molex 207129 Series User manual
Tool Kit for Bulb Socket Earth Crimp Terminals
Doc No: ATS-63 1979HM Release Date: 01-30-09 UNCONTROLLED COPY Page 1 of 9
Revision: B Revision Date: 10-0 -10
BRUSH
INSULATION
CRIMP HEIGHT
▲SEE NOTE
BELL MOUTH
BEND DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP HEIGHT
TWISTING
SEAM
STRIP LENGTH
Application Tooling
Speci ication Sheet
Tool Kit
Order No. 63819-7970
Hand Crimp Tool
Order No. 63819-7900
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 63 16-0300 Power Crimp Head which is installed
into the 63 16-0200 (110 V) or the 63 16-0250 (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 Earth Terminal for 0.50 to 0. 5mm² wire.
Terminal Series No.
Terminal Order No. Wire Size Insulation
Diameter Strip Length
Available in Reel Only
mm² mm In. mm In.
35439 35439- 000 0.50 to 0. 5
1. 0 – 2. 0
.071-.110
3.00 – 3.60
.11 - .142
Customer to cut off terminal from reel. Cut tab flush with terminal on both ends.
DEFINITION OF TERMS
TYPE 2C
Tool Kit for Bulb Socket Earth Crimp Terminals
Doc No: ATS-63 1979HM Release Date: 01-30-09 UNCONTROLLED COPY Page 2 of 9
Revision: B Revision Date: 10-0 -10
▲Insulation Crimp Note:
Due to the terminal’s insulation grip design
and/or insulation diameter range, this tool
uses “overlap” form geometry in the
insulation punch. This produces an overlap
insulation crimp (A620 – compliant). While
the insulation punch profile may appear
“lopsided”, this is a normal condition for this
tool. See figure to the right. (Some tools with
multiple crimp pockets may not have the
“overlap” profile on all pockets).
CONDITIONS:
After crimping, the conductor profiles should measure the following (see notes below).
Terminal Series No. Wire Size Conductor Crimp
Pro ile
Height (Re .) Width (Re .)
mm2 mm In. mm In. A
B
35439 0.50 1.00 – 1.10 .039 - 043 1.90 – 2.10 .075 - .0 3 X
0. 5 1.20 – 1.30 .047 - .051 1.90 – 2.10 .075 - .0 3 X
Terminal Series No. Wire Size Insulation Crimp Pull Force
Minimum
Height (Re .) Width (Re .)
mm2 mm In. mm In. N Lb.
35439 0.50 2.33 .092 2.7 - 2.9 .106 - .114 5 .
13.2
0. 5 2.50 .09 2.7 - 2.9 .106 - .114 9 .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.
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.
OVERLAP
INSULATION
CRIMP
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
WIRE
Tool Kit for Bulb Socket Earth Crimp Terminals
Doc No: ATS-63 1979HM Release Date: 01-30-09 UNCONTROLLED COPY Page 3 of 9
Revision: B Revision Date: 10-0 -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
2. Insert the Punches into the top slots of the nest. Install the M4 x 1 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.
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.
2. Place the terminal into the correct nest profile (A or B) on the hand
tool. Make sure the terminal is seated into the slot between the
conductor and insulation anvils. See Figure 3.
3. Swinging the locator away from the crimp tool is an option. In this
hand tool the locator serves as a wire stop and it can be kept in the
closed position.
Figure 3
LOCATOR
JAWS OPEN
LOCATOR IS USE
FOR THE WIRE
STOP
TERMINAL
PROPERLY
SEATED
BETWEEN
ANVILS
TERMINAL
IN PLACE
Figure 4
Tool Kit for Bulb Socket Earth Crimp Terminals
Doc No: ATS-63 1979HM Release Date: 01-30-09 UNCONTROLLED COPY Page 4 of 9
Revision: B Revision Date: 10-0 -10
CONDUCTOR
PUNCH
WIRE
LOCATOR
TERMINAL
INSULATION
PUNCH
INSULATION
ANVIL
CONDUCTOR
ANVIL
WIRE AGAINST
WIRE STOP
(LOCATOR)
Figure 5
4. Partially close the tool until the terminal is held in place. See Figure 4.
5. Insert the pre-stripped wire into the terminal until it gently touches the wire stop (locator) with the ends 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.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
7. Remove the crimped terminal. Inspect for
proper crimp location, and check for insulation
closure
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.
Locator Replacement
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.
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 Bulb Socket Earth Crimp Terminals
Doc No: ATS-63 1979HM Release Date: 01-30-09 UNCONTROLLED COPY Page 5 of 9
Revision: B Revision Date: 10-0 -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 .
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 (63 10-0101), 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
OR
5,000 CRIMPS)
Figure 7A
Tool Kit for Bulb Socket Earth Crimp Terminals
Doc No: ATS-63 1979HM Release Date: 01-30-09 UNCONTROLLED COPY Page 6 of 9
Revision: B Revision Date: 10-0 -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.
Certi ication
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 Bulb Socket Earth Crimp Terminals
Doc No: ATS-63 1979HM Release Date: 01-30-09 UNCONTROLLED COPY Page 7 of 9
Revision: B Revision Date: 10-0 -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.
63 19-7970
63 10-0100
Hand Crimp Frame (Short) N/A N/A 9
63 10-0400
Hand Crimp Frame (Long) N/A N/A 9
63 16-0200
Battery Power Tool (110 V)
63 16-0300 Power Crimp Head
10
63 16-0250
Battery Power Tool (220 V)
63 16-0300 Power Crimp Head
10
Applications or 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 Bulb Socket Earth Crimp Terminals
Doc No: ATS-63 1979HM Release Date: 01-30-09 UNCONTROLLED COPY Page of 9
Revision: B Revision Date: 10-0 -10
RATCHET
RELEASE SCREW
Figure 11
1
3
M4 X 6mm
LONG BHCS
M4 X 12mm
LONG BHCS
5
6
WITH TOOL KIT
LOCATOR ONLY
M4 X 12mm
LONG BHCS
4
4
2
5
HAND TOOL PARTS LIST
Item Number Order Number Description Quantity
1 63 10-0100 Hand Crimp Frame (Short) 1
2 63 10-0101 Wrench Set (Not included) 0
3 63 10-0102 Locator Base 1
4 63 10-0103 Repair Kit (Not included) 0
5 63 19-7970 Tool Kit with Locator 1
6 63 19-7975 Locator (only) REF
Tool Kit for Bulb Socket Earth Crimp Terminals
Doc No: ATS-63 1979HM Release Date: 01-30-09 UNCONTROLLED COPY Page 9 of 9
Revision: B Revision Date: 10-0 -10
Figure 12
1
2
2
M4 by 8 Long
BHCS
M4 by 18 Long
BHCS
M4 by 10 Long
BHCS
1
POWER HEAD PARTS LIST
Item Order No Engineering No. Description Quantity
1
63 16-0300 63 16-0300 Power Crimp Head 1
2
63 19-7970 63 19-7970 Tool Kit 1
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