Molex 207129 Series User manual

Tool Kit for 14-24 AWG Crimp Terminals

Doc No: ATS-6381132HM Release Date: 11-07-03 UNCONTROLLED COPY Page 1 of 11

Revision: G Revision Date: 10-04-10

Application Tooling

Specification Sheet

Tool Kit

Order No. 63811-3270

Hand Crimp Tool

Order No. 63811-3200

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: 14-24 AWG .093” Pin and Socket, Commoning Connector Terminal, Claspcon™, .125” Pin and Socket

Crimp Terminals.

Terminal

Series No.

Terminal Order No.

Wire Size

Insulation Diameter

Strip Length

Loose Piece

Reel

AWG

mm²

In.

1189

02-09-1103

02-09-5111

39-00-0289

14-20

2.08-0.52

1.65-4.06

.065-.160

3.30-3.80

.130-.150

02-09-1104

39-00-0072

39-00-0291

02-09-3102

39-00-0135

39-00-0294

02-09-3104

39-00-0288

39-00-0295

02-09-5106

1190

02-09-2103

02-09-6110

39-00-0299

14-20

2.08-0.52

1.65-4.06

.065-.160

3.30-3.80

.130-.150

02-09-4104

39-00-0106

39-00-0301

02-09-6106

39-00-0297

1380

02-09-2118

02-09-6126

39-00-0304

18-22

0.82-0.32

1.52-3.05

.060-.120

3.30-3.80

.130-.150

02-09-2119

39-00-0302

39-00-0306

02-09-6123

1381

02-09-1118

39-00-0307

39-00-0313

18-22

0.82-0.32

1.52-3.05

.060-.120

3.30-3.80

.130-.150

02-09-1119

39-00-0308

39-00-0314

02-09-5133

39-00-0310

40-01-1191

02-09-5142

1457-1

05-02-0048

05-02-0047

18-22

0.82-0.32

1.55-2.59

.061-.102

3.30-3.80

.130-.150

05-02-0057

05-02-0056

05-02-0058

1457-2

05-02-0050

05-02-0049

14-16

2.08-0.82

3.56 Max.

.140 Max.

3.30-3.80

.130-.150

1881-2

02-08-1102

16-24

1.31-0.32

3.51 Max.

.138 Max.

3.30-3.80

.130-.150

1973

02-09-8104

18-22

0.82-0.32

3.51 Max.

.138 Max.

3.30-3.80

.130-.150

1973-2

02-09-8109

14-18

2.08-1.31

4.06 Max.

.160 Max.

3.30-3.80

.130-.150

2046

18-12-2222

16-18

2.08-1.31

3.05 Max.

.120 Max.

3.30-3.80

.130-.150

2047

18-12-1222

16-18

2.08-1.31

3.05 Max.

.120 Max.

3.30-3.80

.130-.150

TYPE 2C

Tool Kit for 14-24 AWG Crimp Terminals

Doc No: ATS-6381132HM Release Date: 11-07-03 UNCONTROLLED COPY Page 2 of 11

Revision: G Revision Date: 10-04-10

INSULATION

CRIMP

BRUSH

STRIP

LENGTH

BELL MOUTH

CRIMP HEIGHT

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP

TWISTING

Terminal

Series No.

Terminal Order No.

Wire Size

Insulation Diameter

Strip Length

Loose Piece

Reel

AWG

mm²

In.

2273

02-09-1123

02-09-1140

18-22

0.82-0.32

1.52-3.05

.060-.120

3.30-3.80

.130-.150

2282

18-09-2804

18-09-2807

14-18

2.08-0.82

3.56 Max.

.140 Max.

3.60-4.10

.140-.160

4272

02-09-1149

18-22

0.82-0.32

1.52-3.05

.060-.120

3.30-3.80

.130-.150

4549

02-09-2167

14-20

2.08-0.52

3.56 Max.

.140 Max.

3.30-3.80

.130-.150

4550

02-09-1206

02-09-5170

14-20

2.08-0.52

3.56 Max

.140 Max

3.30-3.80

.130-.150

6271

02-09-1212

02-09-5208

18-22

0.82-0.32

1.52-3.05

.060-.120

3.30-3.80

.130-.150

6310

02-09-1211

02-09-5206

14-20

2.08-0.52

1.65-4.06

.065-.160

3.30-3.80

.130-.150

7238

02-09-1112

14-18

2.08-0.82

3.56 Max.

.140 Max.

3.60-4.10

.140-.160

Customer to cut off terminal from reel using the Cut-off Tab dimension from the terminals selected.

DEFINITION OF TERMS

The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the

scope.

CONDITIONS:

After crimping, the conductor profiles should measure the following (see notes below).

Terminal Series No.

Hand Tool

Locator

Wire Size

Conductor Crimp

Height (REF)

Conductor

Crimp Width (Ref)

Pull Force

Minimum

Profile

AWG

mm2

In.

Lb.

1189

2.08

1.38-1.48

.054-.058

2.30

.090

178.0

40.00

1.31

1.38-1.48

.054-.058

2.30

.090

155.0

35.00

0.82

1.23-1.33

.049-.052

1.70

.067

111.3

25.00

0.52

1.23-1.33

.049-.052

1.70

.067

66.8

15.00

1190

2.08

1.38-1.48

.054-.058

2.30

.090

178.0

40.00

1.31

1.38-1.48

.054-.058

2.30

.090

155.8

35.00

0.82

1.23-1.33

.049-.052

1.70

.067

111.3

25.00

0.52

1.23-1.33

.049-.052

1.70

.067

66.8

15.00

1380

0.82

1.23-1.33

.049-.052

1.70

.067

111.3

25.00

0.52

1.23-1.33

.049-.052

1.70

.067

66.8

15.00

0.32

1.23-1.33

.049-.052

1.70

.067

53.4

12.00

1381

0.82

1.23-1.33

.049-.052

1.70

.067

111.3

25.00

0.52

1.23-1.33

.049-.052

1.70

.067

66.8

15.00

0.32

1.23-1.33

.049-.052

1.70

.067

53.4

12.00

Tool Kit for 14-24 AWG Crimp Terminals

Doc No: ATS-6381132HM Release Date: 11-07-03 UNCONTROLLED COPY Page 3 of 11

Revision: G Revision Date: 10-04-10

Terminal Series No.

Hand Tool

Locator

Wire Size

Conductor Crimp

Height (REF)

Conductor

Crimp Width (Ref)

Pull Force

Minimum

Profile

AWG

mm2

In.

Lb.

1457-1

0.82

1.23-1.33

.049-.052

1.70

.067

111.3

25.00

0.52

1.23-1.33

.049-.052

1.70

.067

66.8

15.00

0.32

1.23-1.33

.049-.052

1.70

.067

53.4

12.00

1457-2

2.08

1.38-1.48

.054-.058

2.30

.090

178.0

40.00

1.31

1.38-1.48

.054-.058

2.30

.090

155.8

35.00

1881-2

1.31

1.38-1.48

.054-.058

2.30

.090

155.8

35.00

0.82

1.23-1.33

.049-.052

1.70

.067

111.3

25.00

0.52

1.23-1.33

.049-.052

1.70

.067

66.8

15.00

0.32

1.23-1.33

.049-.052

1.70

.067

53.4

12.00

0.20

1.23-1.33

.049-.052

1.70

.067

35.6

8.00

1973

0.82

1.23-1.33

.049-.052

1.70

.067

155.8

35.00

0.52

1.23-1.33

.049-.052

1.70

.067

80.1

18.00

0.32

1.23-1.33

.049-.052

1.70

.067

53.4

12.00

1973-2

2.08

1.38-1.48

.054-.058

2.30

.090

178.0

40.00

1.31

1.38-1.48

.054-.058

2.30

.090

155.8

35.00

0.82

1.23-1.33

.049-.052

1.70

.067

111.3

25.00

2046

N/A

1.31

1.38-1.48

.054-.058

2.30

.090

200.3

45.00

0.82

1.38-1.48

.054-.058

2.30

.090

155.8

35.00

2047

N/A

1.31

1.38-1.48

.054-.058

2.30

.090

200.3

45.00

0.82

1.38-1.48

.054-.058

2.30

.090

155.8

35.00

2273

0.82

1.23-1.33

.049-.052

1.70

.067

89.0

20.00

0.52

1.23-1.33

.049-.052

1.70

.067

62.3

14.00

0.32

1.23-1.33

.049-.052

1.70

.067

44.5

10.00

2282

2.08

1.38-1.48

.054-.058

2.30

.090

178.0

40.00

1.31

1.38-1.48

.054-.058

2.30

.090

155.8

35.00

0.82

1.23-1.33

.049-.052

1.70

.067

111.3

25.00

4272

0.82

1.23-1.33

.049-.052

1.70

.067

89.0

20.00

0.52

1.23-1.33

.049-.052

1.70

.067

62.3

14.00

0.32

1.23-1.33

.049-.052

1.70

.067

44.5

10.00

4549

2.08

1.38-1.48

.054-.058

2.30

.090

178.0

40.00

1.31

1.38-1.48

.054-.058

2.30

.090

155.8

35.00

0.82

1.23-1.33

.049-.052

1.70

.067

111.3

25.00

0.52

1.23-1.33

.049-.052

1.70

.067

66.8

15.00

4550

2.08

1.38-1.48

.054-.058

2.30

.090

178.0

40.00

1.31

1.38-1.48

.054-.058

2.30

.090

155.8

35.00

0.82

1.23-1.33

.049-.052

1.70

.067

111.3

25.00

0.52

1.23-1.33

.049-.052

1.70

.067

66.8

15.00

6271

0.82

1.23-1.33

.049-.052

1.70

.067

89.0

20.00

0.52

1.23-1.33

.049-.052

1.70

.067

62.3

14.00

0.32

1.23-1.33

.049-.052

1.70

.067

44.5

10.00

6310

2.08

1.38-1.48

.054-.058

2.30

.090

178.0

40.00

1.31

1.23-1.33

.049-.052

1.70

.067

155.8

35.00

0.82

1.23-1.33

.049-.052

1.70

.067

89.0

20.00

0.52

1.23-1.33

.049-.052

1.70

.067

62.3

14.00

7238

2.08

1.38-1.48

.054-.058

2.30

.090

178.0

40.00

1.31

1.38-1.48

.054-.058

2.30

.090

155.8

35.00

0.82

1.38-1.48

.054-.058

2.30

.090

111.3

25.00

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.

Tool Kit for 14-24 AWG Crimp Terminals

Doc No: ATS-6381132HM Release Date: 11-07-03 UNCONTROLLED COPY Page 4 of 11

Revision: G Revision Date: 10-04-10

SWING

LOCATOR

OPEN

PRESS DOWN

ON THE BRASS

PIVOT SHAFT

LIFT UP ON

THE LOCATOR

Figure 2

ANVILS

POWER

CRIMP

HEAD

Figure 1

PUNCHES

M4 X 10 LONG

BHCS

M4 X 18 LONG

BHCS

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.

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.

2. Swing the existing 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.

Figure 3

LOCATOR

JAWS OPEN

Tool Kit for 14-24 AWG Crimp Terminals

Doc No: ATS-6381132HM Release Date: 11-07-03 UNCONTROLLED COPY Page 5 of 11

Revision: G Revision Date: 10-04-10

TERMINAL

SWING OPEN

PRESS HERE ON LOCATOR

LOCATOR

TERMINAL IN PLACE

Figure 4

FRAME

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. Make sure that the

proper locator is mounted on the tool.

2. Swing the terminal locator away from the crimp tool shown in

Figure 4. 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.

3. When using the desired locator, swing the locator away from

the crimp tool, and gently press the locator against the tool

frame as shown in Figure 4. The wire stop will automatically

open. Insert the proper terminal into the proper nest opening.

Make sure when choosing the nest opening, it will correspond

with the A or B profile on the hand tool.

4. Return the locator to its original position.

5. Insert the proper wire over the terminal. Some large O.D. wires

may need to be placed into the terminal before closing the tool.

Gently touch the wire stop with the end of the wire.

See Figure 5.

6. Compress the terminal by squeezing the tool handles until the

ratchet mechanism cycle has been completed. Release

handles to open the jaws.

7. 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.

8. 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 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. The terminal locator can be in either position.

3. Visually inspect the crimped terminal for proper crimp location.

WIRE

LOCATOR

IN PLACE

WIRE STOP

TERMINAL

WIRE STOP

WIRE

AGAINST STOP

Figure 5

Tool Kit for 14-24 AWG Crimp Terminals

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Revision: G Revision Date: 10-04-10

TERMINAL FLUSH WITH

INSULATION TOOLING

Figure 5A

Crimping Terminals without a Locator

1. With the hand tool in the open position, select the proper profile.

2. Position the terminal in the proper profile; partially close the hand

tool until the terminal is held in place. The terminal should be

positioned so that the front of the insulation grips is flush with the

front face of the insulation tooling. See Figure 5A.

3. Gently slip the wire into the terminal, and then position the

insulation and stripped strands into the terminal insulation and

conductor grips. Note: No wire stop is provided. If the wire will not

fit into the partially closed tool, due to large insulation diameter, the terminal and wire must then be placed in

the open tool. Applying slight downward pressure on the wire may help hold the terminal in place while

crimping.

4. Compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.

Release handles to open the jaws.

Locator Change Over

Two styles of locators are provided with the crimp hand tool 63811-3300. They are locator no. 1 (63811-3375),

which is black and locator no.2 (63811-3376), which is gray. Make sure the desired style of locator is installed for

the proper terminal and wire. Follow the steps below to change the locators.

1. Open the crimp hand tool.

2. Swing the existing 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. See

Figure 6.

4. Replace it with the desired locator by putting

over the brass pivot shaft and snapping it into

place.

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 fine piece of equipment it needs

cleaning and lubrication for a maximum service life of trouble free crimping. Use a 30 weight automotive (light)

oil used at the oil points, every 5,000 crimps or 3 months, shown in Figure 7A or 7B will significantly enhance

the tool life.

SWING

LOCATOR

OPEN

PRESS DOWN ON

BRASS PIVOT SHAFT

LIFT UP

LOCATOR

JAWS

OPEN

Figure 6

Tool Kit for 14-24 AWG Crimp Terminals

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Revision: G Revision Date: 10-04-10

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 pressing the ratchet release lever. See Figure 8.

How to Adjust Tool Preload (See Figure 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 (63810-0101), is not

supplied. It is sold separately from the hand

tool.

3. 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 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.

RATCHET

RELEASE LEVER

Figure 8

HANDLE

GRIP

REMOVED

ECCENTRIC AXLE

HANDLE

GRIP

LOCKING

SCREW

WRENCH SET

(SOLD

SEPERATELY)

PRELOAD

CHECK POINT

25.4MM

SETTING WHEEL

Figure 7B

LUBRICATION

POINTS

(BOTH SIDES)

LIGHT OIL

(EVERY MONTH

5,000 CRIMPS)

Figure 7A

Tool Kit for 14-24 AWG Crimp Terminals

Doc No: ATS-6381132HM Release Date: 11-07-03 UNCONTROLLED COPY Page 8 of 11

Revision: G Revision Date: 10-04-10

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.

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.

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 14-24 AWG Crimp Terminals

Doc No: ATS-6381132HM Release Date: 11-07-03 UNCONTROLLED COPY Page 9 of 11

Revision: G Revision Date: 10-04-10

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.

63811-3270

63810-0100

Hand Crimp Frame (Short)

N/A

63810-0400

Hand Crimp Frame (Long)

N/A

63816-0200

Battery Power Tool (110 V)

63816-0300

Power Crimp Head

63816-0250

Battery Power Tool (220 V)

63816-0300

Power Crimp Head

Applications for the Tool Kit

Hand Crimp Tool

Battery Powered Tool

Figure 9

Figure 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 14-24 AWG Crimp Terminals

Doc No: ATS-6381132HM Release Date: 11-07-03 UNCONTROLLED COPY Page 10 of 11

Revision: G Revision Date: 10-04-10

RATCHET

RELEASE SCREW

Figure 11

M4 X 6mm

LONG BHCS

M4 X 12mm

LONG BHCS

WITH TOOL KIT

LOCATOR ONLY

M4 X 12mm

LONG BHCS

WITH TOOL KIT

LOCATOR ONLY

HAND TOOL PARTS LIST

Item Number

Order Number

Description

Quantity

63810-0100

Hand Crimp Frame (Short)

63810-0101

Wrench Set (Not included)

63810-0102

Locator Base

63810-0103

Repair Kit (Not included)

63811-3270

Tool Kit with Locator

63811-3275

Locator #1-Black

63811-3276

Locator #2-Gray

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