molex 207129 Series User manual

Hand Crimp Tool for 2.00/2.50mm (.079/.098") Board-In Crimp Terminals
Do No: ATS-6381177HM Release Date: 08-29-07 UNCONTROLLED COPY Page 1 of 7
Revision: B Revision Date: 08-02-10
INSULATION
CRIMP
▲
SEE NOTE
BRUSH
STRIP
LENGTH
BELL MOUTH
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
Application Tooling
Speci ication Sheet
Modular Crimp Head
Order No. 63811-7770
Hand Crimp Tool
Order No. 63811-7700
FEATURES
% A full y le rat heting hand tool ensures omplete rimps
% Ergonomi ally designed soft handles
% Pre isely designed rimping profiles with simple onta t positioning
% Easy handling due to outstanding for e ratio
% A-620 Class 3 ompliant and RoHS ompliant
% Modular Crimp Head is removable and an be use in the Air Powered Tool Order No.63816-0100,
a ompanied by Air Powered Crimp Adapter (Order No. 63816-0700).
% Can also be used in the Battery Powered Tool Order No.63816-0200 (110 V) or 63816-0250 (220 V),
a ompanied by Battery Powered Crimp Adapter (Order No. 63816-0600).
SCOPE
Produ ts: 2.00/2.50mm (.079/.098") Board-In Terminal, 22-28 AWG.
Terminal
Series No.
Terminal Order No.


 Reel
Wire Size Insulation Diameter Strip Length
AWG mm² mm In. mm In.
35044
35044-9101 35044-9160
24-28 0.20-0.08 0.90-1.50 .035-.059 3.00-3.50 .118-.138 35044-9102 35044-9210
35044-9110 35044-9260
35044
35044-9103 35044-9360
22-28 0.35-0.08 1.20-1.90 .047-.075 3.00-3.50 .118-.138 35044-9104 35044-9410
35044-9310 35044-9460
Follow the Cut-Off Tab spe ifi ations on Appli ator spe ifi ation sheets
See Conditions on page 2.
DEFINITION OF TERMS
The above terminal drawing is a generi terminal representation. It is not an image of a terminal listed in the s ope.
TYPE 4A

Hand Crimp Tool for 2.00/2.50mm (.079/.098") Board-In Crimp Terminals
Do No: ATS-6381177HM Release Date: 08-29-07 UNCONTROLLED COPY Page 2 of 7
Revision: B Revision Date: 08-02-10
▲Insulation Crimp Note:
Due to the terminal’s insulation grip design and/or
insulation diameter range, this tool uses “overlap”
form geometry in the insulation pun h. This
produ es an overlap insulation rimp (A620 –
ompliant). While the insulation pun h profile may
appear “lopsided”, this is a normal ondition for this
tool. See figure to the right. (Some tools with
multiple rimp po kets may not have the “overlap”
profile on all po kets).
CRIMP SPECIFICATION
After rimping, the rimp profiles should measure the following (see notes on page 4).
Terminal
Order No.
Wire Size
Conductor Crimp Insulation Crimp Pull Force
Minimum 

Pro ile
Height (Re ) Width (Re ) Height (Re ) Width (Re )
AWG mm2 mm In. mm In. mm In. mm In. N Lb. A B C D
35044-9101
35044-9102
35044-9110
35044-9160
35044-9210
35044-9260
26 0.12 0.64-0.74 .025-.029 1.30 .051 1.50 .059 1.50 .059 19.6 4.40 X
28 0.08 0.64-0.74 .025-.029 1.30 .051 1.50 .059 1.50 .059 9.8 2.20 X
35044-9103
35044-9104
35044-9310
35044-9360
35044-9410
35044-9460
26 0.12 0.64-0.74 .025-.029 1.30 .051 1.60 .063 1.90 .075 19.6 4.40 X
28 0.08 0.64-0.74 .025-.029 1.30 .051 1.60 .063 1.90 .075 9.8 2.20 X
35044-9101
35044-9102
35044-9110
35044-9160
35044-9210
35044-9260
24 0.20 0.77-0.87 .030-.034 1.30 .051 1.65 .065 1.50 .059 29.4 6.60 X
35044-9103
35044-9104
35044-9310
35044-9360
35044-9410
35044-9460
22 0.35 0.77-0.87 .030-.034 1.30 .051 1.90 .075 1.90 .075 39.1 8.80 X
24 0.20 0.77-0.87 .030-.034 1.30 .051 1.90 .075 1.90 .075 29.4 6.60 X
To A hieve IPC-A-620 Class 3 Crimps, the following over-all wire insulation diameter ranges are re ommended:
Profile A: 0.90mm (.035”) maximum-Up to the maximum terminal rating 1.50mm (.059”).
Profile B: 1.20-1.90mm (.047-.075”)
Profile C: 0.90-1.50-1.90mm (.035-.059”)
Profile D: 1.20-1.90mm (.047-.075”)
Τ
ΤΤ
Τ Tool Qualifi ation Notes:
1. Pull For e should be measured with no influen e from the insulation rimp.
2. The above spe ifi ations are guidelines to an optimum rimp.
OVERLAP
INSULATION
CRIMP
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
WIRE

Hand Crimp Tool for 2.00/2.50mm (.079/.098") Board-In Crimp Terminals
Do No: ATS-6381177HM Release Date: 08-29-07 UNCONTROLLED COPY Page 3 of 7
Revision: B Revision Date: 08-02-10
Figure 3
WIRE
TERMINAL
LOCATOR INSULATION
PUNCH
INSULATION
ANVIL
WIRE STOP
BLADE
CONDUCTOR
ANVIL
CONDUCTOR PUNCH
WIRE
CONDUCTOR
PUNCH
TERMINAL
WIRE STOP
BLADE
Figure 2
OPERATION
Open the tool by squeezing the handles together,
at the end of the losing stroke, the rat het
me hanism will release the handles, and the
hand tool will spring open.
1. With the hand tool in the open position, pivot
the terminal lo ator open by pulling up on the
lo ator knob and lift the wire stop blade up.
See Figure 1.
2. Insert the terminal into the orre t profile until
the terminal is fully seated and stops. Make
sure the wire stop blade is fully seated on the
terminal behind the ondu tor grip se tion.
3. Gently pivot the lo ator losed.
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 onstant 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 pla e until the terminal is fully rimped. See Figure 3.
6. Close the tool until the rat het releases.
7. Lift the wire stop blade up.
8. Carefully remove the rimped terminal.
Note: To maintain good brush ontrol and a onsistent bell mouth the rimping instru tions must be
followed.
Note: The tamper proof rat het a tion will not release the tool until it has been fully losed.
Note: To maintain good brush ontrol and a onsistent bell mouth the rimping instru tions must be followed.
TERMINAL
SEATED IN
LOCATOR
SWING
LOCATOR
OPEN
Figure 1
HAND TOOL
OPEN
WIRE
STOP BLADE

Hand Crimp Tool for 2.00/2.50mm (.079/.098") Board-In Crimp Terminals
Do No: ATS-6381177HM Release Date: 08-29-07 UNCONTROLLED COPY Page 4 of 7
Revision: B Revision Date: 08-02-10
INCORRECT
Figure 5
CORRECT INCORRECT
Terminal Locator Replacement/Change Over
This se tion des ribes the pro edure for hanging lo ators.
Removal
1. With the tool in the open position, pivot the terminal lo ator outward.
2. Remove the M4 BHCS. See Figure 4.
Installation
1. Pla e the proper lo ator, (See Chart on page 2), on the hand tool.
Install the M4 BHCS. See Figure 4.
2. Tighten the s rew enough to hold the lo ator. Make sure the lo ator
an still float freely with hand pressure.
3. Insert the proper terminal fully into the orre t profile slot until the
terminal is fully seated and stops. Then gently pivot the lo ator
losed.
4. With hand pressure, slowly slide the lo ator to the orre t position. See Figure 5.
5. Gently pivot the lo ator open without disturbing the lo ation.
6. Hold the lo ator firmly in pla e and slowly tighten the M4 BHCS.
Maintenance
It is re ommended that ea h operator of the tool be made
aware of, and responsible for, the following maintenan e
steps:
1. Remove dust, moisture, and other ontaminants with a
lean brush, or soft, lint free loth.
2. Do not use any abrasive materials that ould damage the
tool.
3. Make ertain all pins; pivot points and bearing surfa es
are prote ted with a thin oat of high quality ma hine oil.
Do not oil ex essively. The tool was engineered for
durability but like any other equipment it needs leaning and lubri ation for a maximum servi e life of trouble
free rimping. Light oil (su h as 30 weight automotive oil) used at the oil points, every 5,000 rimps or 3
months, will signifi antly enhan e the tool life.
4. Wipe ex ess oil from hand tool, parti ularly from rimping area. Oil transferred from the rimping area onto
ertain terminations may affe t the ele tri al hara teristi s of an appli ation.
5. When tool is not in use, keep the handles losed to prevent obje ts from be oming lodged in the rimping dies,
and store the tool in a lean, dry area.
Miscrimps or Jams
Should this tool ever be ome stu k or jammed in a partially losed position, Do Not for e the handles open or
losed. The tool will open easily by lifting the rat het release lever. See Figure 9.
Warranty
This tool is for ele tri al terminal rimping purposes only. This tool is made of the best quality materials. All vital
omponents are long life tested. All tools are warranted to be free of manufa turing defe ts for a period of 30
days. Should su h a defe t o ur, we will repair or ex hange the tool free of harge. This repair or ex hange will
M4 BHCS
PIVOT LOCATOR
Figure 4

Hand Crimp Tool for 2.00/2.50mm (.079/.098") Board-In Crimp Terminals
Do No: ATS-6381177HM Release Date: 08-29-07 UNCONTROLLED COPY Page 5 of 7
Revision: B Revision Date: 08-02-10
not be appli able to altered, misused, or damaged tools. This tool is designed for hand use only. Any lamping,
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 NOT intended for
produ tion use. Repetitive use of this tool should be avoided.
2. Insulated rubber handles are not prote tion against ele tri al sho k.
3. Wear eye prote tion at all times.
4. Use only the Molex terminals spe ified for rimping with this tool.
Notes:
1. This tool should only be used for the terminals and wire gauges spe ified on this sheet.
2. This tool is not adjustable for rimp height; however rimp for e is adjustable (See instru tions above).
Variations in tools, terminals, wire stranding, and insulation types may affe t rimp height.
3. This tool is intended for standard ondu tor sizes. It may not give a good insulation rimp support for all
insulation sizes.
4. Molex does not repair hand tools (see warranty above). The repla ement parts listed are the only parts
available for repair. If the handles or rimp tooling is damaged or worn, a new tool must be pur hased.
5. Pull for e should be used as the final riteria for an a eptable rimp. Pull for e is measured with no
influen e from the insulation rimp. The insulation should be stripped long (1/2 in.) so the insulation grips
on the terminal do not grip the wire insulation or the ondu tor. Refer to Molex Quality Crimping
Handbook 63800-0029 for additional information on rimping and rimp testing.
6. Molex does not ertify rimp hand tools.
CAUTION: Molex rimp spe ifi ations are valid only when used with Molex terminals and tooling.
Applications or the Modular Crimp Head
WARNING: NEVER operate, servi e, install, or adjust this Modular Crimp Head without proper instru tion
and without first reading and understanding the instru tions in the proper Manual or Spe ifi ation Sheet.
See Chart below for the orre t Manual or Spe ifi ation Sheet.
WARNING: NEVER install tooling or servi e this tool while it is into any power sour e. Dis onne t the
power by unplugging or turn off the A tuator from its power sour e.
CAUTION: Keep fingers away from the rimping area when operating this tool. It may ause severe injury.
CAUTION: Wear safety glasses when operating or serving this tool.

Hand Crimp Tool for 2.00/2.50mm (.079/.098") Board-In Crimp Terminals
Do No: ATS-6381177HM Release Date: 08-29-07 UNCONTROLLED COPY Page 6 of 7
Revision: B Revision Date: 08-02-10
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 hart below shows all appli ations for this Modular Crimp Head.
Modular Crimp Head
Order No.
Tool
Order no.
Tool
Description
Adapter
Order No.
Adapter
Description
Figure
No.
63811-7770
63816-0000 Hand Crimp Frame (Short) N/A N/A 6
63816-0050 Hand Crimp Frame (Long) N/A N/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
Applications or the Modular Crimp Head
Hand 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 2.00/2.50mm (.079/.098") Board-In Crimp Terminals
Do No: ATS-6381177HM Release Date: 08-29-07 UNCONTROLLED COPY Page 7 of 7
Revision: B Revision Date: 08-02-10
RATCHET
RELEASE LEVER
HANDLE
SPRING
CRIMPING
SPRING (2)
LOCATOR
2
1
4
Figure 9
M4 X 8mm
LONG BHCS
3
5
6
PARTS LIST
Hand Crimp Tool 63811-7700
Item Order Number Description Quantity
1 63811-7770 Modular Crimp Head 1
2 63816-0000 Hand Crimp Frame (Short) 1
3 63811-7775 Lo ator 1
4 63816-0001 Lo king Pin 2
5 63600-0525 Handle Spring 1
6 63600-0520 Crimping Spring 2
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