molex 207129 Series User manual

Tool Kit for 9.14mm (.360") Pitch Crimp Terminal.
Doc No: TS-6381956HM Release Date: 11-05-08 UNCONTROLLED COPY Page 1 of 8
Revision: D Revision Date: 02-14-17
CONDUCTOR
BRUSH
STRIP LENGTH
SEAM
CONDUCTOR
CRIMP
CUT
-
OFF
TAB
BELL MOUTH
BEND UP
TWISTING
ROLLING
BEND
DOWN
WIRE
Application Tooling
Sp cification Sh t
Tool Kit
Ord r No. 63819-5670
Hand Crimp Tool
Ord r No. 63819-5600
FEATURES
% 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
% Tool kits are easily installed into the Hand Crimp Tool or the 63816-0300 Power Crimp Head, which is installed
into the 63816-0200 (110 V) or the 63816-0250 (220 V) Battery Powered Tool
% Many different Tool kits can be used with a single Battery Powered Tool
% This tool is IPC/WHM - -620 Class 2 and RoHS compliant
SCOPE
Products: 9.14mm (.360") Pitch Crimp Terminal, Power Contact, 8 and (2)12 WG.
T rminal S ri s No.
T rminal Ord r No.

Availabl in R l form only
Wir Siz
Strip L ngth
AWG
mm²
mm
in
44262
44
262
-
430
4
44
262
-
440
4
44
262
-
450
4
44
262
-
460
4
8 and,
(2) 12
8.50 and
(2) 3.31 6.35 .25
44
262
-
433
4
44
262
-
443
4
44
262
-
453
4
44
262
-
463
4
173693 173693-4634
8 and
,
(2) 12
8.50 and
(2) 3.31 6.35 .25

The terminals above are reeled parts only. Customer to cut off terminal from reel 0.40mm (.016”) maximum.
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 4C

Tool Kit for 9.14mm (.360") Pitch Crimp Terminal.
Doc No: TS-6381956HM Release Date: 11-05-08 UNCONTROLLED COPY Page 2 of 8
Revision: D Revision Date: 02-14-17
SWING
LOCATOR
OPEN
PRESS DOWN
ON THE BRASS
PIVOT SHAFT
LIFT UP ON
THE LOCATOR
Figur
2
ANVILS
POWER
CRIMP
HEAD
Figur
1
PUNCHES
M4 X 10 LONG
BHCS
M4 X 18 LONG
BHCS
CONDITIONS:
fter crimping, the conductor profiles should measure the following (See notes below):
T rminal S ri s No. Wir Siz
Conductor
Pull Forc
Minimum Profil
Crimp H ight (R f)
Punch
Width (R f)
AWG
mm
2
mm
I
n.
mm
I
n.
N
Lb.
8
(2)12
44262
173693
8
8.50
3.95
-
4.05
.156
-
.160
5.90
.232
400
90.0
X
(2)
12
3.31
3.75
-
3.85
.148
-
.152
5.
9
0
.232
311
70.0
X
Tool Qualification Notes:
1. Pull force should be measured with no influence from the insulation crimp.
2. The above specifications are guidelines to an optimal crimp.
Not :
crimp height chart is provided with this manual as reference only. Due to the wide range of wires, strands,
insulation diameters and durometers, actual crimp height measurements may very slightly. n occasional
destructive pull force test should be preformed to check hand tool crimp. Pull force value must exceed the minimum
pull force specifications listed.
CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects as damage
can occur to the tool or die.
INSTALLATION
To install the Tool Kit into the Power Crimp Head, follow the steps below:
Anvils and Punch s Installation
1. Insert the nvils into the bottom slots of the nest. Install the M4 x 10 long BHCS, and tighten in place.
2. Insert the Punches into the top slots of the nest. Install the M4 x 18 long BHCS, and tighten in place. See
Figure 1.

Tool Kit for 9.14mm (.360") Pitch Crimp Terminal.
Doc No: TS-6381956HM Release Date: 11-05-08 UNCONTROLLED COPY Page 3 of 8
Revision: D Revision Date: 02-14-17
SWING OPEN
TERMINAL
PUSH HERE TO
OPEN WIRE STOP
LOCATOR
LOCATOR
TERMINAL
IN PLACE
Figur 3
LOCATOR LATCH
IN OPEN POSITION
HANDLE
OPEN
LOCATOR
CLOSED
Figur 4
TERMINAL
PUSH HERE TO
OPEN WIRE STOP
LOCK IN
UP RIGHT
POSITION
Figur 5
WIRE IN TERMINAL
JAWS
PARTIALLY
CLOSED
WIRE AGAINST
WIRE STOP
Locator Installation and R moval
Follow the steps below to install or replace the locator. See Figure 2.
To install th locator
1. Position the locator with the
hole over the brass pivot
shaft, and snap it into place.
To r mov th locator
1. Open the crimp hand tool.
2. Swing the existing locator
open and away from the
hand tool.
3. Firmly press down on the
brass pivot shaft with your
thumb while pulling the
locator up. Slip the locator
off of the top of the brass
pivot shaft.
OPERATION
Open the tool by squeezing the handles together. t the end of the closing stroke, the ratchet mechanism will
release the handles, and the hand tool will spring open.
Crimping T rminals
1. Select the desired terminal listed in the preceding charts.
2. Swing the terminal locator away from the crimp tool shown in Figure 3. Some terminals with large insulation
grips may interfere with the crimp tooling when swinging the locator into position. The terminal must then be
loaded into the locator in the closed crimp position. See Figure 4.

Tool Kit for 9.14mm (.360") Pitch Crimp Terminal.
Doc No: TS-6381956HM Release Date: 11-05-08 UNCONTROLLED COPY Page 4 of 8
Revision: D Revision Date: 02-14-17
3. Press down on the wire stop on the locator as shown in Figure 4. Insert the proper terminal into the proper
nest opening. Make sure when choosing the nest opening that it will correspond with the 8 or (2)12 profile on
the hand tool. See Figure 5.
4. Return the locator to its original position.
5. Insert the proper wire over the terminal. Gently touch the wire stop with the end of the wire.
See Figures 5 and 6.
6. Compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.
Release handles to open the jaws.
Not : The tamper-proof ratchet action will not release the tool until it has been fully closed.
7. Remove the crimped terminal from the
terminal locator by pressing down on the wire
stop and gently pulling on the wire. The
terminal locator can be in either position.
8. Visually inspect the crimped terminal for
proper crimp location.
For th Batt ry Pow r Tool:
1. Cycle the Battery Power Tool to crimp the
terminal to the wire.
2. Remove the crimped terminal from the
terminal locator by pressing down on the wire
stop and gently pulling on the wire. The
terminal locator can be in either position.
3. Visually inspect the crimped terminal for
proper crimp location.
Maint nanc
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 in the tool head are
protected with a thin coat of high-quality
machine oil. Do not oil excessively. This 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.
The use of light oil such as 30 weight automotive oil every 5,000 crimps or monthly will significantly enhance
the tool life and ensure a stable calibration. See Figure 7 or 7B for lubrication points.
4. Store the tool in a clean and dry area when not in use.
Figur 6
WIRE
CONDUCTOR ANVIL
LOCATOR
WIRES AGAINST
LOCATOR STOP
CONDUCTOR
PUNCH
TERMINAL
LUBRICATION
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY MONTH
OR
5,000 CRIMPS)
Figur 7A
Figur 7B

Tool Kit for 9.14mm (.360") Pitch Crimp Terminal.
Doc No: TS-6381956HM Release Date: 11-05-08 UNCONTROLLED COPY Page 5 of 8
Revision: D Revision Date: 02-14-17
Miscrimps or Jams for Crimp Hand Tools Only
(S Figur 10)
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 rotating the small slotted screw marked with an arrow. See Figure 10.
Warranty
This tool kit is for electrical terminal crimping purposes only. This tool kit is made of the best quality materials. ll
vital components are long life tested. ll 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 kit free of charge. This repair or exchange
will not be applicable to altered, misused or damaged tools.
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.
CAUTION: Repetitive use of this tool should be avoided.
C rtification
Molex does not certify or re-certify commercial grade 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 that 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 website 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 taken out of service and
replaced.
% This tool is very difficult to disassemble and reassemble. Customer repair is not recommended.

Tool Kit for 9.14mm (.360") Pitch Crimp Terminal.
Doc No: TS-6381956HM Release Date: 11-05-08 UNCONTROLLED COPY Page 6 of 8
Revision: D Revision Date: 02-14-17
The chart below shows all applications for this Tool Kit:
Tool Kit
Ord r No.
Tool
Ord r No.
Tool
D scription
Pow r
H ad
Ord r No.
Adapt r
D scription
Figur
No.
63819-5670
6381
0
-
1050
Hand Crimp Frame (Short)
N/
N/
8
6381
0
-
100
0
Hand Crimp Frame (Long)
N/
N/
8
63816
-
0200
Battery Power
Tool (110 V)
63816
-
0300
Power Crimp Head
9
63816
-
0250
Battery Power
Tool (220 V)
63816
-
0300
Power Crimp
Head
9
Applications for th
Tool Kit
Hand Crimp Tool
Batt ry Pow r d Tool
Figur
8
Figur
9
WARNING: NEVER operate service, install tool kits or adjust the Power Crimp Head without proper
instruction and without first reading and understanding the instructions in the proper manual or specification
sheet. See chart above for the correct manual or specification sheet.
WARNING: NEVER install tooling or service this tool while it is into any power source. Make sure the
power is turned off.
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.
HAND CRIMP
FRAME LONG
AND SHORT
TOOLING KIT
POWER
CRIMP
HEAD
LOCKING PINS
BATTERY
POWERED
TOOL
TOOLING KIT

Tool Kit for 9.14mm (.360") Pitch Crimp Terminal.
Doc No: TS-6381956HM Release Date: 11-05-08 UNCONTROLLED COPY Page 7 of 8
Revision: D Revision Date: 02-14-17
RATCHET
RELEASE SCREW
Figur
10
M4 X 8mm
LONG BHCS
2
1
3
M4 X 18mm
LONG BHCS
M4 X 10mm
LONG BHCS
2
4
WITH TOOL KIT
LOCATOR ONLY
HAND TOOL PARTS LIST
It m Numb r
Ord r Numb r
D scription
Quantity
1
63810
-
1000
Hand Crimp Frame (Long)
1
2
63819
-
56
70
Tool Kit with
Locator
1
3
63811
-
47
7
3
Locator Base
1
4
63819
-
56
75
Locator (only)
R
EF

Tool Kit for 9.14mm (.360") Pitch Crimp Terminal.
Doc No: TS-6381956HM Release Date: 11-05-08 UNCONTROLLED COPY Page 8 of 8
Revision: D Revision Date: 02-14-17
Figur 11
1
2
2
M
4
by
8
Long
BHCS
M
4
by
18
Long
BHCS
M
4
by
10
Long
BHCS
1
POWER HEAD PARTS LIST
It m
Ord r No
.
Engin ring No.
D scription
Quantity
1
63816-0300 63816-0300 Power Crimp Head 1
2
63819-5670 63819-5670 Tool Kit 1
Application Tooling Support
Phon : +1-402-458-TOOL (8665)
E-Mail: [email protected]
W bsit : www.molex.com/applicationtooling