molex 207129 Series User manual

Hand Crimp Tool for FIQD Terminals
Doc No: ATS-640160042 elease Date: 07-13-12 UNCONTROLLED COPY Page 1 of 4
evision: A evision Date: 07-13-12
ServiceGrade


Hand Crimp Tool
Application Tooling
Specification S eet Order No. 64016-0042
FEATURES


 A full cycle ratcheting hand tool ensures complete crimps


 Ergonomic soft grip handles for comfortable crimping


 For crimps conforming to industry standards such as UL requirements, use the 64001-4500
Premium Grade™ hand tool
SCOPE
Products: Fully insulated Quick Disconnect for 14-22 AWG and .Step Down Butt Splices for 10-12 to 14-16
AWG and 14-16 to 18-22 AWG.
Crimping Information:
Crimp the terminal and appropriate gauge wire in the specified profile.
Description Wire Size Pull Force UL486A
Minimum ▼
Tool Crimp Profile
Markings
AWG
mm
2
N
Lb.
22
-
18
16
-
14
12
-
10
Quick
Disconnects
10
5.00
356.0
80.0
X
12
3.30
311.5
70.0
X
14
2.00
222.6
50.0
X
16
1.30
133.5
30.0
X
18
0.80
89.0
20.0
X
20
0
.50
57.9
13.0
X
22
0.35
35.6
8.0
X
Splices
(Butt splices or
parallel splices)
10
5.00
178.0
40.00
X
12
3.30
155.7
35.00
X
14
2.00
111.2
25.00
X
16
1.30
66.8
15.00
X
18
0.80
44.5
10.00
X
20
0.50
44.5
10.00
X
22
0.35
35.6
8.0
X
▼
Pull force test samples should not have the wire insulation crimped.
Note:
An occasional, destructive, pull force test with the terminal and wire crimped should be performed to check hand tool
crimp. The pull force value must exceed the terminal’s minimum pull force specifications listed above. If values do
not exceed the minimum pull force when all instructions are followed then a new tool is required.

Hand Crimp Tool for FIQD Terminals
Doc No: ATS-640160042 elease Date: 07-13-12 UNCONTROLLED COPY Page 2 of 4
evision: A evision Date: 07-13-12
MALE QD TAPE OR
MOLDED REF
TAB
SIZE
CUT
-
OFF TAB
TERMINAL
STRIP
MWID OR MAX
INSULATION
DIAMETER
STRIP
LENGTH
WIRE STOP
BRUSH
TAB SIZE
FEMALE QD
Figure 1
TERMINAL WIRE
HAND TOOL
OPEN
Figure 2
TERMINAL
BARREL
CONDUCTOR ANVIL
TERMINAL
CONDUCTOR
PUNCH
WIRE
DEFINITION OF TERMS
The following illustrations are a
generic terminal. Some of the
terminals may look different and be
held in a different area of the
terminal.
OPERATION
CAUTION: Crimp only Molex
terminals listed above with this
tool. Do not crimp hardened
objects as damage can occur
to the tool.
WARNING: Make sure that the wire is DISCONNECTED from any power supply
Make sure work area is clean and dry and wear approved eye protection.
Open the hand tool by squeezing the handles together; at the end of the closing stroke the anti-backup ratchet will
release. elease the handles and the hand tool will open.
Crimping Terminals
1. Select the desired terminal listed in scope.
2. Holding the terminal at the contact end, place the terminal in the appropriate nest. See Figure 1.
Note: some terminals may have a large insulation or conductor grip; the grip may need to be slightly closed (by
hand) so it will fit between the open jaws.
3. Slowly close the handles of the tool until the terminal is held in place. If the handles are closed too far the
terminal will begin to crimp.
4. Place a pre-stripped wire into the terminal. For wire strip length, see terminal product specification on the
Molex website. Push the wire into the terminal barrel until it stops. See Figure 2.

Hand Crimp Tool for FIQD Terminals
Doc No: ATS-640160042 elease Date: 07-13-12 UNCONTROLLED COPY Page 3 of 4
evision: A evision Date: 07-13-12
Fig
ure
3
Figure 3
TERMINAL
BARREL
CONDUCTOR ANVIL
TERMINAL
WIRE STOP
C
ONDUCTOR
PUNCH
WIRE
5. While holding the wire in place, slowly close the handles of the tool. If a jam occurs, stop closing the tool and
release the anti-backup ratchet located on the top of the tool. Pushing it forward will release the jaws. See
Figure 4.
6. Continue to close the tool handles until the anti-backup ratchet releases. Allow the handles to open.
7. emove the crimped terminal from the tool.
8. Inspect the crimp for loose wire strands, missing crimp, or other damage. Any minor terminal bending may be
straightened by hand.
Crimping Butt Splices
1. Position the splice into the desired nest.
2. Partially close the tool to hold the splice in place.
3. Insert the properly stripped wire into the splice. The wires end
should butt against the tab in the terminal. See Figure 3.
4. Continue to close the tool handles until the anti-backup ratchet
releases. Allow the handles to open.
5. emove the crimped splice. Inspect for proper crimp location.
6. otate the butt splice terminal 180°, so that the opposite end of
splice is in the nest.
7. epeat steps 1 thru 4.
8. Inspect the crimp for loose wire strands, missing crimp, or other
damage. Any minor terminal bending may be straightened by hand.
Maintenance
It is recommended that each operator of the tool be made aware of, and responsible for, the following maintenance
steps:
1. emove 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.
Light oil (such as SAE30W oil) applied at the oil points, shown in
Figure 3, every 5,000 crimps or 3 months, is recommended.
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
If the tool ever becomes jammed in a partially closed position, DO NOT
force the handles open or closed. The tool will open by lifting the ratchet
release lever. See Figure 4.
Fig
ure
4
RATCHET RELEASE
LEVER

Hand Crimp Tool for FIQD Terminals
Doc No: ATS-640160042 elease Date: 07-13-12 UNCONTROLLED COPY Page 4 of 4
evision: A evision Date: 07-13-12
Tool Handle Preload
Tool handle preload should NOT require adjustment upon receipt of tool.
This hand tool is set from the factory to a preload that will fully close the tool jaws without excessive force from the
operator. Over the life of the tool the tool linkage can wear and handle preload force may decrease and preload
can be adjusted. It is the operator’s responsibility to periodically perform a tensile pull test on the crimped wire. If
the pull test value falls below the specification, the preload should be adjusted. If after adjustment, the crimp does
not meet the pull test value, then the tool should be replaced.
Warranty
This tool is for electrical terminal crimping purposes only. All tools are warranted to be free of manufacturing
defects for a period of 30 days. Should such a defect occur, the tool will be repaired or exchanged free of charge.
This 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.
ServiceGrade™ crimp hand tools are low cost tools used in field repair for a limited number of terminations. If a
high quality tool is required or a higher volume of terminations required, please purchase the corresponding
PremiumGrade™ crimp hand tool. A ServiceGrade™ crimp tool may or may not have a terminal locator and in
some case may need the locator removed to operate properly.
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. epetitive use of this tool should be avoided.
2. Insulated rubber handles are not protection against electrical shock. NEVER perform crimps on active
electrical circuits.
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 ServiceGrade™ hand tools but rather supplies the following guidelines for
customers to maintain their 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.
% When the hand tool is no longer capable of achieving minimum pull force, it should be replaced.
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