molex 207129 Series User manual

Hand Crimp Tool for 2.50mm (.098”) Wire-to-Board Crimp Terminals
Doc o: ATS-6382386HM Release Date: 09-27-10 UNCONTROLLED COPY Page 1 of 7
Revision: B Revision Date: 10-14-10
INSULATION
CRIMP
▲SEE NOTE
BRUSH
STRIP
LENGTH
BELL MOUTH
COND.CRIMP
HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
CUT-OFF TAB
SEAM
Applicatio Tooli g
Specificatio Sheet
Modular Crimp Head
Order No. 63823-8670
Ha d Crimp Tool
Order No. 63823-8600
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 o.63816-0100,
accompanied by Air Powered Crimp Adapter (Order o. 63816-0700).
% Can also be used in the Battery Powered Tool Order o.63816-0200 (110 V) or 63816-0250 (220 V),
accompanied by Battery Powered Crimp Adapter (Order o. 63816-0600).
SCOPE
Products: 2.50mm (.098”) Wire-to-Board Crimp Terminals, 22-28 AWG.
Termi al
Series No.
Termi al
Order No. Wire Size I sulatio Diameter Strip Le gth
●Reel AWG mm² mm I . mm I .
57915 57915-8001 22-28 0.35-0.08 1.15-1.80 .045-.071 2.30-2.80 .091-.110
57915-9002
● Customer to cut off terminal from reel: 0.20mm (.008”) maximum Cut-off Tab.
See Conditions on page 2.
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 4A

Hand Crimp Tool for 2.50mm (.098”) Wire-to-Board Crimp Terminals
Doc o: ATS-6382386HM Release Date: 09-27-10 UNCONTROLLED COPY Page 2 of 7
Revision: B Revision Date: 10-14-10
▲I sulatio Crimp Note:
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).
CRIMP SPECIFICATIONS:
Termi al Series No. Bell mouth Co ductor Brush Be d up Be d Dow Twist Roll
mm I . mm I . Degree Degree
57915 0.05-0.40 .002-.016 0.00-0.80 .000-.032 3 3 3 6
After crimping, the crimp profiles should measure the following.
Termi al
Order No.
Wire Size
Co ductor Crimp I sulatio Crimp Pull Force
Mi imum 

Profile
Height (Ref) Width (Ref) Height (Ref) Width (Ref)
AWG mm2 mm I . mm I . mm I . mm I . N Lb. 22 24 26 28
57915
22 0.35 0.84-0.89 .033-.035 1.20 .047 1.65 .065 1.90 .075 39.2 8.8 X
24 0.20 0.76-0.81 .030-.032 1.20 .047 1.60 .063 1.90 .075 29.4 6.6 X
26 0.12 0.71-0.76 .028-.030 1.20 .047 1.60 .063 1.85 .073 19.6 4.4 X
28 0.08 0.67-0.72 .026-.028 1.20 .047 1.60 .063 1.85 .073 9.8 2.2 X
To Achieve IPC-A-620 Class 3 Crimps, the following over-all wire insulation diameter ranges are recommended:
Profile 22: 1.50-1.65mm (.059-.065”)
Profile 24: 1.30-1.50mm (.051-.059”)
Profile 26: 1.20-1.40mm (.047-.055”)
Profile 28: 1.20-1.30mm (.047-.051”)
• Tool Qualification otes:
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.
1. With the hand tool in the open position, pivot
the terminal locator open by pulling up on
the locator knob and lift the wire stop blade
up. See Figure 1.
TERMINAL
SEATED IN
LOCATOR
SWING
LOCATOR
OPEN
Figure 1
HAND TOOL
OPEN
WIRE
STOP BLADE
OVERLAP
INSULATION
CRIMP
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
WIRE

Hand Crimp Tool for 2.50mm (.098”) Wire-to-Board Crimp Terminals
Doc o: ATS-6382386HM Release Date: 09-27-10 UNCONTROLLED COPY Page 3 of 7
Revision: B Revision Date: 10-14-10
WIRE
CONDUCTOR
PUNCH
TERMINAL
WIRE STOP
BLADE
Figure 2
WIRE
CONDUCTOR
PUNCH
WIRE STOP
BLADE INSULATION
PUNCH
LOCATOR
CONDUCTOR
ANVIL
INSULATION
ANVIL
TERMINAL
Figure 3
2. Insert the terminal into the correct profile until the terminal is fully seated and stops. Make sure the wire
stop blade is fully seated on the terminal behind the conductor grip section.
3. Gently pivot the locator closed.
4. Bring down the wire stop blade.
5. Slide the pre-stripped wire into the terminal; make sure to aim the wire brush towards the tip point on the
wire stop blade. See Figure 2. Align the wire so that it is parallel and sitting into the terminal. Maintain a
light and constant pressure on the wire that is seated in the terminal at all times. (Do not let go of the
wire.) Be sure to hold the wire and terminal in place until the terminal is fully crimped. See Figure 3.
6. Close the tool until the ratchet releases.
7. Lift the wire stop blade up.
8. Carefully remove the crimped terminal.
Note: To maintain good brush control and a consistent bell mouth the crimping instructions must be
followed.
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.
Termi al Locator Replaceme t/Cha ge 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 M4 BHCS. See Figure 4.
I stallatio
1. Place the proper locator, (See Chart on page 2), on the hand tool.
Install the M4 BHCS. See Figure 4.
2. Tighten the screw enough to hold the locator. Make sure the
locator can still float freely with hand pressure. M4 BHCS
PIVOT LOCATOR
Figure 4

Hand Crimp Tool for 2.50mm (.098”) Wire-to-Board Crimp Terminals
Doc o: ATS-6382386HM Release Date: 09-27-10 UNCONTROLLED COPY Page 4 of 7
Revision: B Revision Date: 10-14-10
INCORRECT
Figure 5
CORRECT INCORRECT
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.
4. 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 M4
BHCS.
Mai te a ce
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.
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 lifting the ratchet release lever. See Figure 9.
Warra ty
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 OT 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.

Hand Crimp Tool for 2.50mm (.098”) Wire-to-Board Crimp Terminals
Doc o: ATS-6382386HM Release Date: 09-27-10 UNCONTROLLED COPY Page 5 of 7
Revision: B Revision Date: 10-14-10
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.
4. 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.
Applicatio s for the Modular Crimp Head
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.

Hand Crimp Tool for 2.50mm (.098”) Wire-to-Board Crimp Terminals
Doc o: ATS-6382386HM Release Date: 09-27-10 UNCONTROLLED COPY Page 6 of 7
Revision: B Revision Date: 10-14-10
MODULAR
CRIMP
HEAD
BATTERY
POWER
CRIMP
ADAPTER
LOCKING
PINS
LOCKING PINS
BATTERY
POWERED
TOOL
AIR
POWER
TOOL
MODULAR
CRIMP HEAD
LOCKING
PINS
LOCKING
PINS
AIR
POWER
CRIMP
ADAPTER
The chart below shows all applications for this Modular Crimp Head.
Modular Crimp Head
Order No.
Tool
Order o.
Tool
Descriptio
Adapter
Order No.
Adapter
Descriptio
Figure
No.
63823-8670
63816-0000 Hand Crimp Frame (Short) /A /A 6
63816-0050 Hand Crimp Frame (Long) /A /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
Applicatio s for the Modular Crimp Head
Ha d Crimp Tool Battery Powered Tool Air Powered Tool
Figure 6 Figure 7 Figure 8
MODULAR
CRIMP
HEAD
LOCKING
PINS
HAND CRIMP
FRAME LONG
OR SHORT

Hand Crimp Tool for 2.50mm (.098”) Wire-to-Board Crimp Terminals
Doc o: ATS-6382386HM Release Date: 09-27-10 UNCONTROLLED COPY Page 7 of 7
Revision: B Revision Date: 10-14-10
RATCHET
RELEASE LEVER
HANDLE
SPRING
CRIMPING
SPRING (2)
LOCATOR
2
1
4
Figure 9
M4 X 8mm
LONG BHCS
3
5
6
PARTS LIST
Ha d Crimp Tool 63823-8600
Item Order Number Descriptio Qua tity
1 63823-8670 Modular Crimp Head 1
2 63816-0000 Hand Crimp Frame (Short) 1
3 63823-8675 Locator 1
4 63816-0001 Locking Pin 2
5 63600-0525 Handle Spring 1
6 63600-0520 Crimping Spring 2
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