molex 207129 Series User manual

Tool Kit for MX150L™ Crimp Terminals
Doc No: ATS-6 81154HM Release Date: 11-05-08 UNCONTROLLED COPY Page 1 of 8
Revision: C Revision Date: 09-08-10
CONDUCTOR
BRUSH
STRIP LENGTH
SEAM
CONDUCTOR
CRIMP
CUT-OFF
TAB
GAP
BELL MOUTH BEND UP
TWISTING
ROLLING
BEND
DOWN
WIRE
WIRE
ANGLE
Application Tooling
Sp cification Sh t
Tool Kit
Ord r No. 63811-5470
Hand Crimp Tool
Ord r No. 63811-5400
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
 Tool kits are easily installed into the Hand Crimp Tool or the 6 816-0 00 Power Crimp Head which is installed
into the 6 816-0200 (110 V) or the 6 816-0250 (220 V) Battery Powered Tool.
 Many different Tool kits can be used with a single Battery Powered Tool.
 This tool is IPC/WHMA-A-620 Class 2 and RoHS compliant.
SCOPE
Products: MX150L™ 8 AWG
T rminal S ri s No.
T rminal Ord r No. Wir Siz Insulation Diam t r Strip L ngth
Loos Pi c 

R l AWG mm² mm In. mm In.
194 1 194 1-0017 194 1-0015 8 8. 7 6. 0-6.70 .248-.264 8.90-9.40 . 50-. 70
194 4 194 4-0004 194 4-0002 8 8. 7 6. 0-6.70 .248-.264 8.90-9.40 . 50-. 70
Customer to cut off terminal from reel: 0.50mm (.020”) maximum Cut-off Tab.
DEFINITION OF TERMS
TYPE 4C

Tool Kit for MX150L™ Crimp Terminals
Doc No: ATS-6 81154HM Release Date: 11-05-08 UNCONTROLLED COPY Page 2 of 8
Revision: C Revision Date: 09-08-10
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
CRIMP SPECIFICATION
T rminal
S ri s No.
B ll Mouth B nd up B nd down Twist Roll Conductor
Brush Wir Angl
mm In. D gr D gr mm In. D gr
194 1 0.25-1.25 .010-.049 2 4 8 0.10-0.50 .004-.020 5° Max
194 4 0.25-1.25 .010-.049 2 4 8 0.10-0.50 .004-.020 5° Max
S am: Seam shall not be open and no wire allowed out of the crimping area.
CONDITIONS:
After crimping, the conductor profiles should measure the following (See notes below).
T rminal
S ri s No.
Wir Siz Conductor Crimp
H ight (REF)
Conductor Crimp
Width (R f)
Pull Forc
Minimum Gap
AWG mm2 mm In. mm In. N Lb. mm In.
194 1 8 8. 7 .07- .20 .121-.126 4.70-4.90 .185-.19 400.5 90.0 . 0-4.06 .1 0-.160
194 4 8 8. 7 .07- .20 .121-.126 4.70-4.90 .185-.19 400.5 90.0 . 0-4.06 .1 0-.160
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.
Not :
A 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. An 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

Tool Kit for MX150L™ Crimp Terminals
Doc No: ATS-6 81154HM Release Date: 11-05-08 UNCONTROLLED COPY Page of 8
Revision: C Revision Date: 09-08-10
HANDLE
OPEN
LOCK IN
UP RIGHT
POSITION
LOCATOR
CLOSED
Figur 4
TERMINAL
PUSH HERE TO
OPEN WIRE STOP
JAWS
PARTIALLY
CLOSED
Figur 5
WIRE IN TERMINAL
WIRE AGAINST
WIRE STOP
To install the Tool Kit into the Power Crimp Head follow the steps below:
Anvils and Punch s Installation
1. Insert the Anvils 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.
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.
. Firmly press down on the brass pivot shaft with
your thumb, while pulling the locator up. Slip the
locator off the top of the brass pivot shaft.
OPERATION
CAUTION: Install only Molex terminals listed above with this tool. Do 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 T rminals
1. Select the desired terminal listed in the preceding charts.
2. Turn the Locator Lock Latch down to unlock.
Figur 3
LATCH LOCKED
LATCH UNLOCKED

Tool Kit for MX150L™ Crimp Terminals
Doc No: ATS-6 81154HM Release Date: 11-05-08 UNCONTROLLED COPY Page 4 of 8
Revision: C Revision Date: 09-08-10
. Swing the terminal locator away from the crimp tool
shown in Figure . 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.
4. Press down on the wire stop on the locator as
shown in Figure . Insert the proper terminal into
the proper nest opening. Make sure when choosing
the nest opening, it will correspond with the 8 profile
on the hand tool.
5. Return the locator to its original position.
6. Turn the Locator Lock Latch up to lock. Make sure
that the terminal is visually centered over the punch.
7. Insert the proper wire over the terminal.
8. Gently touch the wire stop with the end of the wire. See Figure 5 and 6.
9. Compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.
Release handles to open the jaws.
10. 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.
11. Visually inspect the crimped terminal for proper crimp location.
Not : The tamper proof ratchet action will not release the tool until it has been fully closed.
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.
. 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 soft, lint-free cloth.
2. Do not use any abrasive materials that could damage the tool.
. 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 a
light oil, such as 0 weight automotive oil, every 5,000 crimps or monthly, will significantly enhance the tool life
and ensure a stable calibration. See Figure 7A or 7B for lubrication points.
LUBRICATION
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY MONTH
OR
5,000 CRIMPS)
Figur 7A
Figur 7B
LOCATOR ANVIL
TERMINAL
WIRE
PUNCH
WIRE AGAINST STOP
Figur 6
WIRE STOP

Tool Kit for MX150L™ Crimp Terminals
Doc No: ATS-6 81154HM Release Date: 11-05-08 UNCONTROLLED COPY Page 5 of 8
Revision: C Revision Date: 09-08-10
4. Store the tool in a clean and dry area when not in use.
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. All
vital components are long life tested. All tools are warranted to be free of manufacturing defects for a period of 0
days. Should such a defect occur, we will repair or exchange the tool kit free of charge. This repair or exchange
will not be applicable to altered, misused, or damaged tools.
Hand held crimping tools are intended for low volume, prototyping, or repair requirements only.
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. Repetitive use of this tool should be avoided.
2. Insulated rubber handles are not protection against electrical shock.
. 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, 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 taken out of service and
replaced.
% This tool is very difficult to disassemble and reassemble. Customer repair is not recommended.

Tool Kit for MX150L™ Crimp Terminals
Doc No: ATS-6 81154HM Release Date: 11-05-08 UNCONTROLLED COPY Page 6 of 8
Revision: C Revision Date: 09-08-10
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.
6 811-5470
6 810-1050 Hand Crimp Frame (Short) N/A N/A 8
6 810-1000 Hand Crimp Frame (Long) N/A N/A 8
6 816-0200 Battery Power Tool (110 V) 6 816-0 00 Power Crimp Head 9
6 816-0250 Battery Power Tool (220 V) 6 816-0 00 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.
POWER
CRIMP
HEAD
LOCKING PINS
BATTERY
POWERED
TOOL
TOOLING KIT
HAND CRIMP
FRAME LONG
AND SHORT
TOOLING KIT

Tool Kit for MX150L™ Crimp Terminals
Doc No: ATS-6 81154HM Release Date: 11-05-08 UNCONTROLLED COPY Page 7 of 8
Revision: C Revision Date: 09-08-10
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 6 810-1000 Hand Crimp Frame (Long) 1
2 6 811-5470 Tool Kit with Locator 1
6 811-477 Locator Base 1
4 6 811-5475 Locator REF

Tool Kit for MX150L™ Crimp Terminals
Doc No: ATS-6 81154HM Release Date: 11-05-08 UNCONTROLLED COPY Page 8 of 8
Revision: C Revision Date: 09-08-10
Figur 11
1
2
2
M4 by 8 Long
BHCS
M4 by 18 Long
BHCS
M4 by 10 Long
BHCS
1
POWER HEAD PARTS LIST
It m Ord r No Engin ring No. D scription Quantity
1
6 816-0 00 6 816-0 00 Power Crimp Head 1
2
6 811-5470 6 811-5470 Tool Kit 1
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