molex 207129 Series User manual

Hand Crimp Tool For Cluster Block Terminal
Doc No: ATS-6382 0200 Release Date: 02-08-12 UNCONTROLLED COPY Page 1 of 8
Revision: A Revision Date: 02-08-12
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
CONDUCTOR
CRIMP HEIGHT
CUT-OFF TAB
SEAM
BELL MOUTH
WIRE
TYPE 4D
HAND CRIMP
TOOL
Application Toolin
Specification Sheet Order No. 63825-0200
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 as indicated
 This tool is RoHS compliant, however RoHS compliant is not required
SCOPE
Products: Cluster Block Terminal for 18 AWG UL Style 048 Wire.
Terminal
Series No.
Terminal Order No.
Reel Form only
Wire Size
Insulation Diameter
Strip Len th
IPC/WHMA-A620 (1)
Terminal (2)
Insulation ran e
AWG mm² mm In. mm In. mm In.
7920 7920-6002 18 0.82 2.30-2.4 .091-.097 2.1 -2.4 .08 -.097 .00- . 0 .197-.217
Note: This terminal will accommodate the UL Style 048 wire.
(1) To achieve optimum IPC-A620 insulation crimps, use this insulation OD range.
(2) Overall insulation OD specification for terminal.
 Customer to cut off terminal from reel: 0.40mm (.016”) maximum Cut-off Tab.
DEFINITION OF TERMS

Hand Crimp Tool For Cluster Block Terminal
Doc No: ATS-6382 0200 Release Date: 02-08-12 UNCONTROLLED COPY Page 2 of 8
Revision: A Revision Date: 02-08-12
▲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 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
After crimping, the crimp profiles should measure the following:
Terminal Series No. Bell mouth Conductor Brush
mm In. mm In.
7920 0.20-0. 0 .008-.020 0. 0-1.00 .020-.039
Terminal Series No. Bend up Bend down Twist Roll Seam
Seam shall not be open and no wire
Allowed out of the crimping area
De ree De ree
7920 3 3 3
Terminal
Series No.
Wire Size Conductor Crimp Insulation Crimp Pull Force
Minimum
Hei ht Width (Ref) Hei ht Maximum Width Maximum
AWG mm2 mm In. mm In. mm In. mm In. N Lb.
7920 18 0.82 1.4 -1. .0 7-.061 2.40 .09 3.80 .1 0 3. 0 .138 107.8 24.2
CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects as damage can
occur to the tool or die.


 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.
Note:
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.
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.
See Figure 1.
OVERLAP
INSULATION
CRIMP
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
WIRE
SQUEEZE
HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Fi ure 1

Hand Crimp Tool For Cluster Block Terminal
Doc No: ATS-6382 0200 Release Date: 02-08-12 UNCONTROLLED COPY Page 3 of 8
Revision: A Revision Date: 02-08-12
PRE
-
STRIPPED WIRE
TERMINAL
Fi ure 5
TERMINAL
WIRE AGAINST
THE WIRE
STOP
WIRE
WIRE STOP IS
PART OF
THE LOCATOR
Crimpin Terminals
1. Select the desired terminal listed in the preceding charts.
2. Make sure the locator is attached behind the lower tooling and is above all the
anvils surfaces.
3. The spring loaded wire stop should be clear of the locator’s cavity, if not push up
on the red tab to move the wire stop out of the way while inserting the terminal.
See Figure 3.
4. 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.
. Partially close the tool handle until the first ratchet position engages, and
holds the terminal in place. See Figure 4.
6. Insert the properly stripped wire through the terminal and against the wire
stop. See Figure .
7. Crimp the terminal by squeezing the tool handles until the ratchet
mechanism cycle has been completed. Release the handles to open the
jaws.
TERMINAL
Fi ure 3 TERMINAL
PUSH UP
ON THE
RED TAB
PARTIALLY
CLOSE HANDLE
TOOLING
PARTIALLY
CLOSED
Fi ure 4
FIRST
RATCHET
POSITION
OPEN
POSITION
LOCATOR
IN DOWN
POSTION
RED
TAB
Fi ure 2

Hand Crimp Tool For Cluster Block Terminal
Doc No: ATS-6382 0200 Release Date: 02-08-12 UNCONTROLLED COPY Page 4 of 8
Revision: A Revision Date: 02-08-12
SQUEEZE
HERE
SQUEEZE
HERE
LOCATOR
Fi ure 7
TOP HOOKS
TOP SLOTS OF
HANDTOOL
LOWER TABS
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.
10. 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.
Locator Replacement
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.
1. Open the crimp hand tool.
2. Squeeze gently on the lower area shown in Figure 7 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 7.
4. To reinstall the new locator, make sure the hand tool is in the open
position.
. 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.
6. 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.
Ri ht or Left Hand Operation
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:
1. The locator must be removed before reversing the tooling.
2. Remove the M3 BHCS which is holding the upper tooling.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.
3. Do the same thing with the lower tooling and tighten the M3 screws. Be sure the small markings line up.
4. Reinstall the locator by following the Instructions in the locator replacement section.
TERMINAL
Fi ure 6
WIRE
WIRE STOP

Hand Crimp Tool For Cluster Block Terminal
Doc No: ATS-6382 0200 Release Date: 02-08-12 UNCONTROLLED COPY Page of 8
Revision: A Revision Date: 02-08-12
MATCH
UP MARKS
FRONT BACK
Fi ure 9
Fi ure 8
PUSH ON
HANDLE
JAWS OPEN
PULL OPEN
TOOLING TOOLING
M3 BHCS
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 ,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.
. 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 11.
RATCHET RELEASE
LEVER
Fi ure 11
LUBRICATION
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Fi ure 10

Hand Crimp Tool For Cluster Block Terminal
Doc No: ATS-6382 0200 Release Date: 02-08-12 UNCONTROLLED COPY Page 6 of 8
Revision: A Revision Date: 02-08-12
Fi ure 12
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
SETTING
WHEEL
RATCHET
RELEASE LEVER
How to Adjust Tool Preload
(See Fi ure 12)
This hand tool is factory preset to 2 -4
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:
1. Hold the hand tool in the palm of your
hand as shown in Figure 12. 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:
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.

Hand Crimp Tool For Cluster Block Terminal
Doc No: ATS-6382 0200 Release Date: 02-08-12 UNCONTROLLED COPY Page 7 of 8
Revision: A Revision Date: 02-08-12
Certification
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. To re-certify, crimp a terminal to a wire, which has been stripped
12.7mm (1/2”) long, so there is no crimping of the insulation. Pull the terminal and wire at a rate no faster than
2 mm (1.00”) per minute. 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 Cluster Block Terminal
Doc No: ATS-6382 0200 Release Date: 02-08-12 UNCONTROLLED COPY Page 8 of 8
Revision: A Revision Date: 02-08-12
RATCHET
RELEASE LEVER
2
Fi ure 13
1
3
PARTS LIST
Item Number Order Number Description Quantity
REF 6382 -0200 Hand Crimp Tool Figure 13
1 6382 -027 Locator Assembly 1
2 63810-0104 Spring, Return 1
3 63810-010 Spring, Ratchet 1
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