molex 207129 Series User manual

Hand Crimp Tool For Milli-Grid™ Crimp Terminal
Doc No: ATS-638236700 elease Date: 07-19-11 UNCONTROLLED COPY Page 1 of 8
evision: B evision Date: 09-11-12
INSULATION CRIMP
BRUSH
STRIP LENGTH
BELL MOUTH
SEAM
BEND DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP HEIGHT
TWISTING
CUT-OFF TAB
HAND CRIMP
TOOL
Application Tooling
Sp cification Sh t Ord r No. 63823-6700
FEATURES
 A full cycle ratcheting hand tool ensures complete crimps
 Ergonomic soft grip handles for comfortable crimping
 A precision user-friendly terminal locator wire stop holds terminals in the proper crimping position
 ight and Left handed applications
 This tool is IPC/WHMA A-620 Class 2 compliant
 This tool is oHS compliant, however oHS compliant is not required
SCOPE
Products: Milli-Grid™ Crimp Terminal, 22-28 AWG.
T rminal
S ri s No.
T rminal Ord r No. Wir Siz
Insulation Diam t r
Strip L ngth
T rminal
(1)
Loos Pi c



R l
AWG
mm²
mm
In.
mm
In.
87396 87396-8100
87396
-
8051
87396-8999
22-28 0.35-0.08 1.15-1.80 .045-.070 1.30-1.80 .051-.071
87396-9051

Customer to cut off terminal from reel: 0.
2
0mm (.0
08
”) maximum Cut
-
off Tab.
(1) Overall insulation OD specification for terminal.
DEFINITION OF TERMS
TYPE 4D

Hand Crimp Tool For Milli-Grid™ Crimp Terminal
Doc No: ATS-638236700 elease Date: 07-19-11 UNCONTROLLED COPY Page 2 of 8
evision: B evision Date: 09-11-12
CONDITIONS:
After crimping, the conductor profile should measure the following.
T rminal S ri s No.
Wir Siz
Conductor
Profil
Crimp H ight
Crimp Width
Maximum
(R f)
AWG
mm
2
mm
In.
mm
In.
2
2
24
26
28
87396
22
0.35
0.84
-
0.89
.033
-
.035
1.10
.043
X
24
0.20
0.76
-
0.81
.029
-
.032
1.10
.043
X
26
0.12
0.71
-
0.76
.027
-
.029
1.10
.043
X
28
0.08
0.67
-
0.72
.026
-
.028
1.10
.043
X
♦
To Achi v IPC
-
A
-
620 Class th following wir insulation d
iam t r rang s ar r comm nd d:
1. Profile 22: 1.17-1.60mm (.046-.063 inch)
2. Profile 24: 1.25-1.70mm (.049-.067 inch)
3. Profile 26: 1.20-1.70mm (.047-.067 inch)
4. Profile 28: 1.20-1.60mm (.047-.063 inch)
T rminal S ri s No.
Wir Siz
Insulation (R f)
Pull Forc Minimum
Crimp H ight
Maximum
Crimp Width
Maximum (R f)
AWG
mm
2
mm
In.
mm
In.
N
Lb.
87396
22
0.35
1.70
.067
1.40
.055
39.2
8.81
24
0.20
1.70
.067
1.40
.055
29.4
6.61
26
0.12
1.70
.067
1.40
.055
19.6
4.41
28
0.08
1.70
.067
1.40
.055
9.8
2.20
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.
▲Insulation Crimp Not :
Due to the terminal’s insulation grip design
and/or insulation diameter range, this tool
uses “overlap” form geometry in the
insulation punch. This produces an overlap
insulation crimp (A620 – compliant). While
the insulation punch profile may appear
“lopsided”, this is a normal condition for this
tool. See figure to the right. (Some tools
with multiple crimp pockets may not have
the “overlap” profile on all pockets).
Not :
A crimp height chart is provided with this
manual as eference Only. Due to the
wide range of wires, strands, insulation
diameters, and durometers available, actual crimp height measurements may very slightly. An occasional,
destructive, pull force test should be performed to check hand tool crimp. Pull Force value Must exceed the
Minimum pull force specifications listed.
MAKE SURE
CENTER OF
LOCATOR
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
WIRE

Hand Crimp Tool For Milli-Grid™ Crimp Terminal
Doc No: ATS-638236700 elease Date: 07-19-11 UNCONTROLLED COPY Page 3 of 8
evision: B evision Date: 09-11-12
RELEASE LOCATOR
BUTTON
TERMINAL
Figur 3
LOCATOR
PUSHED THRU
TOOLING
TERMINAL
LOCATOR BUTTON
PUSHED IN
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. See Figure 1.
Crimping T rminals
1. Select the desired terminal listed in the
preceding charts.
2. Make sure the center of the locator is in the
down position. With the locator attached,
push the locator button on the back of the
hand tool to bring the locator forward through
the tooling. See Figure 2.
3. While holding the locator button in, load the
terminal into the proper nest opening in the
locator based on the wire gauge or terminal
type markings on the hand tooling. See
Figure 3.
4. elease the locator button, allowing the locator to return to the
crimping position.
5. Close the tool handle until the first ratchet position engages. See
Figure 4.
6. Insert the properly stripped wire through the terminal and against the
wire stop. See Figure 5.
7. Crimp the terminal by squeezing the tool handles until the ratchet
mechanism cycle has been completed. elease the handles to open
the jaws.
PARTIALLY
CLOSE HANDLE
TOOLING
PARTIALLY
CLOSED
Figur 4
FIRST RATCHET
POSITION
OPEN
POSITION
SQUEEZE
HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Figur 1
LOCATOR
IN DOWN
POSTION
PUSH ON THE
LOCATOR BUTTON
Figur 2

Hand Crimp Tool For Milli-Grid™ Crimp Terminal
Doc No: ATS-638236700 elease Date: 07-19-11 UNCONTROLLED COPY Page 4 of 8
evision: B evision Date: 09-11-12
PRE
-
STRIPPED
WIRE
TERMINAL
WIRE TERMINAL
WIRE AGAINST
THE WIRE STOP
WIRE STOP IS PART OF
THE LOCATOR
Figur 5
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
8. emove the crimped terminal from the terminal
locator by pulling on the wire.
9. Visually inspect the crimped terminal for proper
crimp location.
10. On some large O.D. wires, it may not be possible to
insert the wire with the tool partially closed. Those
wires should be inserted with the hand tool in the
open position. Insert the wire above the terminal in
the punch and against the wire stop then close the
tool. See Figure 6.
Locator R plac m nt
See the parts list on the last page of this
document for the proper locator order number.
Follow the steps below to replace the locator.
1. Open the crimp hand tool.
2. Squeeze gently on the lower area shown in
Figure 7A with your thumb and index finger.
The lower tabs of the locator should
disengage from the hand tool.
3. Lift and pull away from the hand tool. The top
locator hooks should slip out of the top slots
easily. See Figure 7A.
4. To reinstall the new locator, make sure the
hand tool is in the open position.
5. Press the red insert down as far as it will go
as shown in Figure 7B.
6. Holding onto the lower part of the locator with
your thumb and index finger, insert the
locators top hooks (2) into the hand tool top
slots.
TERMINAL
Figur 6
WIRE
WIRE STOP
SQUEEZE
HERE
SQUEEZE
HERE
LOCATOR
Figur 7A
TOP HOOKS
TOP SLOTS OF
HANDTOOL
LOWER TABS
MAKE SURE
CENTER OF THE
LOCATOR IS IN THE
DOWN POSTION
Figur 7B

Hand Crimp Tool For Milli-Grid™ Crimp Terminal
Doc No: ATS-638236700 elease Date: 07-19-11 UNCONTROLLED COPY Page 5 of 8
evision: B evision Date: 09-11-12
Figur 8
PUSH ON
HANDLE
JAWS OPEN
PULL OPEN
TOOLING
TOOLING
M3 BHCS
7. otate the locator down and press the lower tabs
into the two bottom slots of the hand tool. To
secure the locator into place, the lower tabs must
snap into place on the hand tool frame.
Right or L ft Hand Op ration
This hand tool has an added feature that can be
converted from a right handed application to a left
handed application. It is necessary to reverse the
tooling if using the left handed application along with the
locator. Follow the steps below:
1. The locator must be removed before reversing the
tooling.
2. emove the M3 BHCS which is holding the upper
tooling.
3. Flip the upper tooling to the opposite side and
replace the M3 BHCS. Make sure the small
markings on the front and back of the hand tool
frame match up and are on the outside of the
hand tool frame. See Figure 8 and 9.
4. Do the same thing with the lower tooling and
tighten the M3 screws. Be sure the small
markings line up.
5. einstall the locator by following the Instructions
in the locator replacement section.
Maint nanc
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. 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.
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.
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figur 10
MATCH
UP MARKS
FR
ONT
BACK
Figur 9

Hand Crimp Tool For Milli-Grid™ Crimp Terminal
Doc No: ATS-638236700 elease Date: 07-19-11 UNCONTROLLED COPY Page 6 of 8
evision: B evision Date: 09-11-12
Figur 12
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
SETTING
WHEEL
RATCHET
RELEASE LEVER
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 up
on the ratchet release lever in the movable handle. See Figure 11.
How to Adjust Tool Pr load (S Figur 12)
This hand tool is factory preset to 25-45 LBS. 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. Hold the hand tool in the palm of your hand as shown in Figure 10. Using the index finger squeeze the link
towards the top of the hand tool frame. This will release the preload adjustment wheel.
2. otate the setting wheel counter-clockwise (CCW) to increase handle force. The numbers will display higher.
To decrease handle force rotate the
setting wheel clockwise (CW).
3. elease the link to lock the setting
wheel in place.
4. Check the crimp specifications or
conduct a pull test after tool handle
preload force is adjusted.
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.
RATCHET RELEASE
LEVER
Figur 11

Hand Crimp Tool For Milli-Grid™ Crimp Terminal
Doc No: ATS-638236700 elease Date: 07-19-11 UNCONTROLLED COPY Page 7 of 8
evision: B evision Date: 09-11-12
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.
3. Wear eye protection at all times.
4. Use only the Molex terminals specified for crimping with this tool.
C rtification
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. 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 For Milli-Grid™ Crimp Terminal
Doc No: ATS-638236700 elease Date: 07-19-11 UNCONTROLLED COPY Page 8 of 8
evision: B evision Date: 09-11-12
RATCHET
RELEASE LEVER
2
Figur 13
1
3
PARTS LIST
It m Numb r
Ord r Numb r
D scription
Quantity
EF
63823
-
6700
Hand Crimp Tool
Figure
13
1
63823
-
6
7
75
Locator Assembly
1
2
63810
-
0104
Spring, eturn
1
3
63810
-
0105
Spring, atchet
1
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