is recommended. 4. When tool is not in use, keep the handles closed to prevent cutting edges being damaged, and store the tool in a clean, dry area. Tool Handle Preload Tool handle preload should is NOT adjustable on this tool. Restrictions Termination quality is dependent on wire choice and skill of the operator. Customers Figure 3 should independently verify that intended termination meets quality and performance needs. Molex makes no warranties, express or implied, regarding the performance or reliability of the crimp, or the appropriateness of the tool application. Molex does not certify or repair hand tools. Warranty This tool is for electrical terminal crimping purposes only. All tools are warranted to be free of manufacturing defects for a period of 30 days. Should such a defect occur, the tool will be repaired or exchanged free of charge. This 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. ServiceGrade™ crimp hand tools are low cost tools used in field repair for a limited number of terminations. If a high quality tool is required or a higher volume of terminations required, please purchase the corresponding PremiumGrade™ crimp hand tool. A ServiceGrade™ crimp tool may or may not have a terminal locator and in some case may need the locator removed to operate properly. CAUTION: Molex crimp specifications are valid only when used with Molex connectors 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. NEVER perform crimps on active electrical circuits. 3. Wear eye protection at all times. 4. Use only the Molex terminals specified for crimping with this tool. Visit our Web site at http://www.molex.com Doc No: ATS-640160044 Revision: A Release Date: 07-12-12 Revision Date: 07-12-12 UNCONTROLLED COPY Page 2 of 2