molex 207129 Series User manual
Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals
Doc No: ATS-6382343HM Release Date: 01-19-11 UNCONTROLLED COPY Page 1 of 8
Revision: A Revision Date: 01-19-11
CONDUCTOR
BRUSH
STRIP LENGTH
SEAM
CONDUCTOR
CRIMP
CRIMP
CUT-OFF
TAB
BELL MOUTH
BEND UP
TWISTING
ROLLING
BEND
DOWN
WIRE
SEAL
Application Tooling
Specification Sheet
Tool Kit
Order No. 63823-4370
Hand Crimp Tool
Order No. 63823-4300
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 63816-0300 Power Crimp Head which is installed
into the 63816-0200 (110 V) or the 63816-0250 (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: CP 2.8 receptacle for 18 - 20 AWG type TXL wire and
0.5 –1.0mm2type ID and IR wire with 2.80mm (.110") CMC Wire Seal color RED.
Terminal Series No.
Terminal Order No.
Wire Size and Type
Insulation Diameter
Strip Length
Available in Reel only
AWG
mm²
mm
In.
mm
In.
64324
64324-1049
64324-1149
18-20 TXL
0.5 -1.0 Type ID and IR
1.40 -2.15
.055 -.085
4.90 -5.10
.193 -.201
64324-2049
64324-2149
Customer to cut off terminal from reel: 0.30mm (.012”) maximum Cut-off Tab.
Note: Terminal will accommodate the thin wall small insulation with the TXL type American wires and the ID or IR type metric wires.
DEFINITION OF TERMS
TYPE 4C
Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals
Doc No: ATS-6382343HM Release Date: 01-19-11 UNCONTROLLED COPY Page 2 of 8
Revision: A Revision Date: 01-19-11
ANVILS
POWER
CRIMP
HEAD
Figure 1
PUNCHES
M4 X 10 LONG
BHCS
M4 X 18 LONG
BHCS
CRIMP SPECIFICATION
Terminal Series No.
Bell Mouth
Bend up Bend down
Twist Roll
Conductor Brush
mm
In.
Degree
Degree
mm
In.
64324
0.1-0.5
.004-.020
2
2
2
3
0.2 - 0.6
.008-.024
Seam: Seam shall not be open and no wire allowed out of the crimping area.
After crimping, the conductor profiles should measure the following (See notes below).
Terminal
Series No.
Wire
Size
Conductor
Insulation
Pull Force
Minimum
Profile
Crimp Height
(Ref)
Crimp
Width
(Ref)
Crimp Height
(Ref)
Crimp Width
(Ref)
AWG
mm2
mm
In.
mm
In.
mm
In.
mm
In.
N
Lb
0.5mm2
20 AWG
0,75mm2
18 AWG
1,0mm2
64324
-
0.5
1.13-1.23
.044-.048
2.06
.081
4.30-4.50
.169-.177
4.97
.196
70
15.7
X
20
0.52
1.13-1.23
.044 .048
2.06
081
4.30-4.50
.169-.177
4.97
.196
58
13.0
X
-
0.75
1.18-1.28
.046-.050
2.06
081
4.40-4.60
.173-181
4.99
.196
90
20.2
X
18
0.82
1.18-1.28
.046-.050
2.06
081
4.40-4.60
.173-181
4.99
.196
89
20.0
X
-
1.0
1.25-1.35
.049-.053
2.07
.081
4.60-4.80
.181-.189
5.00
.197
115
25.8
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.
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, 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 Punches 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.
Locator Installation and Removal
Follow the steps below to install or replace the locator. See Figure 2.
Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals
Doc No: ATS-6382343HM Release Date: 01-19-11 UNCONTROLLED COPY Page 3 of 8
Revision: A Revision Date: 01-19-11
SWING
LOCATOR
OPEN
PRESS DOWN
ON THE BRASS
PIVOT SHAFT
LIFT UP ON
THE LOCATOR
Figure 2
SWING OPEN
TERMINAL
PUSH HERE TO
OPEN WIRE STOP
LOCATOR
TERMINAL
IN PLACE
Figure 4
LOCATOR LATCH
IN OPEN POSITION
To install the locator
1. Position the locator with the hole over the brass pivot shaft and snap it
into place.
To remove the locator
1. Open the crimp hand tool and unlock the locator latch.
2. Swing the locator open and away from the hand tool.
3. 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 Terminals
1. Select the desired terminal listed in the preceding
charts.
2. Unlock the locator latch and swing the terminal locator
away from the crimp tool shown in Figure 3 and 4.
3. Press down on the wire stop on the locator as shown in
Figure 4. Insert the proper terminal into the proper nest
opening. Make sure when choosing the nest opening, it
will correspond with the correct profile on the hand tool.
4. Return the locator to closed position. Make sure the locator latch is in lock position. Insert the proper wire with
the seal over the terminal. Gently touch the wire stop with the end of the wire and align the seal with the grips
on the terminal. See Figure 5 and 6.
Figure 3
LATCH LOCKED
LATCH UNLOCKED
Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals
Doc No: ATS-6382343HM Release Date: 01-19-11 UNCONTROLLED COPY Page 4 of 8
Revision: A Revision Date: 01-19-11
LOCATOR
Figure 6
WIRE
INSULATION
PUNCH
CONDUCTOR ANVIL
INSULATION
ANVIL
WIRES AGAINST
LOCATOR STOP
CONDUCTOR
PUNCH
TERMINAL
SEAL
TERMINAL
PRE-STRIPPED
WIRE WITH SEAL
Figure 5
WIRE STOP
BLADE
5. Compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.
Release handles to open the jaws.
6. Unlock the locator latch and swing the locator open.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
7. Remove the crimped terminal from the terminal locator by pressing down on the wire stop and gently pulling on
the wire.
8. Visually inspect the crimped terminal for an acceptable crimp.
For the Battery Power 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.
3. Visually inspect the crimped terminal for
an acceptable crimp.
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.
IRE
LUBRICATION
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY MONTH
OR
5,000 CRIMPS)
Figure 7A
Figure 7B
Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals
Doc No: ATS-6382343HM Release Date: 01-19-11 UNCONTROLLED COPY Page 5 of 8
Revision: A Revision Date: 01-19-11
3. Make certain all pins; pivot points and bearing surfaces in the tool head are protected with a thin coat of high
quality machine oil. Do not oil excessively. This 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. The use of
light oil, such as 30 weight automotive oil, every 5,000 crimps or monthly, will significantly enhance the tool life
and ensure a stable calibration. See Figure 7A or 7B for lubrication points.
4. Store the tool in a clean and dry area when not in use.
Miscrimps or Jams for Crimp Hand Tools Only
(See Figure 10)
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 rotating the small slotted screw marked with an arrow. See Figure 10.
Warranty
This tool kit is for electrical terminal crimping purposes only. This tool kit 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 kit free of charge. This repair or exchange
will not be applicable to altered, misused, or damaged tools.
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.
3. Wear eye protection at all times.
4. Use only the Molex terminals specified for crimping with this tool.
CAUTION: Repetitive use of this tool should be avoided.
Certification
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.
When the hand tool is no longer capable of achieving minimum pull force, it should be taken out of service and
replaced.
This tool is very difficult to disassemble and reassemble. Customer repair is not recommended.
Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals
Doc No: ATS-6382343HM Release Date: 01-19-11 UNCONTROLLED COPY Page 6 of 8
Revision: A Revision Date: 01-19-11
The chart below shows all applications for this Tool Kit.
Tool Kit
Order No.
Tool
Order no.
Tool
Description
Power Head
Order No.
Adapter
Description
Figure No.
63823-4370
63810-1050
Hand Crimp Frame (Short)
N/A
N/A
8
63810-1000
Hand Crimp Frame (Long)
N/A
N/A
8
63816-0200
Battery Power Tool (110 V)
63816-0300
Power Crimp Head
9
63816-0250
Battery Power Tool (220 V)
63816-0300
Power Crimp Head
9
Applications for the Tool Kit
Hand Crimp Tool
Battery Powered Tool
Figure 8
Figure 9
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
Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals
Doc No: ATS-6382343HM Release Date: 01-19-11 UNCONTROLLED COPY Page 7 of 8
Revision: A Revision Date: 01-19-11
RATCHET
RELEASE SCREW
Figure10
M4 X 8mm
LONG BHCS
2
1
1
M4 X 18mm
LONG BHCS
M4 X 10mm
LONG BHCS
2
3
WITH TOOL KIT
LOCATOR ONLY
HAND TOOL PARTS LIST
Item Number
Order Number
Description
Quantity
1
63810-1000
Hand Crimp Frame (Long)
1
2
63823-4370
Tool Kit with Locator
1
3
63823-4375
Locator (only)
REF
Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals
Doc No: ATS-6382343HM Release Date: 01-19-11 UNCONTROLLED COPY Page 8 of 8
Revision: A Revision Date: 01-19-11
Figure 11
1
2
2
M4 by 8 Long
BHCS
M4 by 18 Long
BHCS
M4 by 10 Long
BHCS
1
POWER HEAD PARTS LIST
Item
Order No
Engineering No.
Description
Quantity
1
63816-0300
63816-0300
Power Crimp Head
1
2
63823-4370
63823-4370
Tool Kit with Locator
1
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