molex 207129 Series User manual

Hand Crimp Tool for SC Panel Mount Terminals
Doc No. 64003-3600 Release Date: 01-04-06 UNCONTROLLED COPY Page 1 of 6
Revision: A Revision Date: 01-04-06
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
BELL MOUTH
COND.CRIMP
HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
SEAM
Hand Crimp Tool
Operating Instruction Sheet And Specifications
Part No. 64003-3600
(Replaces 19285-0096)
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
SCOPE
Female Terminals for Self Contained (SC) Power Panel Mount Connectors10 AWG
Testing
Mechanical
The tensile test or pull test is a means of evaluating the mechanical properties of the crimped connections. The following chart
shows the UL specifications for various wire sizes. The tensile strength is shown in pounds and indicates the minimum acceptable
force to break or separate the terminal from the conductor.
Wire Size (AWG) *UL – 486 A
10 80
*UL – 486 A – Terminals (copper conductor only)
The following is a partial list of the product part numbers and their specifications that this tool is designed to run. We will be adding
to this list and an up to date copy is available on www.molex.com.
Wire Size Insulation Diameter Strip Length
Terminal Series No. Terminal Order No. AWG mm²mm In. mm In.
19403-1241 19403-1241 10 5.00 4.57 Max. .180 Max. 4.75 .187
DEFINITION OF TERMS
This terminal drawing is a generic terminal representation. It is not an image of a terminal listed in
the scope.
TYPE 4C

Hand Crimp Tool for SC Panel Mount Terminals
Doc No. 64003-3600 Release Date: 01-04-06 UNCONTROLLED COPY Page 2 of 6
Revision: A Revision Date: 01-04-06
HANDLE OPEN
LOCK IN
UP RIGHT
POSITION
LOCATOR
CLOSED
Figure 1
TERMINAL
PUSH HERE TO
OPEN WIRE STOP
JAWS
PARTIALLY
CLOSED
Figure 2
WIRE IN TERMINAL
WIRE AGAINST
WIRE STOP
CONDITIONS:
After crimping, the conductor profiles should measure the following (See notes on page 4).
Bell mouth Conductor Brush Bend up Bend down Twist RollTerminal
Series No. mm In. mm In. Degree Degree
19403-1241 1.14 .045 1.27 .050 3 3 5 8
Seam
Seam shall not be open
and no wire allowed out
of the crimping area
Conductor Crimp (REF) Insulation Crimp (REF)
Wire Size Height Width Height Width Pull Force Min.
Terminal
Series No. AWG mm²mm In mm In. mm In. mm In. N Lb.
19403-1241 10 5.00 2.08-2.24 .082-088 4.64-4.77 .183-.188 4.37-4.57 .172-.180 6.17-6.37 .243-.250 356.0 80.0
OPERATION
CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects - damage can occur to the tool
or die.
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 Terminals
Terminals may be loaded when locator is swung open, however when swinging the locator into crimping position, the spring loaded
locator may need to be pushed down to clear the tooling. Swing the terminal locator against the crimp tool and turn lock up to lock the
locator. Terminals may also be loaded easily while locator is up against the crimp tool and locked.

Hand Crimp Tool for SC Panel Mount Terminals
Doc No. 64003-3600 Release Date: 01-04-06 UNCONTROLLED COPY Page 3 of 6
Revision: A Revision Date: 01-04-06
LOCATOR
INSULATION
ANVIL
TERMINAL
WIRE
INSULATION
PUNCH
WIRE
AGAINST
STOP
Figure 3
WIRE STOP
CONDUCTOR
ANVIL
CONDUCTOR
PUNCH
1. Press down on the wire stop on the locator. Insert the
terminal into the nest opening as shown in Figure 2.
2. When the locator is against the crimp tool and locked the
terminal is now in proper position for crimping.
3. Insert the proper pre-striped wire over or into the
terminal. Gently touch the wire stop with the end of the
wire. See Figure 2 and 3.
4. Crimp the terminal by squeezing the tool handles until the
ratchet mechanism cycle has been completed. Release
handles to open the jaws.
Note: The tamper proof ratchet action will not release the tool
until it has been fully closed.
5. Remove the crimp terminal from the terminal locator by pressing down on the wire stop and gently pulling on the wire. The
terminal locator can be in either position
6. Visually inspect the crimped terminal for proper crimp location and other attributes.
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
64003-3600 was engineered for durability, but like any fine piece of
equipment it needs cleaning and lubrication for a maximum service life
of trouble-free crimping. A light oil, such as 30 weight automotive oil
used at the oil points shown in Figure 4, every 5,000 crimps or 3
months will significantly enhance the tool life and ensure a stable
calibration.
4. 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 (See Figure 4)
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 rotating the small slotted screw marked with an arrow. See Figure 4.
Figure 4
LUBRICATION POINTS
(BOTH SIDES)
LIGHT OIL (EVERY 3 MONTHS
OR 5,000 CRIMPS)
ALL PIVOT POINTS
SLOTTED SCREW

Hand Crimp Tool for SC Panel Mount Terminals
Doc No. 64003-3600 Release Date: 01-04-06 UNCONTROLLED COPY Page 4 of 6
Revision: A Revision Date: 01-04-06
NOT POSSIBLE TO PIN GAUGE. MEASURE
A CRIMPED TERMINAL OR A SLUG *
*SOLDER, LEAD OR
SIMILAR SOFT METAL
X
Tool Calibration
A Certificate of Calibration (see last page) was supplied with the tool. To recalibrate this Tool, Pin Gauge measurements should be taken
in each conductor nest and compared to this chart. The tool should be lubricated prior to recalibration to ensure consistent
measurements.
Wire Range “X”Dimension Conductor Crimp
Mean Go No Go
Nest
Color Code AWG mm²mm In. mm In. mm In.
Crimp Inspection
Marking
None 10 5.00 2.16 .085 2.11 .083 2.24 .088 None
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
would exchange the tool free of charge. This 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.
Hand held crimping tools are intended for low volume, prototyping, or repair requirements only.
CAUTION: Repetitive use of this tool should be avoided.
Notes:
1. This tool should only be used for the terminals and wire gauges specified on this sheet.
2. This tool is not adjustable. Variations in tools, terminals, wire stranding and insulation types may affect crimp height. A crimp
height chart is provided with this manual as Reference Only.
3. 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.
4. An occasional destructive pull force test should be performed to check hand tool crimp. Pull force should be used as the final
criteria for an acceptable crimp. Pull force values Must exceed the Minimum pull force specifications listed on pages 2 and 3.
Refer to Molex Quality Crimping Handbook 63800-0029 for additional information on crimping and crimp testing.
5. Molex does not certify crimp hand tools.
6. This tool is very difficult to disassemble and reassemble. Customer repair is not recommended.
CAUTION: Molex crimp specifications are valid only when used with Molex terminals, applicators and tooling.

Hand Crimp Tool for SC Panel Mount Terminals
Doc No. 64003-3600 Release Date: 01-04-06 UNCONTROLLED COPY Page 5 of 6
Revision: A Revision Date: 01-04-06
Figure 5
RATCHET
RELEASE SCREW
1
M4 X 8mm
LONG BHCS
2
PARTS LIST
Item Number Order Number Description Quantity
1 63811-4773 Locator Base 1
2 64003-3675 Locator 1

Hand Crimp Tool for SC Panel Mount Terminals
Doc No. 64003-3600 Release Date: 01-04-06 UNCONTROLLED COPY Page 6 of 6
Revision: A Revision Date: 01-04-06
Certificate of Calibration
Tool Order Number _____________________
Tool Eng. Number______________________
Tool Revision_________________________
Serial Number________________________
Date of Manufacture____________________
Pin Gauge of Conductor Nest/Nests or Slug height if the nest is the “F”Crimp style.
Range Conductor Nest # 1 =______________Actual =______________
Technician_______________________
Date of Calibration__________________
Calibration should be done every 5,000 cycles or 3 months. Tools should be lubricated during this operation.
Molex Application Tooling Group
1150 E. Diehl Road
Naperville, IL, 60563
Tel: [phone]
Fax: [phone]
Visit our Web site at http://www.molex.com
TYPE 4C