Molex 207129 Series User manual

Tool Kit for Bulb Socket Contact Crimp Terminals

Doc No: ATS-6381 4 HM Release Date: 01-30-0 UNCONTROLLED COPY Page 1 of 8

Revision: B Revision Date: 10-06-10

INSULATION

CRIMP HEIGHT

BRUSH

STRIP LENGTH

BELL MOUTH

BEND DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP HEIGHT

TWISTING

CUT-OFF

TAB

SEAM

WIRE

Application Tooling

Sp cification Sh t

Tool Kit

Ord r No. 63819-4970

Hand Crimp Tool

Ord r No. 63819-4900

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: Bulb Socket Contact Terminal for 0.50 to 0.85mm² wire

T rminal

S ri s No.

T rminal Ord r No. Wir Siz Insulation

Diam t r Strip L ngth

 Availabl in R l Only

mm² mm In. mm In.

35438 35438-8000 0.50 to 0.85

1.8 – 2.8

.071-.110

3.00 – 3.60

.118 - .142

Customer to cut off terminal from reel 0.50mm (.020”) maximum Cut-off Tab.

DEFINITION OF TERMS

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

scope.

TYPE 2C

Tool Kit for Bulb Socket Contact Crimp Terminals

Doc No: ATS-6381 4 HM Release Date: 01-30-0 UNCONTROLLED COPY Page 2 of 8

Revision: B Revision Date: 10-06-10

SWING

LOCATOR

OPEN

PRESS DOWN

ON THE BRASS

PIVOT SHAFT

LIFT UP ON

THE LOCATOR

Figur 2

ANVILS

POWER

CRIMP

HEAD

Figur 1

PUNCHES

M4 X 10 LONG

BHCS

M4 X 18 LONG

BHCS

CONDITIONS:

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

T rminal

S ri s No.

Wir Siz

Actual mm²

Conductor 



Profil

Crimp H ight Crimp Width (R f.)

mm In. mm In. A B

35438 0.50 0.50 1.00-1.10

.03 -.043

1. 0-2.10

.075-.083

0.85 0.85 1.20-1.30

.047-.051

1. 0-2.10

.075-.083

T rminal

S ri s No.

Wir Siz

Actual mm²

Insulation Pull Forc

Minimum

Crimp H ight (R f.)

Crimp Width (R f.)

mm In. mm In. N Lb.

35438 0.50 0.50 2.65 .104 2.70-2. 0

.106-.114

58.

13.2

0.85 0.85 2.66 .105 2.70-2. 0

.106-.114

8.0

22.0

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.

Not :

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:

Tool Kit for Bulb Socket Contact Crimp Terminals

Doc No: ATS-6381 4 HM Release Date: 01-30-0 UNCONTROLLED COPY Page 3 of 8

Revision: B Revision Date: 10-06-10

Anvils and Punch s 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 R moval

Follow the steps below to install or replace the locator. See Figure

To install th locator

1. Position the locator with the hole over the brass pivot shaft and snap it into place.

To r mov th 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.

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 T rminals

1. Select the desired terminal listed in the preceding charts.

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 locator, press down on the wire stop on the locator

as shown in Figure 4.

4. Insert the 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.

5. Return the locator to its original position. Insert the pre-stripped

wire. 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.

Figur 3

LOCATOR

JAWS OPEN

TERMINAL

SWING OPEN

PRESS HERE

ON LOCATOR

LOCATOR TERMINAL IN PLACE

Figur 4

LOCATOR

WIRE

LOCATOR

IN PLACE

WIRE STOP

WIRE AGAINST STOP

Figur 5

Tool Kit for Bulb Socket Contact Crimp Terminals

Doc No: ATS-6381 4 HM Release Date: 01-30-0 UNCONTROLLED COPY Page 4 of 8

Revision: B Revision Date: 10-06-10

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 th Batt ry Pow r 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.

Locator R plac m nt

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 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 proper locator by putting over the brass pivot shaft and snapping it into place.

Maint nanc

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.

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.

SWING

LOCATOR

OPEN

PRESS DOWN

ON BRASS PIVOT

SHAFT

LIFT UP

LOCATOR

JAWS

OPEN

Figur 6

Figur 7B

LUBRICATION

POINTS

(BOTH SIDES)

LIGHT OIL

(EVERY MONTH

5,000 CRIMPS)

Figur 7A

Tool Kit for Bulb Socket Contact Crimp Terminals

Doc No: ATS-6381 4 HM Release Date: 01-30-0 UNCONTROLLED COPY Page 5 of 8

Revision: B Revision Date: 10-06-10

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 Pr load (S Figur 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.

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.

C rtification

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

customers to re-certify hand tools.

RATCHET

RELEASE LEVER

Figur 8

HANDLE

GRIP

REMOVED

ECCENTRIC AXLE

HANDLE

GRIP

LOCKING

SCREW

WRENCH SET

(SOLD

SEPERATELY)

PRELOAD

CHECK POINT

25.4MM

SETTING WHEEL

Tool Kit for Bulb Socket Contact Crimp Terminals

Doc No: ATS-6381 4 HM Release Date: 01-30-0 UNCONTROLLED COPY Page 6 of 8

Revision: B Revision Date: 10-06-10

% 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.

The chart below shows all applications for this Tool Kit.

Tool Kit

Ord r No.

Tool

Ord r no.

Tool

D scription

Pow r H ad

Ord r No.

Adapt r

D scription

Figur

No.

6381 -4 70

63810-0100

Hand Crimp Frame (Short) N/A N/A

63810-0400

Hand Crimp Frame (Long) N/A 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 th Tool Kit

Hand Crimp Tool Batt ry Pow r d Tool

Figur 9 Figur 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 Bulb Socket Contact Crimp Terminals

Doc No: ATS-6381 4 HM Release Date: 01-30-0 UNCONTROLLED COPY Page 7 of 8

Revision: B Revision Date: 10-06-10

RATCHET

RELEASE SCREW

Figur 11

M4 X 6mm

LONG BHCS

M4 X 12mm

LONG BHCS

WITH TOOL KIT

LOCATOR ONLY

M4 X 12mm

LONG BHCS

HAND TOOL PARTS LIST

It m Numb r Ord r Numb r D scription Quantity

1 63810-0100 Hand Crimp Frame (Short) 1

2 63810-0101 Wrench Set (Not included) 0

3 63810-0102 Locator Base 1

4 63810-0103 Repair Kit (Not included) 0

5 6381 -4 70 Tool Kit with Locator 1

6 6381 -4 75 Locator (only) REF

Tool Kit for Bulb Socket Contact Crimp Terminals

Doc No: ATS-6381 4 HM Release Date: 01-30-0 UNCONTROLLED COPY Page 8 of 8

Revision: B Revision Date: 10-06-10

Figur 12

M4 by 8 Long

BHCS

M4 by 18 Long

BHCS

M4 by 10 Long

BHCS

POWER HEAD PARTS LIST

It m Ord r No Engin ring No. D scription Quantity

63816-0300 63816-0300 Power Crimp Head 1

6381 -4 70 6381 -4 70 Tool Kit 1

http://www.molex.com

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