Molex 207129 Series User guide

Hand Crimp Tool For Cluster Block Terminal

Doc No: ATS-638250200 Release Date: 02-08-12 UNCONTROLLED COPY Page 1 of 7

Revision: B Revision Date: 09-03-20

INSULATION

CRIMP

BRUSH

STRIP

LENGTH

CONDUCTOR

CRIMP HEIGHT

CUT-OFF TAB

SEAM

BELL MOUTH

WIRE

Application Tooling Specification

FEATURES

A full cycle ratcheting hand tool ensures complete crimps

Ergonomic soft grip handles for comfortable crimping

A precision user-friendly terminal locator wire stop holds terminals in the proper crimping position

Right- and left-handed applications

This tool is IPC/WHMA-A-620 Class 2 compliant as indicated

This tool is RoHS compliant; however, RoHS compliance is not required

SCOPE

Products: Cluster Block Terminal for 18 AWG UL Style 5048 Wire.

Terminal

Series No.

Terminal Order No.

Reel Form Only

Wire Size

Insulation Diameter

Strip Length

IPC/WHMA-A620 (1)

Terminal (2)

Insulation Range

AWG

mm²

In.

57920

57920-6002

0.82

2.30-2.45

.091-.097

2.15-2.45

.085-.097

5.00-5.50

.197-.217

Note: This terminal will accommodate the UL Style 5048 wire.

(1) To achieve optimum IPC-A620 insulation crimps, use this insulation OD range.

(2) Overall insulation OD specification for terminal.

Customer to cut off terminal from reel: 0.40mm (.016”) maximum cut-off tab.

DEFINITION OF TERMS

TYPE 4D

Order Number

63825-0200

Hand Crimp Tool For Cluster Block Terminal

Doc No: ATS-638250200 Release Date: 02-08-12 UNCONTROLLED COPY Page 2 of 7

Revision: B Revision Date: 09-03-20

▲Insulation Crimp Note

Due to the terminal’s insulation grip design or insulation

diameter range, this tool uses overlap form geometry in

the insulation punch. This produces an overlap insulation

crimp (A-620-compliant). Although 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 SPECIFICATIONS

After crimping, the crimp profiles should measure the following:

Terminal Series No.

Bell Mouth

Conductor Brush

In.

57920

0.20-0.50

.008-.020

0.50-1.00

.020-.039

Terminal Series No.

Bend Up

Bend Down

Twist

Roll

Seam

Degree

57920

Seam shall not be open

and no wire allowed out

of the crimping area

Terminal

Series No.

Wire Size

Conductor Crimp

Insulation Crimp

Pull Force

Minimum

Height

Width (Ref)

Height Maximum

Width Maximum

AWG

mm2

In.

Lb.

57920

0.82

1.45-1.55

.057-.061

2.40

.095

3.80

.150

3.50

.138

107.8

24.25

CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects

as damage can occur to the tool or die.

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.

Note

A crimp height chart is provided with this manual as reference only. Due to the wide range of

wires, strands, insulation diameters and durometers available, actual crimp height measurements

may very slightly. An occasional destructive pull force test should be performed to check hand tool

crimp. Pull force value must exceed the minimum pull force specifications listed.

OVERLAP FORM GEOMETRY

ANVIL

PUNCH

WIRE

OVERLAP

INSULATION

CRIMP

Hand Crimp Tool For Cluster Block Terminal

Doc No: ATS-638250200 Release Date: 02-08-12 UNCONTROLLED COPY Page 3 of 7

Revision: B Revision Date: 09-03-20

PRE-STRIPPED WIRE

TERMINAL

Figure 5

TERMINAL

WIRE AGAINST

THE WIRE

STOP

WIRE

WIRE STOP IS

PART OF

THE LOCATOR

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. See Figure 1.

Crimping Terminals

1. Select the desired terminal listed in the preceding

charts.

2. Make sure the locator is attached behind the lower

tooling and is above all the surface of the anvils.

3. The spring-loaded wire stop should be clear of the

locator’s cavity. If not, push up on the red tab to

move the wire stop out of the way while inserting the

terminal. See Figure 3.

4. Load the terminal into the proper nest opening in the

locator based on the wire gauge or terminal type

markings on the hand tooling. See Figure 3.

5. Partially close the tool handle until the first ratchet position

engages and holds the terminal in place. See Figure 4.

6. Insert the properly stripped wire through the terminal and against

the wire stop. See Figure 5.

7. Crimp the terminal by squeezing the tool handles until the ratchet

mechanism cycle has been completed. Release the handles to open

the jaws.

8. Remove the crimped terminal from the terminal locator by pulling

on the wire.

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

TERMINAL

Figure 3

TERMINAL

PUSH UP

ON THE

RED TAB

PARTIALLY

CLOSE HANDLE

TOOLING

PARTIALLY

CLOSED

Figure 4

FIRST

RATCHET

POSITION

OPEN

POSITION

SQUEEZE

HANDLES

TOGETHER

HANDLE WILL

SPRING OPEN

Figure 1

LOCATOR

IN DOWN

POSTION

RED

TAB

Figure 2

Hand Crimp Tool For Cluster Block Terminal

Doc No: ATS-638250200 Release Date: 02-08-12 UNCONTROLLED COPY Page 4 of 7

Revision: B Revision Date: 09-03-20

MATCH

UP MARKS

FRONT

BACK

Figure 9

9. Visually inspect the crimped terminal for proper crimp

location.

10. On some large O.D. wires, it may not be possible to insert

the wire with the tool partially closed. Those wires should

be inserted with the hand tool in the open position. Insert

the wire above the terminal in the punch and against the

wire stop, and then close the tool. See Figure 6.

Locator Replacement

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 hand crimp tool.

2. Squeeze gently on the lower area shown in Figure 7 with

your thumb and index finger. The lower tabs of the locator

should disengage from the hand tool.

3. Lift and pull away from the hand tool. The top locator hooks

should slip out of the top slots easily. See Figure 7.

4. To reinstall the new locator, make sure the hand tool is in

the open position.

5. Holding onto the lower part of the locator with your thumb

and index finger, insert the locator’s top hooks into the

hand tool’s top slots.

6. Rotate the locator down, and press the lower tabs into the

two bottom slots of the hand tool. To secure the locator

into place, the lower tabs must snap into place on the hand

tool frame.

Right- or Left-Handed Operation

This hand tool can be converted from a right-handed application to

a left-handed application. It is necessary to reverse the tooling if using the left-handed application

along with the locator. Follow the steps below:

1. The locator must be removed before reversing the

tooling.

2. Remove the M3 BHCS which is holding the upper

tooling. Flip the upper tooling to the opposite side and

replace the M3 BHCS. Make sure the small markings on

the front and back of the hand tool frame, match up

and are on the outside of the hand tool frame. See

Figures 8 and 9.

3. Do the same thing with the lower tooling and tighten

the M3 screws. Be sure the small markings line up.

4. Reinstall the locator by following the instructions in the

locator replacement section.

TERMINAL

Figure 6

WIRE

STOP

Figure 8

PUSH ON

HANDLE

JAWS OPEN

PULL OPEN

TOOLING

M3 BHCS

SQUEEZE

HERE

SQUEEZE

HERE

LOCATOR

Figure 7

TOP HOOKS

TOP SLOTS OF

HAND TOOL

LOWER TABS

Hand Crimp Tool For Cluster Block Terminal

Doc No: ATS-638250200 Release Date: 02-08-12 UNCONTROLLED COPY Page 5 of 7

Revision: B Revision Date: 09-03-20

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 a

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.

See Figure 10.

4. Wipe excess oil from the hand tool, particularly from the crimping area.

Oil transferred from the crimping area onto certain terminations may

affect the electrical characteristics of an application.

5. When the 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 up on the ratchet release lever in the movable handle. See

Figure 11.

How to Adjust Tool Preload (See Figure 12)

Hand tool frame preload is factory preset to ensure crimp quality. 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. Open the hand tool.

2. Close the handle 2 ratchet clicks.

3. Hold the hand tool in the palm of

your hand as shown in Figure 12.

Using your index finger, squeeze the

link toward the top of the hand tool

frame. This will release the preload

adjustment wheel.

4. Rotate the setting wheel

counterclockwise (CCW) to increase

handle force. The numbers will

display higher. To decrease handle

force, rotate the setting wheel

clockwise (CW).

5. Release the link to lock the setting

wheel in place.

6. Check the crimp specifications or conduct a pull test after tool handle preload force is

adjusted.

RATCHET RELEASE

LEVER

Figure 11

LUBRICATION

POINTS

(BOTH SIDES)

LIGHT OIL

(EVERY 3

MONTHS OR

5,000 CRIMPS)

Figure 10

HANDLE CLOSED

2 CLICKS

SQUEEZE THE

LINK IN THE

HANDLE

HOLD THE HAND

TOOL IN POSITION

SETTING WHEEL

Figure 12

Hand Crimp Tool For Cluster Block Terminal

Doc No: ATS-638250200 Release Date: 02-08-12 UNCONTROLLED COPY Page 6 of 7

Revision: B Revision Date: 09-03-20

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, Molex 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 use 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.

CERTIFICATION

Molex does not certify or re-certify hand tools but rather supplies the following guidelines for

customers to re-certify hand tools:

This tool is qualified to pull force only. See the Molex website 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 should be 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.

Hand Crimp Tool For Cluster Block Terminal

Doc No: ATS-638250200 Release Date: 02-08-12 UNCONTROLLED COPY Page 7 of 7

Revision: B Revision Date: 09-03-20

RATCHET

RELEASE LEVER

Figure 13

PARTS LIST

Item Number

Order Number

Description

Quantity

REF

63825-0200

Hand Crimp Tool

Figure 13

63825-0275

Locator Assembly

63810-0104

Spring, Return

63810-0105

Spring, Ratchet

Application Tooling Support

Phone: (402) 458-TOOL (8665)

E-Mail: [email protected]

Website: www.molex.com/applicationtooling

Molex is a registered trademark of Molex, LLC in the United States of America and may be registered in other countries; all other

trademarks listed herein belong to their respective owners.

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