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

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

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

63 16-0250

Battery Power Tool (220 V)

63 16-0300 Power Crimp Head

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

M4 X 6mm

LONG BHCS

M4 X 12mm

LONG BHCS

WITH TOOL KIT

LOCATOR ONLY

M4 X 12mm

LONG BHCS

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

M4 by 8 Long

BHCS

M4 by 18 Long

BHCS

M4 by 10 Long

BHCS

POWER HEAD PARTS LIST

Item Order No Engineering No. Description Quantity

63 16-0300 63 16-0300 Power Crimp Head 1

63 19-7970 63 19-7970 Tool Kit 1

http://www.molex.com

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