Molex 207129 Series User manual

Hand Crimp Tool for 2.00mm (.079") Pitch iGrid Wire-to-Board Crimp Terminal

Doc No: ATS-638192400 Release Date: 09-17-08 UNCONTROLLED COPY Page 1 of 7

Revision: B Revision Date: 02-04-20

Application Tooling Specification

FEATURES

A full cycle ratcheting hand tool ensures complete crimps

Ergonomic soft grip handles for comfortable crimping

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

Right- and left-handed applications

This tool is IPC/WHMA-A-620 Class 2 compliant as indicated

This tool is RoHS compliant; however, RoHS compliance is not required

SCOPE

Products: 2.00mm (.079") Pitch iGrid Wire-to-Board Crimp Terminal, 26-28 AWG.

Terminal Series

No.

Terminal Order No.

Wire Size

Insulation Diameter

Strip Length

Loose

●Reel

AWG

mm²

In.

501648

501648-1100

501648-1000

26-28

0.13-0.08

0.85-1.40

.033-.055

2.10-2.50

.082-.098

503095

503095-2200

26-28

—

0.85-1.40

.033-.055

1.30-1.80

.051-.071

503095-3200

503095-4200

●Customer to cut off terminal from reel: 0.25mm (.010”) maximum cut-off tab.

DEFINITION OF TERMS

The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed

in the scope.

INSULATION

CRIMP

BRUSH

STRIP

LENGTH

BELL MOUTH

CRIMP HEIGHT

BEND

DOWN

BEND UP

ROLL

CONDUCTOR

CRIMP

TWIST

Order Number

63819-2400

Type 4D

Hand Crimp Tool for 2.00mm (.079") Pitch iGrid Wire-to-Board Crimp Terminal

Doc No: ATS-638192400 Release Date: 09-17-08 UNCONTROLLED COPY Page 2 of 7

Revision: B Revision Date: 02-04-20

RELEASE

LOCATOR BUTTON

TERMINAL

Figure 3

LOCATOR PUSHED

THROUGH TOOLING

TERMINAL

LOCATOR

BUTTON

PUSHED IN

LOCATOR

CONDITIONS

After crimping, the conductor profiles should measure the following:

Terminal

Series No.

Wire Size

Conductor Crimp

Insulation Crimp

Pull Force

Minimum

Profile

Height (Ref.)

Width (Ref.)

Height (Ref.)

Width (Ref.)

AWG

mm2

In.

Lb.

501648

0.13

0.66-0.71

.026-.028

1.0

.039

1.55

.061

1.50

.059

19.6

4.40

0.08

0.63-0.68

.025-.027

1.0

.039

1.50

.059

1.50

.059

9.8

2.20

503095

—

0.66-0.71

.026-.028

1.0

.039

1.55

.061

1.50

.059

19.6

4.40

—

0.63-0.68

.025-.027

1.0

.039

1.50

.059

1.50

.059

9.8

2.20

OPERATION

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

hardened objects because damage can occur to the tool frame or crimp dies.

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. See Figure 1.

Crimping Terminals

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 into the proper nest opening

in the locator based on the wire gauge or

terminal type markings on the hand tool.

See Figure 3.

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

LOCATOR

IN DOWN

POSTION

PUSH ON THE

LOCATOR BUTTON

Figure 2

SQUEEZE

HANDLES

TOGETHER

HANDLE WILL

SPRING OPEN

Figure 1

Hand Crimp Tool for 2.00mm (.079") Pitch iGrid Wire-to-Board Crimp Terminal

Doc No: ATS-638192400 Release Date: 09-17-08 UNCONTROLLED COPY Page 3 of 7

Revision: B Revision Date: 02-04-20

Figure 5

TERMINAL

WIRE AGAINST THE

WIRE STOP

WIRE

WIRE STOP IS PART OF

THE LOCATOR

PRE-STRIPPED

WIRE

TERMINAL

5. Close the tool handle until the first ratchet position engages.

See Figure 4.

6. Insert the properly stripped wire through the terminal and

against the locator. See Figure 5.

7. Crimp the terminal by squeezing the tool handles until the

ratchet mechanism cycle has been completed. Release the

handles to open the jaws.

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.

10. On some large O.D. wires, it may not be possible to

insert the wire with the tool partially closed. Those

wires should be inserted with the hand tool in the

open position. Insert the wire above the terminal in

the punch and against the wire stop, and then close

the tool. See Figure 6.

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 available, actual crimp height measurements

may very slightly. An occasional destructive pull force test should be performed to check hand tool

crimp. Pull force value must exceed the minimum pull force specifications listed.

TERMINAL

Figure 6

WIRE

STOP

PARTIALLY

CLOSE HANDLE

TOOLING

PARTIALLY CLOSED

Figure 4

FIRST RATCHET

POSITION

OPEN

POSITION

Hand Crimp Tool for 2.00mm (.079") Pitch iGrid Wire-to-Board Crimp Terminal

Doc No: ATS-638192400 Release Date: 09-17-08 UNCONTROLLED COPY Page 4 of 7

Revision: B Revision Date: 02-04-20

Locator Replacement

Follow the steps below to remove and install the locator:

1. Open the hand crimp tool.

2. Squeeze gently on the lower area

shown in Figure 7A 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 7A.

4. To reinstall the new locator, make sure

the hand tool is in the open position.

5. Press the center of the locator 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 locator’s top hooks

into the hand tool’s 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.

Right- or Left-Handed Operation

This hand tool has an added feature in that it 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 Figures

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.

Figure 8

PUSH ON

HANDLE

JAWS OPEN

PULL OPEN

TOOLING

M3 BHCS

MAKE SURE

CENTER OF

LOCATOR IS IN

THE DOWN

POSITION

Figure 7B

SQUEEZE

HERE

SQUEEZE

HERE

LOCATOR

Figure 7A

TOP HOOKS

TOP SLOTS OF

HAND TOOL

LOWER TABS

MATCH

UP MARKS

FRONT

BACK

Figure 9

Hand Crimp Tool for 2.00mm (.079") Pitch iGrid Wire-to-Board Crimp Terminal

Doc No: ATS-638192400 Release Date: 09-17-08 UNCONTROLLED COPY Page 5 of 7

Revision: B Revision Date: 02-04-20

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 a 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. See Figure 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 the 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 Preload (See Figure 12)

This hand tool is factory preset to 25-45 pounds. 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. Hold the hand tool in the

palm of your hand as shown

in Figure 12. Using your index

finger, squeeze the link

toward the top of the hand

tool frame. This will release

the preload adjustment

wheel.

2. Rotate the setting wheel

counterclockwise (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.

Figure 12

SQUEEZE

THE LINK IN

THE HANDLE

HOLD THE HAND

TOOL IN POSITION

SETTING

WHEEL

RATCHET

RELEASE LEVER

LUBRICATION POINTS

(BOTH SIDES) LIGHT

OIL

(EVERY 3 MONTHS OR

5,000 CRIMPS)

Figure 10

RATCHET RELEASE

LEVER

Figure 11

Hand Crimp Tool for 2.00mm (.079") Pitch iGrid Wire-to-Board Crimp Terminal

Doc No: ATS-638192400 Release Date: 09-17-08 UNCONTROLLED COPY Page 6 of 7

Revision: B Revision Date: 02-04-20

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, Molex 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.

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 use 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.

Certification

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 website 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.

Hand Crimp Tool for 2.00mm (.079") Pitch iGrid Wire-to-Board Crimp Terminal

Doc No: ATS-638192400 Release Date: 09-17-08 UNCONTROLLED COPY Page 7 of 7

Revision: B Revision Date: 02-04-20

RATCHET

RELEASE LEVER

Figure 13

PARTS LIST

Item Number

Order Number

Description

Quantity

REF

63819-2400

Hand Crimp Tool

Figure 13

63819-2475

Locator Assembly

63810-0104

Spring, Return

63810-0105

Spring, Ratchet

Application Tooling Support

Phone: (402) 458-TOOL (8665)

E-Mail: [email protected]

Website: www.molex.com/applicationtooling

Molex is a registered trademark of Molex, LLC in the United States of America and may be registered in other countries; all other

trademarks listed herein belong to their respective owners.

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