Molex 207129 Series User manual

Tool Kit for Quick Disconnect Flag Female Terminal

Doc No: ATS-63819 8HM Release Date: 0 -30-09 UNCONTROLLED COPY Page 1 of 8

Revision: B Revision Date: 09-20-10

INSULATION

CRIMP

STRIP LENGTH

CRIMP HEIGHT

BEND DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP

TWISTING

CUT-OFF TAB

WIRE

Application Tooling

Sp cification Sh t

Tool Kit

Ord r No. 63819-7870

Hand Crimp Tool

Ord r No. 63819-7800

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: Quick Disconnect Flag Female Terminal 4.8 by 0.8 Tabs 18-20 AWG (.50-.80mm2).

T rminal

S ri s No.

T rminal Ord r No.

 Availabl in R l form only

Wir Siz Insulation Diam t r Strip L ngth

IPC/WHMA-A620 T rminal Maximum

AWG

mm²

mm In. mm In. mm In.

94536 94536-0100

94536-0101

94536-1100

94536-1101

18- N/A 2. 0-3.40

.106-.133

3.50 .138 4.40-5.40

.1 3-.213

20 N/A 2.00-2.90

.0 9-.114



The terminals above are reeled parts only. Customer to cut off terminal from reel: 0.51 mm (.020”) ma imum.

To achieve optimum IPC-A620 insulation crimps, use this insulation OD range.

Overall insulation OD specification for terminal.

DEFINITION OF TERMS

TYPE 4C

Tool Kit for Quick Disconnect Flag Female Terminal

Doc No: ATS-63819 8HM Release Date: 0 -30-09 UNCONTROLLED COPY Page 2 of 8

Revision: B Revision Date: 09-20-10

ANVILS

POWER

CRIMP

HEAD

Figur 1

PUNCHES

M4 X 8 LONG

BHCS

M4 X 18 LONG

BHCS

HAND TOOL

OPEN

18 AWG

TERMINAL

Figur 2

TERMINAL STOP

BUILT IN

CONDITIONS:

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

T rminal

S ri s No.

Wir Siz Conductor Crimp Insulation Crimp Pull Forc

Minimum Profil

H ight Width (R f)

AWG

mm2

mm In. mm In. mm In. mm In. N Lbs

A B

94536 18 N/A 1.69-1. 6

.06 -.069

--- --- 2. 5-2.85

.108-.112

--- --- .8

1 .5

20 N/A 1.62-1.68

.064-.066

--- --- 2.65-2. 5

.104-.108

--- --- 53.4

12.0

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:

Anvils and Punch s Installation

1. Insert the Anvils into the bottom slots of the nest. Install the M4 x 8 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 Quick Disconnect Flag Female Terminal

Doc No: ATS-63819 8HM Release Date: 0 -30-09 UNCONTROLLED COPY Page 3 of 8

Revision: B Revision Date: 09-20-10

MARKING FOR

18 AWG

Figur 3

TERMINAL IN NEST

POSITION FOR

20 AWG TERMINALS

POSITION FOR

18 AWG TERMINALS

MARKING FOR

20 AWG

TERMINAL IN NEST

Figur 4

WIRE

INSULATION

PUNCH

CONDUCTOR

ANVIL

INSULATION ANVIL

CONDUCTOR

PUNCH

TERMINAL

PARTIALLY

CLOSED

WIRE

TERMINAL

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. Insert the terminal centered in the proper nest and up against the terminal stop.

3. If using an 18 AWG terminal, load the profile marked A from the front. See Figure 3.

4. If using a 20 AWG terminal, rotate the hand crimp tool 180° and load in the profile marked B.

5. Make sure when choosing the nest opening, it will correspond with the A or B profile on the hand tool. See

Figure 3.

6. Partially close the tool to hold the terminal in place.

. Insert the properly stripped wire into the insulation crimp nest. See Figure 4.

8. Now close the handle completely and release. The jaws will open when the tool has fully closed.

9. Make sure the insulation grips wrapped snug around the insulation of the wire.

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

Tool Kit for Quick Disconnect Flag Female Terminal

Doc No: ATS-63819 8HM Release Date: 0 -30-09 UNCONTROLLED COPY Page 4 of 8

Revision: B Revision Date: 09-20-10

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.

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 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 5A

or 5B 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 8)

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 8.

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.

LUBRICATION

POINTS

(BOTH SIDES)

LIGHT OIL

(EVERY MONTH

5,000 CRIMPS)

Figur 5A

Figur 5B

Tool Kit for Quick Disconnect Flag Female Terminal

Doc No: ATS-63819 8HM Release Date: 0 -30-09 UNCONTROLLED COPY Page 5 of 8

Revision: B Revision Date: 09-20-10

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.

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. mm (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 Quick Disconnect Flag Female Terminal

Doc No: ATS-63819 8HM Release Date: 0 -30-09 UNCONTROLLED COPY Page 6 of 8

Revision: B Revision Date: 09-20-10

HAND CRIMP

FRAME LONG

AND SHORT

TOOLING

KIT

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.

63819- 8 0

63810-1050

Hand Crimp Frame (Short) N/A N/A 6

63810-1000

Hand Crimp Frame (Long) N/A N/A 6

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 6 Figur 7

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

Tool Kit for Quick Disconnect Flag Female Terminal

Doc No: ATS-63819 8HM Release Date: 0 -30-09 UNCONTROLLED COPY Page of 8

Revision: B Revision Date: 09-20-10

RATCHET

RELEASE SCREW

Figur 8

M4 X 18mm

LONG BHCS

M4 X 12mm

LONG BHCS

HAND TOOL PARTS LIST

It m Numb r Ord r Numb r D scription Quantity

1 63810-1000 Hand Crimp Frame (Long) 1

2 63819- 8 0 Tool Kit 1

Tool Kit for Quick Disconnect Flag Female Terminal

Doc No: ATS-63819 8HM Release Date: 0 -30-09 UNCONTROLLED COPY Page 8 of 8

Revision: B Revision Date: 09-20-10

Figur 9

M4 by 12 Long

BHCS

M4 by 18 Long

BHCS

POWER HEAD PARTS LIST

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

1 63816-0300 63816-0300 Power Crimp Head 1

2 63819- 8 0 63819- 8 0 Tool Kit 1

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