molex 207129 Series User manual

Hand Crimp Tool 1.25mm (.049”) / 2.00 (.078”) Wire-to-Board Crimp Terminal
oc No: ATS-638253300 Release ate: 06-25-12 UNCONTROLLED COPY Page 1 of 5
Revision: A Revision ate: 06-25-12
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
BELL MOUTH
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
HAND CRIMP
TOOL
Application Tooling
Specification S eet Order No. 63825-3300
FEATURES
% A full cycle ratcheting hand tool ensures complete crimps
% This tool is designed to be used with reeled product due to the small size of the connector
% This tool is designed for prototype work only and is not designed for production
% The reeled product must be cut into 5-inch strips to be processed in this hand tool
% This tool is IPC/WHMA A-620 Class 2 compliant as indicated
% This tool is RoHS compliant, however RoHS compliant is not required
SCOPE
Products: 1.25mm (.049”) / 2.00 (.078”) Wire-to-Board Crimp Terminal, 28-30 AWG.
Terminal
Series No.
Terminal Order No.
Reel Form Only
Wire Size Insulation Diameter Strip Lengt
IPC/WHMA-A620 (1) Terminal (2)
AWG mm² mm In. mm In. mm In.
104466 104466-8002 ●28-30 0.08-0.05 0.80-1.00 .032-.039 0.80-1.00 .032-.039 1.40-1.90 .055-.075
1. To achieve optimum IPC-A620 insulation crimps, use this insulation O range.
2. Overall insulation O specification for terminal.
Customer to cut off terminal from reel: 0.15mm (.006”) maximum Cut-off Tab.
● Requires Separate Insulation Punch for 28 and 30 AWG. See Page 6.
DEFINITION OF TERMS
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the
scope.
TYPE 7

Hand Crimp Tool 1.25mm (.049”) / 2.00 (.078”) Wire-to-Board Crimp Terminal
oc No: ATS-638253300 Release ate: 06-25-12 UNCONTROLLED COPY Page 2 of 5
Revision: A Revision ate: 06-25-12
Insulation Crimp Form
This crimp terminal is designed for miniaturization; therefore, each dimension of insulation crimp portion appears
small as compared to the terminal material thickness. In order to avoid insulation piercing the crimp forms by the
insulation barrel, coining is provided inside of the insulation barrel. For this reason, various crimp forms will occur at
the tip of the insulation crimp barrel shown in the figure below.
These crimp forms maybe changed completely by a small change in the wire, insulation punch, or terminal.
These crimp forms are satisfactory for original function of the insulation crimp portion and it is confirmed that all of
these forms below are acceptable insulation crimps.
CONDITIONS:
After crimping, the conductor profiles should measure the following.
Terminal
Series No
Wire Size Conductor Crimp (Ref) Insulation Crimp (Ref) Pull Force
Minimum
Heig t Widt Heig t Widt
AWG mm2 mm In. mm In. mm In. mm In. N Lb.
104466 28 0.08 0.55-0.60 .022-.024 0.80 .032 1.15 .045 1.00 .039 9.8 2.20
104466 30 0.05 0.50-0.55 .020-.022 0.80 .032 1.15 .045 1.00 .039 4.9 1.10
OPERATION
CAUTION: Install only Molex terminals listed above with this tool. o not crimp hardened objects as
damage can occur to the tool or die.
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. Cut a strip of the terminals approximately 5.0” off the reel. Position the terminal strip into the slot of the carrier
guide with terminals facing forward.
3. Push the strip in until it locks into the (2) detent in the carrier guide and a terminal is centered with the punch
nest. See Figure 1.
4. Partially close the jaws of the hand tool by squeezing the handles until you hear the fist click of the ratchet.
5. From the top of the hand tool insert the pre-stripped wire into the terminal.
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. Lift up the crimped terminal from the terminal locator.
8. Visually inspect the crimped terminal for proper crimp location.

Hand Crimp Tool 1.25mm (.049”) / 2.00 (.078”) Wire-to-Board Crimp Terminal
oc No: ATS-638253300 Release ate: 06-25-12 UNCONTROLLED COPY Page 3 of 5
Revision: A Revision ate: 06-25-12
9. If crimping more wires, advance the
terminal strip by (1) detent until the
terminal is centered with the punch nest.
10. Repeat this procedure until all the desired
terminals are crimped on the strip.
Maintenance
It is recommended that each operator of the
tool be made aware of, and responsible for,
the following maintenance steps:
1. Remove the plastic handles from the
metal tool frame by removing the screws
and remove dust, moisture, and other
contaminants with a clean brush, or soft,
lint free cloth.
2. o 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. o 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. Light oil used at the pivot 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.
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 up. See Figure 2.
How to Adjust Tool 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 the 2mm locking screw from the numbered adjusting wheel using a screw driver. See Figure 3.
2. Using the same screw driver turn the adjustment wheel to the next highest number.
Note: The uneven numbers are in clockwise (CW) direction and the even numbers are counter clockwise
(CCW).
3. Example: If the preload is set at number 5, then to increase the preload, turn the adjustment wheel until the 6th
position is located over the 2mm locking screw tapped hole. If it is necessary to move to the 7th position, then
the adjustment wheel should be turned counter clockwise (CCW) until the 7th position is over the 2mm locking
screw tapped hole.
SLIDE WIRE
INTO THE
PUNCH NEST
Figure 1
LOCKS IN THE
TERMIAL STRIP SLIDE TERMINAL
STRIP INTO THE
CARRIER GUIDE
CRIMP TOOL OPEN
WIRE
RATCHET
RELEASE LEVER
Figure 2

Hand Crimp Tool 1.25mm (.049”) / 2.00 (.078”) Wire-to-Board Crimp Terminal
oc No: ATS-638253300 Release ate: 06-25-12 UNCONTROLLED COPY Page 4 of 5
Revision: A Revision ate: 06-25-12
NUMBERED ADJUSTMENT
WHEEL
Figure 3 TURN CLOCKWISE (CW) OR
COUNTER CLOCKWISE (CCW)
TO ADJUST THE PRE-LOAD
TURN WITH A SMALL
SCREW DRIVER
REMOVE THE LOCKING 2MM SCREW
4. Replace the 2mm locking screw, aligning the nearest notch in the setting wheel to locking screw.
5. Check the crimp specifications and conduct a pull test after tool handle preload force is adjusted. Repeat
these steps until the desired result is obtained.
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.
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, prototyping, 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. 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.

Hand Crimp Tool 1.25mm (.049”) / 2.00 (.078”) Wire-to-Board Crimp Terminal
oc No: ATS-638253300 Release ate: 06-25-12 UNCONTROLLED COPY Page 5 of 5
Revision: A Revision ate: 06-25-12
2
Figure 4
1
3
6
5
4
4
8
7
FOR
30 AWG
WIRE
10
9
FOR
28 AWG
WIRE
PARTS LIST
Item Order No Description Use Only Wit Wire AWG Quantity
REF 63825-3300 Hand Crimp Tool --- Figure 4
1 11-11-0320 Spring (Ratchet) All 1
2 63600-0479 Spring (Main) All 1
3 69008-0972 Adjuster Wheel All 1
4 63825-3301 Conductor Punch All 1
5 63825-3302 Insulation Punch (Marked 28) 28 AWG 1
6 63825-3303 Insulation Punch (Marked 30) 30 AWG 1
7 63825-3304 Combination Anvil All 1
8 63825-3305 Carrier Guide All 1
9 63825-3370 28 AWG Wire Tool Kit Includes 1 each of Item No. 4 and 5 1
10 63825-3380 30 AWG Wire Tool Kit Includes 1 each of Item No. 4 and 6
(3 included with hand tool) 1
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