Molex 207128 Series User manual

Hand Crimp Tool for 1.50mm Pitch Pico-Lock™ Crimp Terminals

Doc No: ATS-6382708HM Release Date: 01-31-14 UNCONTROLLED COPY Page 1 of 6

Revision: B Revision Date: 05-24-16

CONDUCTOR

BRUSH

STRIP LENGTH

SEAM

CONDUCTOR

CRIMP HEIGHT

CUT-OFF

TAB

BELL MOUTH

BEND UP

TWISTING

ROLLING

BEND

DOWN

WIRE

INSULATION

CRIMP

Application Tooling

Specification Sheet

Modular Crimp Head

Order No. 63827-0870

Hand Crimp Tool

Order No. 63827-0800

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

Modular Crimp Head is removable and can be use in the Air Powered Tool Order No.63816-0100,

accompanied by Air Powered Crimp Adapter (Order No. 63816-0700).

Can also be used in the Battery Powered Tool Order No.63816-0200 (110 V) or 63816-0250 (220 V),

accompanied by Battery Powered Crimp Adapter (Order No. 63816-0600).

SCOPE

Products: 1.50mm Pitch Pico-Lock™ Crimp Terminal, AWG 24-28.

Terminal Series No.

Terminal

Order No. (1)

Wire Size

Insulation Diameter

Strip Length

AWG

mm²

In.

504052

504052-0098

24-28

0.80-1.15

.032-.045

1.50-1.90

.059-.075

(1) Customer to cut off terminal from reel: 0.10mm (.004”) maximum Cut-off Tab.

TYPE 4A

Hand Crimp Tool for 1.50mm Pitch Pico-Lock™ Crimp Terminals

Doc No: ATS-6382708HM Release Date: 01-31-14 UNCONTROLLED COPY Page 2 of 6

Revision: B Revision Date: 05-24-16

▲Insulation Crimp Note:

Due to the terminal’s insulation grip design and/or

insulation diameter range, this tool uses “overlap” form

geometry in the insulation punch. This produces an

overlap insulation crimp (A620 –compliant). While the

insulation punch profile may appear “lopsided”, this is

a normal condition for this tool. See figure to the right.

(Some tools with multiple crimp pockets may not have

the “overlap” profile on all pockets).

CRIMP SPECIFICATION

After crimping, the crimp profiles should measure the

following.

Terminal Series No.

Bell mouth

Conductor Brush

In.

504052

0.10-0.40

.004-.016

0.10-0.60

.004-.024

Terminal Series No.

Bend up Bend down

Twist Roll

Seam

Seam shall not be

open and no wire allowed

out of the crimping area

Degree Max.

504052

Terminal

Series No.

Wire Size

Conductor

Insulation

Pull Force

Minimum

Profile

Crimp Height

Crimp Width

(Ref)

Crimp Height

(Max)

Crimp Width

(Max)

AWG

mm2

In.

Lb.

504052

0.56-0.61

.022-.024

1.00

.039

1.40

.055

1.15

.045

29.4

6.6

0.52-0.57

.020-.022

1.00

.039

1.40

.055

1.15

.045

19.6

4.4

0.48-0.53

.019-.021

1.00

.039

1.30

.051

1.15

.045

9.8

2.2

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.

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.

OVERLAP

INSULATION

CRIMP

OVERLAP FORM GEOMETRY

ANVIL

PUNCH

WIRE

Hand Crimp Tool for 1.50mm Pitch Pico-Lock™ Crimp Terminals

Doc No: ATS-6382708HM Release Date: 01-31-14 UNCONTROLLED COPY Page 3 of 6

Revision: B Revision Date: 05-24-16

WIRE

PUNCH

TERMINAL

WIRE STOP

BLADE

Figure 2

Figure 3

WIRE

TERMINAL

LOCATOR

INSULATION

PUNCH

INSULATION

ANVIL

WIRE STOP

BLADE

CONDUCTOR

ANVIL

CONDUCTOR

PUNCH

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.

1. With the hand tool in the open position, pivot the terminal

locator open by pulling up on the locator knob and lift the

wire stop blade up. See Figure 1.

2. Insert the terminal into the correct profile until the terminal

is fully seated and stops. Make sure the wire stop blade is

fully seated on the terminal behind the conductor grip

section.

3. Gently pivot the locator closed.

4. Bring down the wire stop blade.

5. Slide the pre-stripped wire into the terminal; make sure to aim the wire brush towards the tip point on the

wire stop blade. See Figure 2. Align the wire so that it is parallel and sitting into the terminal. Maintain a

light and constant pressure on the wire that is seated in the terminal at all times. (Do not let go of the

wire.) Be sure to hold the wire and terminal in place until the terminal is fully crimped. See Figure 3.

6. Close the tool until the ratchet releases.

7. Lift the wire stop blade up.

8. Carefully remove the crimped terminal.

Note: To maintain good brush control and a consistent bell mouth the crimping instructions must be followed.

Note: The tamper proof ratchet action will not release the tool until it has been fully closed.

Terminal Locator Replacement/Change Over

This section describes the procedure for changing locators.

Removal

1. With the tool in the open position, pivot the terminal locator outward.

2. Remove the M4 BHCS. See Figure 4.

TERMINAL

SEATED IN

LOCATOR

SWING

LOCATOR

OPEN

Figure 1

HAND TOOL

OPEN

WIRE

STOP

BLADE

Hand Crimp Tool for 1.50mm Pitch Pico-Lock™ Crimp Terminals

Doc No: ATS-6382708HM Release Date: 01-31-14 UNCONTROLLED COPY Page 4 of 6

Revision: B Revision Date: 05-24-16

INCORRECT

Figure 5

CORRECT

INCORRECT

M4 BHCS

PIVOT

LOCATOR

Figure 4

Installation

1. Place the proper locator, (See Chart on page 2), on the hand tool. Install the M4 BHCS. See Figure 4.

2. Tighten the screw enough to hold the locator. Make sure the locator can still float freely with hand pressure.

3. Insert the proper terminal fully into the correct profile slot until the terminal is fully seated and stops. Then

gently pivot the locator closed.

4. With hand pressure, slowly slide the locator to the correct position. See Figure 5.

5. Gently pivot the locator open without disturbing the location.

6. Hold the locator firmly in place and slowly tighten the M4 BHCS.

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. The tool was engineered for durability but like any other equipment it needs

cleaning and lubrication for a maximum service life of trouble free crimping. Light oil (such as 30 weight

automotive oil) used at the oil points, every 5,000 crimps or 3 months, 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.

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 lifting the ratchet release lever. See Figure 9.

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 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: Repetitive use of this tool should be avoided.

Hand Crimp Tool for 1.50mm Pitch Pico-Lock™ Crimp Terminals

Doc No: ATS-6382708HM Release Date: 01-31-14 UNCONTROLLED COPY Page 5 of 6

Revision: B Revision Date: 05-24-16

MODULAR

CRIMP

HEAD

BATTERY

POWER

CRIMP

ADAPTER

LOCKING

PINS

LOCKING PINS

BATTERY

POWERED

TOOL

AIR

POWER

TOOL

MODULAR

CRIMP HEAD

LOCKING

PINS

LOCKING

PINS

AIR POWER

CRIMP

ADAPTER

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.

3. Wear eye protection at all times.

4. Use only the Molex terminals specified for crimping with this tool.

CAUTION: Molex crimp specifications are valid only when used with Molex terminals and tooling.

Applications for the Modular Crimp Head

WARNING: NEVER operate, service, install, or adjust this Modular Crimp Head without proper instruction

and without first reading and understanding the instructions in the proper Manual or Specification Sheet.

See Chart below for the correct Manual or Specification Sheet.

WARNING: NEVER install tooling or service this tool while it is into any power source. Disconnect the

power by unplugging or turn off the Actuator from its power source.

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.

The chart below shows all applications for this Modular Crimp Head.

Modular Crimp Head

Order No.

Tool

Order no.

Tool

Description

Adapter

Order No.

Adapter

Description

Figure

No.

63827-0870

63816-0000

Hand Crimp Frame (Short)

N/A

63816-0050

Hand Crimp Frame (Long)

N/A

63816-0200

Battery Power Tool (110 V)

63816-0600

Battery Power Crimp Adapter

63816-0250

Battery Power Tool (220 V)

63816-0600

Battery Power Crimp Adapter

63816-0100

Air Power Tool

63816-0700

Air Power Crimp Adapter

Applications for the Modular Crimp Head

Hand Crimp Tool

Battery Powered Tool

Air Powered Tool

Figure 6

Figure 7

Figure 8

MODULAR

CRIMP

HEAD

LOCKING

PINS

HAND CRIMP

FRAME LONG

OR SHORT

Hand Crimp Tool for 1.50mm Pitch Pico-Lock™ Crimp Terminals

Doc No: ATS-6382708HM Release Date: 01-31-14 UNCONTROLLED COPY Page 6 of 6

Revision: B Revision Date: 05-24-16

RATCHET

RELEASE LEVER

HANDLE

SPRING

CRIMPING

SPRING (2)

LOCATOR

Figure 9

M4 X 8mm

LONG BHCS

PARTS LIST

Item

Order Number

Description

Quantity

63827-0870

Modular Crimp Head

63816-0000

Hand Crimp Frame (Short)

63827-0875

Locator

63816-0001

Locking Pin

63600-0525

Handle Spring

63600-0520

Crimping Spring

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