molex 207129 Series User manual

Hand Crimp Tool for Ulti-Mate™ Commercial Micro D Crimp Terminals
Doc No: ATS-63811 8HM Release Date: 0 -0 -05 UNCONTROLLED COPY Page 1 of 7
Revision: D Revision Date: 07-26-10
Application Tooling
Specification Sheet
Modular Crimp ead
Order No. 63811-4870
and Crimp Tool
Order No. 63811-4800
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
% A-620 Class 3 compliant and RoHS compliant
% Modular Crimp Head is removable and can be use in the Air Powered Tool Order No.63816-0100,
accompanied by Air Powered Crimp Adapter (Order No. 63816-0700).
% Can also be used in the Battery Powered Tool Order No.63816-0200 (110 V) or 63816-0250 (220 V),
accompanied by Battery Powered Crimp Adapter (Order No. 63816-0600).
SCOPE
Products: 1.27mm (.050") Pitch Ulti-Mate™ Commercial Micro D, 26-28 AWG.
Terminal
Series No.
Terminal Order No. Wire Size Insulation Diameter Strip Length
Loose Piece 

Reel AWG mm² mm In. mm In.
83000
83000-0083 83000-9502 83000-9558
26 0.12 0.89-1.02 .035-.0 0 1.30-1.60 .051-.063
83000-0106 83000-9503 83000-9559
83000-0110 83000-95 7 83000-9561
83000-9560 83000-9550 83000-9562
83000-9557
83000-0083 83000-9502 83000-9558
28 0.08 0.50-1.00 .020-.039 1.30-1.60 .051-.063
83000-0106 83000-9503 83000-9559
83000-0110 83000-95 7 83000-9561
83000-9560 83000-9550 83000-9562
83000-9557
 Customer to cut off terminal from reel: 0.15mm (.006”) maximum Cut-Off Tab.
Insulation diameters below 0.63mm (.029”) may not provide A-620 Class 3 compliant insulation crimps.
Customer to determine suitability for these applications.
TYPE 4A

Hand Crimp Tool for Ulti-Mate™ Commercial Micro D Crimp Terminals
Doc No: ATS-63811 8HM Release Date: 0 -0 -05 UNCONTROLLED COPY Page 2 of 7
Revision: D Revision Date: 07-26-10
INSULATION
CRIMP
BRUS
STRIP
LENGT
BELL
MOUT
CRIMP EIG T
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
CUT-OFF
TAB
SEAM
DEFINITION OF TERMS
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the scope.
CRIMP SPECIFICATION
After crimping, the conductor profile should measure the following.
Terminal Order No. Wire Size Tool Wire
Insulation Diameter
Crimp Conductor (REF)
eight Width
AWG mm2 mm In. mm In. mm In.
83000-0083, 83000-9502
83000-9503, 83000-9550
26 0.12 0.89-1.02 .035-.0 0 0.5 -0.58 .021-.023 0.81 .031
28 0.08 0.76-1.00 .030-.039 0. 1-0. 6 .016-.018 0.81 .031
28 0.08 0.50-0.75 .020-.029 0. 1-0. 6 .016-.018 0.81 .031
83000-0106
83000-95 7
83000-9557
26 0.12 0.89-1.02 .035-.0 0 0.5 -0.58 .021-.023 0.81 .031
28 0.08 0.76-1.00 .030-.039 0. 1-0. 6 .016-.018 0.81 .031
28 0.08 0.50-0.75 .020-.029 0. 1-0. 6 .016-.018 0.81 .031
83000-0110
83000-9558
83000-9559
26 0.12 0.89-1.02 .035-.0 0 0.5 -0.58 .021-.023 0.81 .031
28 0.08 0.76-1.00 .030-.039 0. 1-0. 6 .016-.018 0.81 .031
28 0.08 0.50-0.75 .020-.029 0. 1-0. 6 .016-.018 0.81 .031
83000-9560
83000-9561
83000-9562
26 0.12 0.89-1.02 .035-.0 0 0.5 -0.58 .021-.023 0.81 .031
28 0.08 0.76-1.00 .030-.039 0. 1-0. 6 .016-.018 0.81 .031
28 0.08 0.50-0.75 .020-.029 0. 1-0. 6 .016-.018 0.81 .031
Terminal
Order No.
Wire Size Pull Force Minimum
Profile
Locator Color 26 AWG
28 AWG
Large Insulation
28 AWG
Small Insulation
AWG mm2 N Lb. A B C
83000-0083, 83000-9502
83000-9503, 83000-9550
26 0.12 13. 3.00 X
Blue 28 0.08 9.8 2.20 X
28 0.08 9.8 2.20 X
83000-0106
83000-95 7
83000-9557
26 0.12 13. 3.00 X
Red 28 0.08 9.8 2.20 X
28 0.08 9.8 2.20 X
83000-0110
83000-9558
83000-9559
26 0.12 13. 3.00 X
Yellow 28 0.08 9.8 2.20 X
28 0.08 9.8 2.20 X
83000-9560
83000-9561
83000-9562
26 0.12 13. 3.00 X
Yellow 28 0.08 9.8 2.20 X
28 0.08 9.8 2.20 X

Hand Crimp Tool for Ulti-Mate™ Commercial Micro D Crimp Terminals
Doc No: ATS-63811 8HM Release Date: 0 -0 -05 UNCONTROLLED COPY Page 3 of 7
Revision: D Revision Date: 07-26-10
INSULATION
OF T E WIRE
STOPS ERE INSULATION
PUNC
TERMINAL
LOCATOR
INSULATION
STOP
Figure 2
CONDUCTOR
PUNC
Figure 3
PUNC
TERMINAL
LOCATOR
INSULATION
STOP
ANVIL
INSULATION
OF T E WIRE
STOPS ERE
Τ
ΤΤ
Τ 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.
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. With the hand tool in the open position, pivot the terminal
locator open. See Figure 1.
2. Insert the terminal fully into the correct profile until the terminal is fully seated and stops.
3. Gently pivot the locator closed.
. Slide the pre-stripped wire into the insulation stop. See Figure 2. The wire strands pass thru the
insulation stop slot, while the end of the insulation touches the stop. Be sure to hold the wire in place until
the terminal is fully crimped. See Figure 3.
5. Close the tool until the ratchet releases.
6. Carefully remove the crimped terminal.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
Note: To maintain good brush control and a consistent bell mouth the crimping instructions must be followed.
TERMINAL
SEATED IN
LOCATOR
LOCATOR
OPEN
Figure 1
AND TOOL
OPEN

Hand Crimp Tool for Ulti-Mate™ Commercial Micro D Crimp Terminals
Doc No: ATS-63811 8HM Release Date: 0 -0 -05 UNCONTROLLED COPY Page of 7
Revision: D Revision Date: 07-26-10
INCORRECT
Figure 5
CORRECT INCORRECT
Terminal Locator Replacement/Change Over
This section describes the procedure for changing locators.
Removal
1. With the tool in the open position, pivot the terminal locator outward.
2. Remove the M BHCS. See Figure .
Installation
1. Place the proper locator, (See Chart on page 2), on the hand tool.
Install the M BHCS. See Figure .
2. Tighten the screw enough to hold the locator. Make sure the
locator can still float freely with hand pressure.
3. Insert the proper terminal fully into the correct profile slot until the terminal is fully seated and stops. Then
gently pivot the locator closed.
. With hand pressure, slowly slide the locator to the correct position. See Figure 5.
5. Gently pivot the locator open without disturbing the location.
6. Hold the locator firmly in place and slowly tighten the M BHCS.
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 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.
. 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 lifting the ratchet release lever. See Figure 9.
M4 B CS
PIVOT LOCATOR
Figure 4

Hand Crimp Tool for Ulti-Mate™ Commercial Micro D Crimp Terminals
Doc No: ATS-63811 8HM Release Date: 0 -0 -05 UNCONTROLLED COPY Page 5 of 7
Revision: D Revision Date: 07-26-10
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: Repetitive use of this tool should be avoided.
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.
. Use only the Molex terminals specified for crimping with this tool.
Notes:
1. This tool should only be used for the terminals and wire gauges specified on this sheet.
2. This tool is not adjustable for crimp height; however crimp force is adjustable (See instructions above).
Variations in tools, terminals, wire stranding, and insulation types may affect crimp height.
3. This tool is intended for standard conductor sizes. It may not give a good insulation crimp support for all
insulation sizes.
. Molex does not repair hand tools (see warranty above). The replacement parts listed are the only parts
available for repair. If the handles or crimp tooling is damaged or worn, a new tool must be purchased.
5. Pull force should be used as the final criteria for an acceptable crimp. Pull force is measured with no
influence from the insulation crimp. The insulation should be stripped long (1/2 in.) so the insulation grips
on the terminal do not grip the wire insulation or the conductor. Refer to Molex Quality Crimping
Handbook 63800-0029 for additional information on crimping and crimp testing.
6. Molex does not certify crimp hand tools.
CAUTION: Molex crimp specifications are valid only when used with Molex terminals and tooling.

Hand Crimp Tool for Ulti-Mate™ Commercial Micro D Crimp Terminals
Doc No: ATS-63811 8HM Release Date: 0 -0 -05 UNCONTROLLED COPY Page 6 of 7
Revision: D Revision Date: 07-26-10
MODULAR
CRIMP
EAD
BATTERY
POWER
CRIMP
ADAPTER
LOCKING
PINS
LOCKING PINS
BATTERY
POWERED
TOOL
AIR
POWER
TOOL
MODULAR
CRIMP EAD
LOCKING
PINS
LOCKING
PINS
AIR POWER
CRIMP
ADAPTER
Applications for the Modular Crimp ead
WARNING: NEVER operate, service, install, or adjust this Modular Crimp Head without proper instruction
and without first reading and understanding the instructions in the proper Manual or Specification Sheet.
See Chart below for the correct Manual or Specification Sheet.
WARNING: NEVER install tooling or service this tool while it is into any power source. Disconnect the
power by unplugging or turn off the Actuator from its power source.
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.
The chart below shows all applications for this Modular Crimp Head.
Modular Crimp ead
Order No.
Tool
Order no.
Tool
Description
Adapter
Order No.
Adapter
Description
Figure
No.
63811- 870
63816-0000 Hand Crimp Frame (Short) N/A N/A 6
63816-0050 Hand Crimp Frame (Long) N/A N/A 6
63816-0200 Battery Power Tool (110 V) 63816-0600 Battery Power Crimp Adapter 7
63816-0250 Battery Power Tool (220 V) 63816-0600 Battery Power Crimp Adapter 7
63816-0100 Air Power Tool 63816-0700 Air Power Crimp Adapter 8
Applications for the Modular Crimp ead
and Crimp Tool Battery Powered Tool Air Powered Tool
Figure 6 Figure 7 Figure 8
MODULAR
CRIMP
EAD
LOCKING
PINS
AND CRIMP
FRAME LONG
OR S ORT

Hand Crimp Tool for Ulti-Mate™ Commercial Micro D Crimp Terminals
Doc No: ATS-63811 8HM Release Date: 0 -0 -05 UNCONTROLLED COPY Page 7 of 7
Revision: D Revision Date: 07-26-10
RATC ET
RELEASE LEVER
ANDLE
SPRING
CRIMPING
SPRING (2)
LOCATOR
2
1
4
Figure 9
M4 X 6mm
LONG B CS
3 5
6
8
7
PARTS LIST
and Crimp Tool 63811-4800
Item Order Number Description Quantity
1 63811- 870 Modular Crimp Head 1
2 63816-0000 Hand Crimp Frame (Short) 1
3 63811- 875 Locator-Blue 1
63811- 876 Locator-Red 1
5 63811- 877 Locator-Yellow 1
6 63816-0001 Locking Pin 2
7 63600-0525 Handle Spring 1
8 63600-0520 Crimping Spring 2
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