molex 207129 Series User guide

Hand Crimp Tool For Cluster Block Terminal
Doc No: ATS-638250200 Release Date: 02-08-12 UNCONTROLLED COPY Page 1 of 7
Revision: B Revision Date: 09-03-20
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
CONDUCTOR
CRIMP HEIGHT
CUT-OFF TAB
SEAM
BELL MOUTH
WIRE
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: Cluster Block Terminal for 18 AWG UL Style 5048 Wire.
Terminal
Series No.
Terminal Order No.
Reel Form Only
Wire Size
Insulation Diameter
Strip Length
IPC/WHMA-A620 (1)
Terminal (2)
Insulation Range
AWG
mm²
mm
In.
mm
In.
mm
In.
57920
57920-6002
18
0.82
2.30-2.45
.091-.097
2.15-2.45
.085-.097
5.00-5.50
.197-.217
Note: This terminal will accommodate the UL Style 5048 wire.
(1) To achieve optimum IPC-A620 insulation crimps, use this insulation OD range.
(2) Overall insulation OD specification for terminal.
Customer to cut off terminal from reel: 0.40mm (.016”) maximum cut-off tab.
DEFINITION OF TERMS
TYPE 4D
Order Number
63825-0200

Hand Crimp Tool For Cluster Block Terminal
Doc No: ATS-638250200 Release Date: 02-08-12 UNCONTROLLED COPY Page 2 of 7
Revision: B Revision Date: 09-03-20
▲Insulation Crimp Note
Due to the terminal’s insulation grip design or insulation
diameter range, this tool uses overlap form geometry in
the insulation punch. This produces an overlap insulation
crimp (A-620-compliant). Although 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.
CRIMP SPECIFICATIONS
After crimping, the crimp profiles should measure the following:
Terminal Series No.
Bell Mouth
Conductor Brush
mm
In.
mm
In.
57920
0.20-0.50
.008-.020
0.50-1.00
.020-.039
Terminal Series No.
Bend Up
Bend Down
Twist
Roll
Seam
Degree
Degree
57920
3
3
3
5
Seam shall not be open
and no wire allowed out
of the crimping area
Terminal
Series No.
Wire Size
Conductor Crimp
Insulation Crimp
Pull Force
Minimum
Height
Width (Ref)
Height Maximum
Width Maximum
AWG
mm2
mm
In.
mm
In.
mm
In.
mm
In.
N
Lb.
57920
18
0.82
1.45-1.55
.057-.061
2.40
.095
3.80
.150
3.50
.138
107.8
24.25
CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects
as damage can occur to the tool or die.
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 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.
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
WIRE
OVERLAP
INSULATION
CRIMP

Hand Crimp Tool For Cluster Block Terminal
Doc No: ATS-638250200 Release Date: 02-08-12 UNCONTROLLED COPY Page 3 of 7
Revision: B Revision Date: 09-03-20
PRE-STRIPPED WIRE
TERMINAL
Figure 5
TERMINAL
WIRE AGAINST
THE WIRE
STOP
WIRE
WIRE STOP IS
PART OF
THE LOCATOR
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. See Figure 1.
Crimping Terminals
1. Select the desired terminal listed in the preceding
charts.
2. Make sure the locator is attached behind the lower
tooling and is above all the surface of the anvils.
3. The spring-loaded wire stop should be clear of the
locator’s cavity. If not, push up on the red tab to
move the wire stop out of the way while inserting the
terminal. See Figure 3.
4. Load the terminal into the proper nest opening in the
locator based on the wire gauge or terminal type
markings on the hand tooling. See Figure 3.
5. Partially close the tool handle until the first ratchet position
engages and holds the terminal in place. See Figure 4.
6. Insert the properly stripped wire through the terminal and against
the wire stop. 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.
8. Remove the crimped terminal from the terminal locator by pulling
on the wire.
Note: The tamper-proof ratchet action will not release the tool until it has been fully closed.
TERMINAL
Figure 3
TERMINAL
PUSH UP
ON THE
RED TAB
PARTIALLY
CLOSE HANDLE
TOOLING
PARTIALLY
CLOSED
Figure 4
FIRST
RATCHET
POSITION
OPEN
POSITION
SQUEEZE
HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Figure 1
LOCATOR
IN DOWN
POSTION
RED
TAB
Figure 2

Hand Crimp Tool For Cluster Block Terminal
Doc No: ATS-638250200 Release Date: 02-08-12 UNCONTROLLED COPY Page 4 of 7
Revision: B Revision Date: 09-03-20
MATCH
UP MARKS
FRONT
BACK
Figure 9
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.
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 hand crimp 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. 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.
6. 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 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. 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.
3. Do the same thing with the lower tooling and tighten
the M3 screws. Be sure the small markings line up.
4. Reinstall the locator by following the instructions in the
locator replacement section.
TERMINAL
Figure 6
WIRE
WIRE
STOP
Figure 8
PUSH ON
HANDLE
JAWS OPEN
PULL OPEN
TOOLING
TOOLING
M3 BHCS
SQUEEZE
HERE
SQUEEZE
HERE
LOCATOR
Figure 7
TOP HOOKS
TOP SLOTS OF
HAND TOOL
LOWER TABS

Hand Crimp Tool For Cluster Block Terminal
Doc No: ATS-638250200 Release Date: 02-08-12 UNCONTROLLED COPY Page 5 of 7
Revision: B Revision Date: 09-03-20
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 the hand tool, particularly from the 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)
Hand tool frame preload is factory preset to ensure crimp quality. 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. Open the hand tool.
2. Close the handle 2 ratchet clicks.
3. 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.
4. 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).
5. Release the link to lock the setting
wheel in place.
6. Check the crimp specifications or conduct a pull test after tool handle preload force is
adjusted.
RATCHET RELEASE
LEVER
Figure 11
LUBRICATION
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY 3
MONTHS OR
5,000 CRIMPS)
Figure 10
HANDLE CLOSED
2 CLICKS
SQUEEZE THE
LINK IN THE
HANDLE
HOLD THE HAND
TOOL IN POSITION
SETTING WHEEL
Figure 12

Hand Crimp Tool For Cluster Block Terminal
Doc No: ATS-638250200 Release Date: 02-08-12 UNCONTROLLED COPY Page 6 of 7
Revision: B Revision Date: 09-03-20
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 should be 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 Cluster Block Terminal
Doc No: ATS-638250200 Release Date: 02-08-12 UNCONTROLLED COPY Page 7 of 7
Revision: B Revision Date: 09-03-20
RATCHET
RELEASE LEVER
2
Figure 13
1
3
PARTS LIST
Item Number
Order Number
Description
Quantity
REF
63825-0200
Hand Crimp Tool
Figure 13
1
63825-0275
Locator Assembly
1
2
63810-0104
Spring, Return
1
3
63810-0105
Spring, Ratchet
1
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.