Molex 207129 Series User manual

Hand Crimp Tool for 2.28mm (.090”) Sealed Receptacle Terminals

Doc No: TS-638257600 Release Date: 08-12-13 UNCONTROLLED COPY Page 1 of 7

Revision: Revision Date: 08-12-13

CONDUCTOR

BRUSH

TRIP LENGTH

SEAM

CONDUCTOR

CRIMP HEIGHT

CUT

OFF

TAB

BELL MOUTH

BEND UP

TWISTING

ROLLING

BEND

DOWN

WIRE

SEAL

INSULATIO

CRIMP HEIGHT

HAND CRIMP

TOOL

Application Tooling

Sp cification Sh t Ord r No. 63825-7600

FEATURES

 full cycle ratcheting hand tool ensures complete crimps

 Ergonomic soft grip handles for comfortable crimping

 precision user-friendly terminal locator wire stop holds terminals in the proper crimping position

 Right and Left handed applications

 This tool is IPC/WHM -620 Class 2 compliant as indicated

 This tool is RoHS compliant, however RoHS compliant is not required

SCOPE

Products: 2.28mm (.090”) Receptacle Terminal with Seal, 0.30-0.50mm² VSS.

T rminal S ri s No.

T rminal Ord r No.

Wir Siz







Insulation Diam t r

Strip

L ngth

AWG

mm²

In.

35407

6302

35407

6702

0.30

0.50

1.40

2.10

.055

.083

5.00

5.60

.197

.220







This

Hand Tool

provides optimum

620 Class 2 crimps with insulation O.D. range of

1.40

2.10

mm.

DEFINITION OF TERMS

TYPE 4D

Hand Crimp Tool for 2.28mm (.090”) Sealed Receptacle Terminals

Doc No: TS-638257600 Release Date: 08-12-13 UNCONTROLLED COPY Page 2 of 7

Revision: Revision Date: 08-12-13

WIRE

INSULATION

SEAL

0.70mm

(REF)

SEAL POSTION

CRIMP SPECIFICATION

T rminal S ri s No.

B ll mouth

Cut

off Tab Maxi

mum

Conductor Brush

In.

35407

0.3

0.6

.01

.02

0.0

0.30

.011

0.3

–

.01

.031

T rminal S ri s No.

B nd up B nd down

Twist Roll

Punch Width mm (R f)

S am

Seam shall not be open

and no wire allowed out

of the crimping area

Conductor

Insulation

D gr

35407

1.80

.071

3.80

.150

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

T rminal S ri s No.

Wir Siz

Conductor

Insulation

Crimp H ight

Crimp Width

(R f

)

Crimp H ight

Crimp Width

Typ

In.

35407

039

044

.07

3.80

.150

039

044

.07

3.80

.150

0.30

0.89

035

039

.07

3.80

.150

VSS

0.30

0.89

035

039

.07

3.80

.150

T rminal S ri s No.

Wir Siz

Pull Forc Minimum





Singl Wir S al Profil

AWG

5mm

35407

88.3

65.1

35903-0022 (M) (Black)

58.8

43.3





Cabl S al Position On a Wir

(Before crimping)

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 :

crimp height chart is provided with this manual as Reference Only. Due to the wide range of wires, strands,

insulation diameters, and durometers available, actual crimp height measurements may very slightly. n

occasional, destructive, pull force test should be performed to check hand tool crimp. Pull Force value Must

exceed the Minimum pull force specifications listed.

OPERATION

CAUTION: Crimp only the Molex terminals listed in the scope for this tool. Do not crimp hardened objects as

damage can occur to the tool frame and/or crimp dies.

Hand Crimp Tool for 2.28mm (.090”) Sealed Receptacle Terminals

Doc No: TS-638257600 Release Date: 08-12-13 UNCONTROLLED COPY Page 3 of 7

Revision: Revision Date: 08-12-13

WIRE AND SEAL

POSITIONED IN

LOWER PART OF

THE PUNCHES

Figur 4

TERMINAL

WIRE AGAINST

THE

WIRE STOP

WIRE AND

SEAL POSITON

WIRE STOP IS

PART OF THE

LOCATOR

TERMINAL

Open the tool by squeezing the handles together. t the end of the closing stroke, the ratchet mechanism will

release the handles and the hand tool will spring open. See Figure 1.

Crimping T rminals

1. Select the desired terminal listed in the

preceding charts.

2. Make sure the center of the locator is in the

down position. With the locator attached, push

the locator button on the back of the hand tool to

bring the locator forward through the tooling.

See Figure 2.

3. While holding the locator button in, load the

terminal with the seal into the proper nest

opening in the locator based on the wire gauge

or terminal type markings on the hand tooling.

See Figure 3.

4. Release the locator button, allowing the locator to return to the crimping position.

5. With the hand tool open, insert the properly stripped wire and seal under the punches into the lower part of the

upper tooling, until the wire is against the wire stop. See Figure 4.

6. Seal position should be under and inside the punches, keep this position while crimping.

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

Release the handles to open the jaws.

SQUEEZE

HANDLES

TOGETHER

HANDLE WILL

SPRING OPEN

Figur 1

LOCATOR

IN DOWN

POSTION

PUSH ON THE

LOCATOR BUTTON

Figur 2

TERMINAL

Figur 3

LOCATOR

PUSHED THRU

TOOLING

TERMINAL

RELEASE LOCATOR

BUTTON

LOCATOR

BUTTON

PUSHED IN

Hand Crimp Tool for 2.28mm (.090”) Sealed Receptacle Terminals

Doc No: TS-638257600 Release Date: 08-12-13 UNCONTROLLED COPY Page 4 of 7

Revision: Revision Date: 08-12-13

Figur 8

PUSH ON

HANDLE

JAWS OPEN

PULL OPEN

TOOLING

M3 BHCS

MATCH

UP MARKS

FRONT

BACK

Figur 8

MAKE SURE

CENTER OF LOCATOR

IS IN THE

DOWN POSITION

Figur 7B

SQUEEZE

HERE

SQUEEZE

HERE

LOCATOR

Figur 7A

TOP HOOKS

TOP SLOTS OF

HANDTOOL

LOWER TABS

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

8. Remove the crimped terminal from the terminal locator by pulling on the wire.

9. 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. Squeeze gently on the lower area shown in Figure 7 with your thumb and index finger. The lower tabs of the

locator should disengage from the hand tool.

3. Lift and pull away from the hand tool. The top locator

hooks should slip out of the top slots easily. See

Figure 7 .

4. To reinstall the new locator, make sure the hand tool

is in the open position.

5. Press the red insert down as far as it will go as shown

in Figure 7B.

6. Holding onto the lower part of the locator with your

thumb and index finger, insert the locators top hooks (2) into the hand tool top slots.

7. Rotate the locator down and press the lower tabs into the two bottom slots of the hand tool. To secure the

locator into place, the lower tabs must snap into place on the hand tool frame.

Hand Crimp Tool for 2.28mm (.090”) Sealed Receptacle Terminals

Doc No: TS-638257600 Release Date: 08-12-13 UNCONTROLLED COPY Page 5 of 7

Revision: Revision Date: 08-12-13

Right or L ft Hand Op ration

This hand tool has an added feature that can be converted from a right handed application to a left handed

application. It is necessary to reverse the tooling if using the left handed application along with the locator. Follow

the steps below:

1. The locator must be removed before reversing the tooling.

2. Remove the M3 BHCS which is holding the upper tooling.

3. Flip the upper tooling to the opposite side and replace the M3 BHCS. Make sure the small markings on the

front and back of the hand tool frame, match up and are on the outside of the hand tool frame. See Figure 8

and 9.

4. Do the same thing with the lower tooling and tighten the M3 screws. Be

sure the small markings line up.

5. Reinstall the locator by following the Instructions in the locator replacement

section.

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 other equipment it needs cleaning and lubrication for a maximum service

life of trouble free crimping. Light oil (such as 30 weight automotive oil) used at the oil points, every 5,000

crimps or 3 months, 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.

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 up on the ratchet release lever in the movable handle. See Figure

11.

How to Adjust Tool Pr load

(S Figur 12)

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:

LUBRICATION POINTS

(BOTH SIDES) LIGHT OIL

(EVERY 3 MONTHS OR

5,000 CRIMPS)

Figur 10

RATCHET RELEASE

LEVER

Figur 11

Hand Crimp Tool for 2.28mm (.090”) Sealed Receptacle Terminals

Doc No: TS-638257600 Release Date: 08-12-13 UNCONTROLLED COPY Page 6 of 7

Revision: Revision Date: 08-12-13

Figur 12

SQUEEZE

THE LINK IN

THE HANDLE

HOLD THE HAND

TOOL IN POSITION

SETTING

WHEEL

RATCHET

RELEASE LEVER

1. Hold the hand tool in the palm of your

hand as shown in Figure 12. Using

the index finger squeeze the link

towards the top of the hand tool

frame. This will release the preload

adjustment wheel.

2. Rotate the setting wheel counter-

clockwise (CCW) to increase handle

force. The numbers will display

higher. To decrease handle force

rotate the setting wheel clockwise

(CW).

3. Release the link to lock the setting

wheel in place.

4. 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. ll vital

components are long life tested. ll 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. ny 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 hand tools but rather supplies the following guidelines for customers to re-certify

hand tools.

% This tool is qualified to pull force only. 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 djust Preload).

% When the hand tool is no longer capable of achieving minimum pull force, it should be taken out of service and

replaced.

Hand Crimp Tool for 2.28mm (.090”) Sealed Receptacle Terminals

Doc No: TS-638257600 Release Date: 08-12-13 UNCONTROLLED COPY Page 7 of 7

Revision: Revision Date: 08-12-13

RATCHET

RELEASE

LEVER

Figur 13

PARTS LIST

It m Numb r

Ord r Numb r

D scription

Quantity

REF

63825

7600

Hand Crimp Tool

Figure

63825

Locator ssembly

63810

0104

Spring, Return

63810

0105

Spring, Ratchet

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