molex 207129 Series User manual

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals
Doc No: ATS-638 98HM Release Date: 07-25-08 UNCONTROLLED COPY Page of 6
Revision: C Revision Date: -22- 0
CONDUCTOR
BRUSH
STRIP LENGTH
SEAM
CONDUCTOR
CRIMP
CUT-OFF
TAB
BELL MOUTH
BEND UP
TWISTING
ROLLING
BEND
DOWN
WIRE
SEAL
Application Tooling
Sp cification Sh t
Modular Crimp H ad
Ord r No. 63811-9870
Hand Crimp Tool
Ord r No. 63811-9800
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.638 6-0 00,
accompanied by Air Powered Crimp Adapter (Order No. 638 6-0700).
% Can also be used in the Battery Powered Tool Order No.638 6-0200 ( 0 V) or 638 6-0250 (220 V),
accompanied by Battery Powered Crimp Adapter (Order No. 638 6-0600).
SCOPE
Products: CP 2.8 receptacle for 2.5 – 3.0 mm2 type ID and IR wire with 2.80mm (. 0"),
CMC Wire Seal Grey Receptacle.
T rminal S ri s No.
T rminal Ord r No. Wir Siz and Typ Insulation Diam t r Strip L ngth
Availabl in R l only AWG mm² mm In. mm In.
989 0 989 0- 029
989 0- 29
--- 2.5 – 3.0 Type ID & IR 2.65 - 3.45 . 04 - . 36 4.90-5. 0 . 93-.20
989 0-2029 989 0-2 29
64324 64324- 029
64324- 29
64324-2029 64324-2 29
Customer to cut off terminal from reel: 0.30mm (.0 2”) maximum Cut-off Tab.
DEFINITION OF TERMS
TYPE 4A

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals
Doc No: ATS-638 98HM Release Date: 07-25-08 UNCONTROLLED COPY Page 2 of 6
Revision: C Revision Date: -22- 0
CRIMP SPECIFICATION
T rminal S ri s No. B ll Mouth B nd up B nd down Twist Roll Conductor Brush
mm In. D gr D gr mm In.
989 0 0. -0.5 .004-.020 2 2 2 3 0.2 - 0.6 .008-.024
64324 0. -0.5 .004-.020 2 2 2 3 0.2 - 0.6 .008-.024
S am: Seam shall not be open and no wire allowed out of the crimping area.
After crimping, the conductor profiles should measure the following (See notes on page 4).
T rminal
S ri s No.
Wir Siz
Conductor Insulation Pull Forc
Minimum Profil
Crimp H ight
(R f)
Crimp Width
(R f)
Crimp H ight
(R f)
Crimp Width
(R f)
AWG mm2 mm In. mm In. mm In. mm In. N Lb 2.5mm2 3mm2
989 0 - 2.50
.80- .90 .07 -.075 2.89 . 4 4.80-5.00 . 99-.2 5.02 . 98 235 52.80 X
- 3.00 .95-2.05 .077-.08 2.90 . 4 5. 0-5.30 .207-.2 5 5.05 . 99 260 58.42 X
64324 - 2.50
.80- .90 .07 -.075 2.89 . 4 4.80-5.00 . 99-.2 5.02 . 98 235 52.80 X
- 3.00 .95-2.05 .077-.08 2.90 . 4 5. 0-5.30 .207-.2 5 5.05 . 99 260 58.42 X
CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects - damage can
occur to the tool or die.
Τ
ΤΤ
Τ Tool Qualification Notes:
. 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.
Crimping T rminals
. Lift up the wire stop blade.
2. Insert the terminal fully into the correct profile until the
terminal is fully seated and stops.
3. Bring down the wire stop blade.
4. Slide the pre-stripped wire with the seal into the wire stop blade. See Figure .
5. Be sure to hold the wire in place until the terminal is fully crimped. See Figure 2.
6. Close the tool until the ratchet releases. The tool handles will then spring open.
7. Lift up the wire stop blade if it is still in down position.
8. Carefully remove the crimped terminal.
TERMINAL
PRE-STRIPPED
WIRE WITH SEAL Figur 1
WIRE STOP
BLADE

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals
Doc No: ATS-638 98HM Release Date: 07-25-08 UNCONTROLLED COPY Page 3 of 6
Revision: C Revision Date: -22- 0
Not : The tamper proof ratchet action will not release the tool until it has been fully closed.
Not : To maintain a good brush control and a consistent bell mouth the crimping instructions must be
followed.
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 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.
Figur 2
CONDUCTOR
PUNCH
WIRE
LOCATOR
TERMINAL
INSULATION
PUNCH
INSULATION ANVIL
CONDUCTOR
ANVIL
WIRE STOP
BLADE
SEAL

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals
Doc No: ATS-638 98HM Release Date: 07-25-08 UNCONTROLLED COPY Page 4 of 6
Revision: C Revision Date: -22- 0
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.
Not s:
. 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 ( /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 th Modular Crimp H ad
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 CP 2.8 Receptacle Crimp Terminals
Doc No: ATS-638 98HM Release Date: 07-25-08 UNCONTROLLED COPY Page 5 of 6
Revision: C Revision Date: -22- 0
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 H ad
Ord r No.
Tool
Ord r no.
Tool
D scription
Adapt r
Ord r No.
Adapt r
D scription
Figur
No.
638 -9870
638 6-0000 Hand Crimp Frame (Short) N/A N/A 3
638 6-0050 Hand Crimp Frame (Long) N/A N/A 3
638 6-0200 Battery Power Tool ( 0 V) 638 6-0600 Battery Power Crimp Adapter 4
638 6-0250 Battery Power Tool (220 V) 638 6-0600 Battery Power Crimp Adapter 4
638 6-0 00 Air Power Tool 638 6-0700 Air Power Crimp Adapter 5
Applications for th Modular Crimp H ad
Hand Crimp Tool Batt ry Pow r d Tool Air Pow r d Tool
Figur 3 Figur 4 Figur 5
MODULAR
CRIMP
HEAD
LOCKING
PINS
HAND CRIMP
FRAME LONG
OR SHORT

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals
Doc No: ATS-638 98HM Release Date: 07-25-08 UNCONTROLLED COPY Page 6 of 6
Revision: C Revision Date: -22- 0
RATCHET
RELEASE LEVER
HANDLE
SPRING
CRIMPING
SPRING (2)
3
6
4
Figur 6
M4 X 14mm
LONG BHCS
2
5
1
M4 FLAT
WASHER
PARTS LIST
Hand Crimp Tool 63811-9800
It m Ord r Numb r D scription Quantity
638 -9870 Modular Crimp Head (Ref)
2 638 6-0050 Hand Crimp Frame (Long) (Ref)
3 638 -9875 Locator
4 638 6-000 Locking Pin 2
5 63600-0525 Handle Spring
6 63600-0520 Crimping Spring 2
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