Molex 207129 Series User manual

Tool Kit for MLX150L™ Crimp Terminals

Doc No: ATS-6 8115 HM Release Date: 04-29-05 UNCONTROLLED COPY Page 1 of 8

Revision: C Revision Date: 09-07-10

CONDUCTOR

BRUSH

STRIP LENGTH

SEAM

CONDUCTOR

CRIMP

CUT-OFF

TAB

BELL MOUTH BEND UP

TWISTING

BEND

DOWN

WIRE

ANGLE

Application Tooling

Sp cification Sh t

Tool Kit

Ord r No. 63811-5370

Hand Crimp Tool

Ord r No. 63811-5300

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 6 816-0 00 Power Crimp Head which is installed

into the 6 816-0200 (110 V) or the 6 816-0250 (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: MX150L™10-12 AWG

T rminal S ri s No.

T rminal Ord r No. Wir Siz Insulation Diam t r Strip L ngth

Loos Pi c





R l AWG

mm² mm In. mm In.

194 1 194 1-0016 194 1-0001

10-12

5.26- . 1

.90-4.85

.15 -.191

5.50-6.20

.217-.244

194 4 194 4-000 194 4-0001

10-12

5.26- . 1

.90-4.85

.15 -.191

5.50-6.20

.217-.244

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

DEFINITION OF TERMS

TYPE 4C

Tool Kit for MLX150L™ Crimp Terminals

Doc No: ATS-6 8115 HM Release Date: 04-29-05 UNCONTROLLED COPY Page 2 of 8

Revision: C Revision Date: 09-07-10

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

CRIMP SPECIFICATION

T rminal S ri s No. B ll Mouth B nd up B nd down Twist Roll Conductor Brush Wir Angl

mm In. D gr D gr mm In. D gr

194 1 0.25-1.25

.010-.049

2 4 8 0.10-0.50

.004-.020

5° Max

194 4 0.25-1.25

.010-.049

2 4 8 0.10-0.50

.004-.020

5° Max

S am: Seam shall not be open and no wire allowed out of the crimping area.

CONDITIONS:

After crimping, the conductor profiles should measure the following (See notes on page 4).

T rminal

S ri s No.

Wir Siz

Conductor Insulation Pull Forc

Minimum

Crimp H ight (R f)

Crimp Width (R f) Crimp H ight (R f)

Crimp Width (R f)

AWG

mm2

mm In. mm In. mm In. mm In. N Lb.

194 1 10 5.26

2.45-2.55

.096-.100

.70- .90

.146-.154

5.00 Max

.197 Max

5.10-5. 0

.201-.209

56.0

80.0

12 . 1

2.05-2.15

.081-.085

.70- .90

.146-.154

4.50 Max

.177 Max

5.00-5.20

.197-.205

11.5

70.0

194 4 10 5.26

2.45-2.55

.096-.100

.70- .90

.146-.154

5.00 Max

.197 Max

5.10-5. 0

.201-.209

56.0

80.0

12 . 1

2.05-2.15

.081-.085

.70- .90

.146-.154

4.50 Max

.177 Max

5.00-5.20

.197-.205

11.5

70.0

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.

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 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.

Tool Kit for MLX150L™ Crimp Terminals

Doc No: ATS-6 8115 HM Release Date: 04-29-05 UNCONTROLLED COPY Page of 8

Revision: C Revision Date: 09-07-10

Locator Installation and R moval

Follow the steps below to install or replace the locator. See Figure 2.

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.

. 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

Swing the terminal locator against the crimp tool and turn the lock up to lock the locator. Terminals can be loaded

easily while the locator is against the crimp tool and locked. The spring-loaded locator needs to be in the up

position for terminals to load easily.

1. To raise the wire stop, press the tab on the wire stop as shown in Figure . Insert the proper terminal into the

nest opening and release the wire stop to lower it.

2. Insert the proper pre-striped wire over the terminal. Gently touch the wire stop with the end of the wire. See

Figure 4 and 5.

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

Release handles to open the jaws.

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

HANDLE

OPEN

LOCK IN

UP RIGHT

POSITION

LOCATOR

CLOSED

Figur 3

TERMINAL

PUSH HERE TO

OPEN WIRE STOP

Figur 4

WIRE IN TERMINAL

JAWS

PARTIALLY

CLOSED

WIRE AGAINST

WIRE STOP

LOCATOR ANVIL

TERMINAL

WIRE

PUNCH

WIRE AGAINST STOP

Figur 5

WIRE STOP

Tool Kit for MLX150L™ Crimp Terminals

Doc No: ATS-6 8115 HM Release Date: 04-29-05 UNCONTROLLED COPY Page 4 of 8

Revision: C Revision Date: 09-07-10

4. Remove the crimp terminal from the terminal locator by pressing the tab on the wire stop and gently pulling on

the wire.

5. Visually inspect the crimped terminal for proper crimp location and crimp height.

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.

. Visually inspect the crimped terminal for proper crimp location.

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.

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.

. 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 0 weight

automotive oil, every 5,000 crimps or monthly, will significantly enhance the tool life and ensure a stable

calibration. See Figure 6A or 6B 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

(S Figur 9)

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 9.

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 0

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.

LUBRICATION

POINTS

(BOTH SIDES)

LIGHT OIL

(EVERY MONTH

5,000 CRIMPS)

Figur 6A

LUBRICATION POINTS

(BOTH SIDES) LIGHT OIL

(EVERY 3 MONTHS OR

5,000 CRIMPS)

Figur 6B

Tool Kit for MLX150L™ Crimp Terminals

Doc No: ATS-6 8115 HM Release Date: 04-29-05 UNCONTROLLED COPY Page 5 of 8

Revision: C Revision Date: 09-07-10

Hand held crimping tools are intended for low volume, prototyping, or repair requirements only.

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.

. 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.

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.

% 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.

Tool Kit for MLX150L™ Crimp Terminals

Doc No: ATS-6 8115 HM Release Date: 04-29-05 UNCONTROLLED COPY Page 6 of 8

Revision: C Revision Date: 09-07-10

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.

6 811-5 70

6 810-1050

Hand Crimp Frame (Short) N/A N/A 7

6 810-1000

Hand Crimp Frame (Long) N/A N/A 7

6 816-0200

Battery Power Tool (110 V)

6 816-0 00 Power Crimp Head

6 816-0250

Battery Power Tool (220 V)

6 816-0 00 Power Crimp Head

Applications for th Tool Kit

Hand Crimp Tool Batt ry Pow r d Tool

Figur 7 Figur 8

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 MLX150L™ Crimp Terminals

Doc No: ATS-6 8115 HM Release Date: 04-29-05 UNCONTROLLED COPY Page 7 of 8

Revision: C Revision Date: 09-07-10

RATCHET

RELEASE SCREW

Figur 9

M4 X 8mm

LONG BHCS

M4 X 18mm

LONG BHCS

M4 X 10mm

LONG BHCS

WITH TOOL KIT

LOCATOR ONLY

HAND TOOL PARTS LIST

It m Numb r Ord r Numb r D scription Quantity

1 6 810-1000 Hand Crimp Frame (Long) 1

2 6 811-5 70 Tool Kit with Locator 1

6 811-477 Locator Base 1

4 6 811-5 75 Locator (only) REF

Tool Kit for MLX150L™ Crimp Terminals

Doc No: ATS-6 8115 HM Release Date: 04-29-05 UNCONTROLLED COPY Page 8 of 8

Revision: C Revision Date: 09-07-10

Figur 10

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

6 816-0 00 6 816-0 00 Power Crimp Head 1

6 811-5 70 6 811-5 70 Tool Kit 1

http://www.molex.com

Other manuals for 207129 Series

100

This manual suits for next models

Table of contents

Popular Crimping Tools manuals by other brands

Panduit

Panduit CT-1000 Operation & instruction manual

JST

JST CS 10 instruction manual

Danfoss

Danfoss ET4200 Operator's manual

Tyco Electronics

Tyco Electronics PRO-CRIMPER III instruction sheet

TE Connectivity

TE Connectivity 2063528-1 instruction sheet

Tyco Electronics

Tyco Electronics 69156-1 instruction sheet

CRH

CRH CRL CBLHCT1 instruction manual

Emerson

Emerson Klauke ES 105CFM manual

KIMBALL MIDWEST

KIMBALL MIDWEST 27-798 Operating instructions manual

Danfoss

Danfoss ET4350 Operator's manual

Milwaukee

Milwaukee M18 Operator's manual

HOGERT

HOGERT HT1P169 user manual

Textron

Textron ESG105L instruction manual

Tyco Electronics

Tyco Electronics 90035-3 instruction sheet

Emerson

Emerson Klauke ES 20RMCCFB manual

Continental Refrigerator

Continental Refrigerator PC150HD quick start guide

TE Connectivity

TE Connectivity ERGOCRIMP 1-1579001-3 instruction sheet

Tyco Electronics

Tyco Electronics CERTI-CRIMP 90418-1 instruction sheet

molex 207129 Series User manual

Popular Crimping Tools manuals by other brands