molex 207129 Series User manual

Hand Crimp Tool for 2.28mm (.090”) Sealed Receptacle Terminals
Doc No: TS-638257600 Release Date: 08-12-13 UNCONTROLLED COPY Page 1 of 7
Revision: Revision Date: 08-12-13
CONDUCTOR
BRUSH
TRIP LENGTH
SEAM
CONDUCTOR
CRIMP HEIGHT
CUT
-
OFF
TAB
BELL MOUTH
BEND UP
TWISTING
ROLLING
BEND
DOWN
WIRE
SEAL
INSULATIO
N
CRIMP HEIGHT
HAND CRIMP
TOOL
Application Tooling
Sp cification Sh t Ord r No. 63825-7600
FEATURES
 full cycle ratcheting hand tool ensures complete crimps
 Ergonomic soft grip handles for comfortable crimping
 precision user-friendly terminal locator wire stop holds terminals in the proper crimping position
 Right and Left handed applications
 This tool is IPC/WHM -620 Class 2 compliant as indicated
 This tool is RoHS compliant, however RoHS compliant is not required
SCOPE
Products: 2.28mm (.090”) Receptacle Terminal with Seal, 0.30-0.50mm² VSS.
T rminal S ri s No. T rminal Ord r No.
Wir Siz



Insulation Diam t r
Strip
L ngth
AWG
mm²
mm
In.
mm
In.
35407
35407
-
6302
35407
-
6702
N/
0.30
-
0.50
1.40
-
2.10
.055
-
.083
5.00
-
5.60
.197
-
.220



This
Hand Tool
provides optimum
-
620 Class 2 crimps with insulation O.D. range of
1.40
-
2.10
mm.
DEFINITION OF TERMS
TYPE 4D

Hand Crimp Tool for 2.28mm (.090”) Sealed Receptacle Terminals
Doc No: TS-638257600 Release Date: 08-12-13 UNCONTROLLED COPY Page 2 of 7
Revision: Revision Date: 08-12-13
WIRE
INSULATION
SEAL
0.70mm
(REF)
SEAL POSTION
CRIMP SPECIFICATION
T rminal S ri s No.
B ll mouth
Cut
-
off Tab Maxi
mum
Conductor Brush
Mm
In.
mm
In.
mm
In.
35407
0.3
-
0.6
.01
1
-
.02
3
0.0
-
0.30
.011
0.3
0
–
0.
80
.01
1
-
.031
T rminal S ri s No.
B nd up B nd down Twist Roll
Punch Width mm (R f)
S am
Seam shall not be open
and no wire allowed out
of the crimping area
Conductor
Insulation
D gr
D gr
mm
In
mm
In
35407
3
3
3
5
1.80
.071
3.80
.150
fter crimping, the conductor profiles should measure the following (See notes).
T rminal S ri s No.
Wir Siz
Conductor
Insulation
Crimp H ight
Crimp Width
(R f
)
Crimp H ight
Crimp Width
Typ
mm
2
mm
In.
mm
In.
mm
In.
mm
In.
35407
VS
0.
50
1.
01
-
1.
12
.
039
-
.
044
1.
8
0
.07
1
N/
N/
3.80
.150
VS
S
0.
50
1.
01
-
1.
12
.
039
-
.
044
1.
8
0
.07
1
N/
N/
3.80
.150
VS
0.30
0.89
-
1.
01
.
035
-
.
039
1.
8
0
.07
1
N/
N/
3.80
.150
VSS
0.30
0.89
-
1.
01
.
035
-
.
039
1.
8
0
.07
1
N/
N/
3.80
.150
T rminal S ri s No.
Wir Siz Pull Forc Minimum


Singl Wir S al Profil
AWG
mm
2
N
Lb
0.
3
mm
2
0.
5mm
2
35407
N/
0.
50
88.3
65.1
35903-0022 (M) (Black)
X
N/
0.
30
58.8
43.3
X


Cabl S al Position On a Wir
(Before crimping)
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.
Not :
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. n
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
CAUTION: Crimp only the Molex terminals listed in the scope for this tool. Do not crimp hardened objects as
damage can occur to the tool frame and/or crimp dies.

Hand Crimp Tool for 2.28mm (.090”) Sealed Receptacle Terminals
Doc No: TS-638257600 Release Date: 08-12-13 UNCONTROLLED COPY Page 3 of 7
Revision: Revision Date: 08-12-13
WIRE AND SEAL
POSITIONED IN
LOWER PART OF
THE PUNCHES
Figur 4
TERMINAL
WIRE AGAINST
THE
WIRE STOP
WIRE AND
SEAL POSITON
WIRE STOP IS
PART OF THE
LOCATOR
TERMINAL
Open the tool by squeezing the handles together. t the end of the closing stroke, the ratchet mechanism will
release the handles and the hand tool will spring open. See Figure 1.
Crimping T rminals
1. Select the desired terminal listed in the
preceding charts.
2. Make sure the center of the locator is in the
down position. With the locator attached, push
the locator button on the back of the hand tool to
bring the locator forward through the tooling.
See Figure 2.
3. While holding the locator button in, load the
terminal with the seal into the proper nest
opening in the locator based on the wire gauge
or terminal type markings on the hand tooling.
See Figure 3.
4. Release the locator button, allowing the locator to return to the crimping position.
5. With the hand tool open, insert the properly stripped wire and seal under the punches into the lower part of the
upper tooling, until the wire is against the wire stop. See Figure 4.
6. Seal position should be under and inside the punches, keep this position while crimping.
7. Crimp the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.
Release the handles to open the jaws.
SQUEEZE
HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Figur 1
LOCATOR
IN DOWN
POSTION
PUSH ON THE
LOCATOR BUTTON
Figur 2
TERMINAL
Figur 3
LOCATOR
PUSHED THRU
TOOLING
TERMINAL
RELEASE LOCATOR
BUTTON
LOCATOR
BUTTON
PUSHED IN

Hand Crimp Tool for 2.28mm (.090”) Sealed Receptacle Terminals
Doc No: TS-638257600 Release Date: 08-12-13 UNCONTROLLED COPY Page 4 of 7
Revision: Revision Date: 08-12-13
Figur 8
PUSH ON
HANDLE
JAWS OPEN
PULL OPEN
TOOLING
TOOLING
M3 BHCS
MATCH
UP MARKS
FRONT
BACK
Figur 8
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
Figur 7B
SQUEEZE
HERE
SQUEEZE
HERE
LOCATOR
Figur 7A
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.
Locator R plac m nt
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.
5. Press the red insert down as far as it will go as shown
in Figure 7B.
6. 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.
7. 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.

Hand Crimp Tool for 2.28mm (.090”) Sealed Receptacle Terminals
Doc No: TS-638257600 Release Date: 08-12-13 UNCONTROLLED COPY Page 5 of 7
Revision: Revision Date: 08-12-13
Right or L ft Hand Op ration
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.
3. 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.
4. Do the same thing with the lower tooling and tighten the M3 screws. Be
sure the small markings line up.
5. Reinstall the locator by following the Instructions in the locator replacement
section.
Maint nanc
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
pressing up on the ratchet release lever in the movable handle. See Figure
11.
How to Adjust Tool Pr load
(S Figur 12)
This hand tool is factory preset to 25-45 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:
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figur 10
RATCHET RELEASE
LEVER
Figur 11

Hand Crimp Tool for 2.28mm (.090”) Sealed Receptacle Terminals
Doc No: TS-638257600 Release Date: 08-12-13 UNCONTROLLED COPY Page 6 of 7
Revision: Revision Date: 08-12-13
Figur 12
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
SETTING
WHEEL
RATCHET
RELEASE LEVER
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. ll vital
components are long life tested. ll 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. ny 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.
C rtification
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. 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 djust 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 2.28mm (.090”) Sealed Receptacle Terminals
Doc No: TS-638257600 Release Date: 08-12-13 UNCONTROLLED COPY Page 7 of 7
Revision: Revision Date: 08-12-13
RATCHET
RELEASE
LEVER
2
Figur 13
1
3
PARTS LIST
It m Numb r
Ord r Numb r
D scription
Quantity
REF
63825
-
7600
Hand Crimp Tool
Figure
13
1
63825
-
76
75
Locator ssembly
1
2
63810
-
0104
Spring, Return
1
3
63810
-
0105
Spring, Ratchet
1
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