molex 207129 Series User manual

Hand Crimp Tool for MX150 ISO (M3) Blade Terminals
Doc No ATS-6382336HM Release Date 08-05-11 UNCONTROLLED COPY Page 1 of 6
Revision A Revision Date 08-05-11
TYPE 4A
Application Tooling
Specification Sheet
Modular Cri p Head
Order No. 63823-3670
Hand Cri p Tool
Order No. 63823-3600
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
% Modular Crimp Head is removable and can be use in the Air Powered Tool Order No.63816-0100,
accompanied 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),
accompanied by Battery Powered Crimp Adapter (Order No. 63816-0600).
SCOPE
Products MX150 ISO (M3) Blade Terminals for 0.35mm2 and 0.50mm2 ISO wires.
Ter inal
Series
Ter inal Order No. Wire Size and Type Insulation Dia eter Strip Length
Reel For only ² Type In. In.
33000 33000-0004 33000-1004 0.35 ISO 1.20-1.40 .047-.055 4.70-5.60 .185-.220
0.50 ISO 1.40-1.70 .055-.067 4.70-5.60 .185-.220
33011 33011-0008
33011-1008
33011-2004
33011-3004
0.35 ISO 1.20-1.40 .047-.055 4.70-5.60 .185-.220
0.50 ISO 1.40-1.70 .055-.067 4.70-5.60 .185-.220
34781 34781-0004 34781-1004 0.35 ISO 1.20-1.40 .047-.055 4.70-5.60 .185-.220
0.50 ISO 1.40-1.70 .055-.067 4.70-5.60 .185-.220
Terminals were validated per USCAR-21 using the ISO 6722 wire specifications.
Customer to cut off terminal from reel 0.50mm (.020”) maximum Cut-off Tab.

Hand Crimp Tool for MX150 ISO (M3) Blade Terminals
Doc No ATS-6382336HM Release Date 08-05-11 UNCONTROLLED COPY Page 2 of 6
Revision A Revision Date 08-05-11
ROLLING
INSULATION
CRIMP
BRUSH
STRIP LENGTH BELL MOUTH
CRIMP
HEIGHT
BEND
DOWN
BEND UP
CONDUCTOR
CRIMP
TWISTING
CUT-OFF
TAB
SEAM
TERMINAL WIDTH
NOT TO EXCEED
2.55 AFTER CRIMP
WIRE BRUSH MUST BE
FLUSH OR BELOW TOP
OF CONDUCTOR CRIMP
THIS AREA
DEFINITION OF TERMS
CRIMP SPECIFICATION
Ter inal Series Bell outh  Conductor Brush Maxi u Bend up Bend Down Twist Roll
In. In. Degree Maxi u Degree Maxi u
33000 33011 0.30-0.70 .012-.028 0.40 .016 1.5 1.5 3 3
34781 0.30-0.70 .012-.028 0.40 .016 1.5 1.5 3 3


 Wire brush must be flush or below top of Conductor Crimp.
After crimping, the crimp profiles should measure the following
Ter inal Series
Wire Size
Conductor Pull Force
Mini u Profile
Cri p Height Cri p Width
2 In. In. N Lb. 0.35 2 0.50 2
33000 0.35 1.02-1.08
.040-.042 1.50-1.70 .059-.067 50 11.3 X
0.50 1.05-1.15 .041-.045 1.50-1.70 .059-.067 75 16.9 X
33011 0.35 1.02-1.08
.040-.042 1.50-1.70 .059-.067 50 11.3 X
0.50 1.05-1.15 .041-.045 1.50-1.70 .059-.067 75 16.9 X
34781 0.35 1.02-1.08
.040-.042 1.50-1.70 .059-.067 50 11.3 X
0.50 1.05-1.15 .041-.045 1.50-1.70 .059-.067 75 16.9 X
Ter inal Series
Wire Size
Insulation
Cri p Height Cri p Width
2 In. In.
33000 0.35 1.65-1.85
.065-.073 1.90-2.10 .075-.083
0.50 1.80-2.00 .071-.079 1.90-2.10 .075-.083
33011 0.35 1.65-1.85
.065-.073 1.90-2.10 .075-.083
0.50 1.80-2.00 .071-.079 1.90-2.10 .075-.083
34781 0.35 1.65-1.85
.065-.073 1.90-2.10 .075-.083
0.50 1.80-2.00 .071-.079 1.90-2.10 .075-.083
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.

Hand Crimp Tool for MX150 ISO (M3) Blade Terminals
Doc No ATS-6382336HM Release Date 08-05-11 UNCONTROLLED COPY Page 3 of 6
Revision A Revision Date 08-05-11
WIRE
CONDUCTOR
PUNCH
TERMINAL
WIRE STOP
BLADE
Figure 1
Figure 2
WIRE
TERMINAL
LOCATOR
INSULATION
PUNCH
INSULATION
ANVIL
WIRE STOP
BLADE
CONDUCTOR ANVIL
CONDUCTOR
PUNCH
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.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
Cri ping Ter inals
1. With the hand tool in the open position lift the wire stop up
and place the terminal into the correct die profile until the
terminal stopped by the locator.
2. Bring down the wire stop blade; make sure the wire stop
blade is fully seated on the terminal behind the conductor
grip section.
3. 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 1. 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 2.
4. Close the tool until the ratchet releases.
5. Lift the wire stop blade up.
6. Carefully remove the crimped terminal.
7. Inspect the crimped terminal for an acceptable crimp.
Note: To maintain a good brush control and a consistent bell mouth, the crimping instructions must be followed.

Hand Crimp Tool for MX150 ISO (M3) Blade Terminals
Doc No ATS-6382336HM Release Date 08-05-11 UNCONTROLLED COPY Page 4 of 6
Revision A Revision Date 08-05-11
Maintenance
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.
Miscri ps or Ja s
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 6.
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: 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
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.
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.

Hand Crimp Tool for MX150 ISO (M3) Blade Terminals
Doc No ATS-6382336HM Release Date 08-05-11 UNCONTROLLED COPY Page 5 of 6
Revision A Revision Date 08-05-11
MODULAR
CRIMP
HEAD
BATTERY
POWER
CRIMP
ADAPTER
LOCKING
PINS
LOCKING PINS
BATTERY
POWERED
TOOL
AIR
POWER
TOOL
M
ODULAR
CRIMP HEAD
LOCKING
PINS
LOCKING
PINS
AIR
POWER
CRIMP
ADAPTER
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.
Applications for the Modular Cri p 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.
The chart below shows all applications for this Modular Crimp Head.
Modular Cri p Head
Order No.
Tool
Order no.
Tool
Description
Adapter
Order No.
Adapter
Description
Figure
No.
63823-3670
63816-0000 Hand Crimp Frame (Short) N/A N/A 3
63816-0050 Hand Crimp Frame (Long) N/A N/A 3
63816-0200 Battery Power Tool (110 V) 63816-0600 Battery Power Crimp Adapter 4
63816-0250 Battery Power Tool (220 V) 63816-0600 Battery Power Crimp Adapter 4
63816-0100 Air Power Tool 63816-0700 Air Power Crimp Adapter 5
Applications for the Modular Cri p Head
Hand Cri p Tool Battery Powered Tool Air Powered Tool
Figure 3 Figure 4 Figure 5
MODULAR
CRIMP
HEAD
LOCKING
PINS
HAND CRIMP
FRAME LONG
OR SHORT

Hand Crimp Tool for MX150 ISO (M3) Blade Terminals
Doc No ATS-6382336HM Release Date 08-05-11 UNCONTROLLED COPY Page 6 of 6
Revision A Revision Date 08-05-11
RATCHET
RELEASE LEVER
HANDLE
SPRING
CRIMPING
SPRING (2)
3
6
4
Figure 6
M4 X 14
LONG BHCS
2
5
1
PARTS LIST
Hand Cri p Tool 63823-3600
Ite Order Nu ber Description Quantity
1 63823-3670 Modular Crimp Head 1 (Ref)
2 63816-0050 Hand Crimp Frame (Long) 1 (Ref)
3 63823-3675 Locator 1
4 63816-0001 Locking Pin 2
5 63600-0525 Handle Spring 1
6 63600-0520 Crimping Spring 2
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