molex 207129 Series User manual

Hand Crimp Tool For SATA Power Cable Crimp Receptacles
Doc No: ATS-638239900 Release Date: 02- - UNCONTROLLED COPY Page of 7
Revision: A Revision Date: 02- -
INSULATION CRIMP
HEIGHT
BRUSH
STRIP
LENGTH
BELL MOUTH
CONDUCTOR CRIMP HEIGHT
BEND
DOWN
BEND
UP
ROLLING
LANCE HEIGHT
TWISTING
SEAM
CUT-OFF
TAB
HAND CRIMP
TOOL
Application Tooling
Sp cification Sh t Ord r No. 63823-9900
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
 Right and Left handed applications
 This tool is IPC/WHMA A-620 Class 2 compliant
 This tool is RoHS compliant, however RoHS compliant is not required
SCOPE
Products: SATA Power Cable Crimp Receptacles, 8-22 AWG.
T rminal
S ri s No.
T rminal Ord r No. Wir Siz and Typ Insulation Diam t r Strip L ngth


R l AWG mm² mm In. mm In.
6758
6758 -0000 6758 -000
8-22 UL 007 .40-2.40 .055-.094 3.50 . 38
6758 -0002 6758 -0009
6758 -00 0 6758 -00
6758 -00 2 6758 -00 9
Customer to cut off terminal from reel: 0.50mm (.020”) maximum Cut-off Tab.
DEFINITION OF TERMS
TYPE 4D

Hand Crimp Tool For SATA Power Cable Crimp Receptacles
Doc No: ATS-638239900 Release Date: 02- - UNCONTROLLED COPY Page 2 of 7
Revision: A Revision Date: 02- -
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the
scope.
▲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).
CONDITIONS:
After crimping, the conductor profiles should measure the following.
T rminal
S ri s No
Wir Siz Conductor Crimp Insulation Crimp Pull Forc
Minimum Profil
H ight Width (R f.) H ight Max. Width (R f.)
AWG mm2 mm In. mm In. mm In. mm In. N Lb. 18 20 22
6758
8 UL 007 . 5- .25 .045-.049 .55- .65 .06 -.065 3.50 . 38 2.90 . 4 88.20 9.8 X
20 UL 007 . 0- .20 .043-.047 .55- .65 .06 -.065 3.50 . 38 2.90 . 4 58.80 3.2 X
22 UL 007 .05- . 5 .04 -.045 .55- .65 .06 -.065 3.50 . 38 2.90 . 4 39.20 8.8 X
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 .
Crimping T rminals
. 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.
OVERLAP
INSULATION
CRIMP
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
WIRE
LOCATOR
IN DOWN
POSTION
PUSH ON THE
LOCATOR BUTTON
Figur 2
SQUEEZE HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Figur 1

Hand Crimp Tool For SATA Power Cable Crimp Receptacles
Doc No: ATS-638239900 Release Date: 02- - UNCONTROLLED COPY Page 3 of 7
Revision: A Revision Date: 02- -
RELEASE
LOCATOR BUTTON
TERMINAL
Figur 3
LOCATOR
PUSHED THRU
TOOLING
TERMINAL
LOCATOR
BUTTON
PUSHED IN
LOCATOR
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. Release 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.
Release the handles to open the jaws.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
8. Remove the crimped terminal from the terminal
locator by pulling on the wire.
9. Visually inspect the crimped terminal for proper
crimp location.
TERMINAL
Figur 6
WIRE
WIRE STOP
PARTIALLY
CLOSE HANDLE
TOOLING
PARTIALLY
CLOSED
Figur 4
FIRST RATCHET
POSITION
OPEN
POSITION
PRE-STRIPPED WIRE
TERMINAL
WIRE AGAINST THE
WIRE STOP
Figur 5 TERMINAL
WIRE
WIRE STOP
IS PART
OF THE
LOCATOR

Hand Crimp Tool For SATA Power Cable Crimp Receptacles
Doc No: ATS-638239900 Release Date: 02- - UNCONTROLLED COPY Page 4 of 7
Revision: A Revision Date: 02- -
Figur 8
PUSH ON
HANDLE
JAWS OPEN
PULL OPEN
TOOLING TOOLING
M3 BHCS
MATCH
UP MARKS
FRONT BACK
Figur 9
0. 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.
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
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.
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.
. 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.
7. Rotate 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:
SQUEEZE
HERE
SQUEEZE
HERE
LOCATOR
Figur 7A
TOP HOOKS
TOP SLOTS OF
HANDTOOL
LOWER TABS
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
Figur 7B

Hand Crimp Tool For SATA Power Cable Crimp Receptacles
Doc No: ATS-638239900 Release Date: 02- - UNCONTROLLED COPY Page 5 of 7
Revision: A Revision Date: 02- -
Figur 12
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
SETTING
WHEEL
RATCHET
RELEASE LEVER
. The locator must be removed before reversing the tooling.
2. Remove 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. Reinstall 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:
. 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.
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
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 .
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:
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figur 10
RATCHET RELEASE
LEVER
Figur 11

Hand Crimp Tool For SATA Power Cable Crimp Receptacles
Doc No: ATS-638239900 Release Date: 02- - UNCONTROLLED COPY Page 6 of 7
Revision: A Revision Date: 02- -
. Hold the hand tool in the palm of your hand as shown in Figure 2. Using the index finger squeeze the link
towards the top of the hand tool frame. This will release the preload adjustment wheel.
2. Rotate 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. Release 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.
CAUTIONS:
. 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.
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 SATA Power Cable Crimp Receptacles
Doc No: ATS-638239900 Release Date: 02- - UNCONTROLLED COPY Page 7 of 7
Revision: A Revision Date: 02- -
2
Figur 13
1
3
PARTS LIST
It m Numb r Ord r Numb r D scription Quantity
REF 63823-9900 Hand Crimp Tool Figure 3
63823-9975 Locator Assembly
2 638 0-0 04 Spring, Return
3 638 0-0 05 Spring, Ratchet
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