molex 207129 Series User manual

Hand Crimp Tool for SPOX™ Terminals
Doc No. 63811-5200 Release Date: 04-03-06 UNCONTROLLED COPY Page 1 of 6
Revision: A Revision Date: 04-03-06
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
BELL MOUTH
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
TYPE 2C
HAND CRIMP TOOL
SPECIFICATION SHEET
Order No. 63811-5200
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
 This tool is WHMA-IPCA620 Class 2 and RoHS compliant
SCOPE
SPOX™, 2.50mm (.098") Pitch Crimp Terminal, 22 - 28 AWG.
Wire Size ✴ Insulation Diameter Strip Length
Terminal Series No. Terminal Order No. AWG mm² mm In. mm In.
08-70-0057 22-28 0.35-0.08 1.15-1.90 .045-.075 3.30-3.80 .130-.150
5103 08-70-0059 22-28 0.35-0.08 1.15-1.90 .045-.075 3.30-3.80 .130-.150
08-70-1040 22-28 0.35-0.08 1.15-1.90 .045-.075 3.30-3.80 .130-.150
08-70-1046 22-28 0.35-0.08 1.15-1.90 .045-.075 3.30-3.80 .130-.150
5263
39-00-0152 22-28 0.35-0.08 1.15-1.90 .045-.075 3.30-3.80 .130-.150
45627 45627-0002 22-24 0.35-0.20 1.15-1.90 .045-.075 3.30-3.80 .130-.150
✴ See Conditions on page 2.
DEFINITION OF TERMS
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the scope.

Hand Crimp Tool for SPOX™Terminals
Doc No. 63811-5200 Release Date: 04-03-06 UNCONTROLLED COPY Page 2 of 6
Revision: A Revision Date: 04-03-06
CONDITIONS:
After crimping, the conductor profiles should measure the following (see notes on page 5).
Conductor Crimp Insulation Crimp
Wire Size Height (Ref.) Width (Ref.) Height (Ref.) Width (Ref.) Pull Force Min. ✴ Profile
Terminal
Series No
Hand
Tool
Locator AWG mm2mm In. mm In. mm In. mm In. N Lb. A B C
5103 1 22 0.35 0.73-0.80 .029-.031 1.40 .055 1.68 .066 1.90 .075 44.48 10.0 X
5103 1 24 0.20 0.67-0.74 .026-.029 1.40 .055 1.57 .062 1.90 .075 28.91 6.5 X
5103 1 26 0.12 0.63-0.69 .025-.027 1.40 .055 1.42 .056 1.50 .059 17.79 4.0 X
5103 1 28 0.08 0.61-0.67 .024-.026 1.40 .055 1.42 .056 1.50 .059 11.12 2.5 X
5263 1 22 0.35 0.73-0.80 .029-.031 1.40 .055 1.68 .066 1.90 .075 44.48 10.0 X
5263 1 24 0.20 0.67-0.74 .026-.029 1.40 .055 1.57 .062 1.90 .075 28.91 6.5 X
5263 1 26 0.12 0.63-0.69 .025-.027 1.40 .055 1.42 .056 1.50 .059 17.79 4.0 X
5263 1 28 0.08 0.61-0.67 .024-.026 1.40 .055 1.42 .056 1.50 .059 11.12 2.5 X
45627 2 22 0.35 0.73-0.80 .029-.031 1.40 .055 1.68 .066 1.90 .075 44.48 10.0 X
45627 2 24 0.20 0.67-0.74 .026-.029 1.40 .055 1.57 .062 1.90 .075 28.91 6.5 X
✴ To Achieve IPC-A-620 Class 2 crimps. The following over-all wire insulation diameter ranges are recommended:
1. Profile A: 1.20-1.90mm (.047-.075 inch)
2. Profile B: 1.20-1.55mm (.047-.061 inch)
3. Profile C: 1.15-1.30mm (.045-.051 inch)
OPERATION
CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects as 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
1. Select the desired terminal listed in the preceding charts. Make sure that the proper locator is mounted on the tool.
2. Swing the terminal locator away from the crimp tool shown in Figure 2. Some terminals
with large insulation grips may interfere with the crimp tooling when swinging the
locator into position. The terminal must then be loaded into the locator in the
closed/crimp position.
3. When using the locator, press down on the wire stop on the locator as shown in Figure
2. Insert the proper terminal into the proper nest opening. Make sure when choosing
the nest opening, it will correspond with the A, B, or C profile on the hand tool.
4. Return the locator to its original position.
5. Insert the proper wire over the terminal. Some large O.D. wires may need to be placed
into the terminal before closing the tool. Gently touch the wire stop with the end of the
wire. See Figure 3.
6. Compress 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.
Figure 1
LOCATOR
JAWS OPEN

Hand Crimp Tool for SPOX™Terminals
Doc No. 63811-5200 Release Date: 04-03-06 UNCONTROLLED COPY Page 3 of 6
Revision: A Revision Date: 04-03-06
TERMINAL
PUSH HERE TO
OPEN WIRE STOP
SWING OPEN
LOCATOR
LOCATOR TERMINAL IN PLACE
Figure 2
7. Remove the crimped 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.
8. Visually inspect the crimped terminal for proper crimp location.
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, actual crimp
height measurements may very slightly. An occasional, destructive, pull force test
should be preformed to check hand tool crimp. Pull Force value Must exceed the
Minimum pull force specifications listed on page 2.
Locator Change Over and Replacement
Multiple styles of locators maybe provided with the crimp hand tool. They
are different colors for easy identification. See the parts list on the last
page of the document. Make sure the desired style of locator is installed
for the proper terminal and wire. Follow the steps below to change the
locators.
1. Open the crimp hand tool.
2. Swing the existing locator open and away from the hand tool.
3. Firmly press down on the brass pivot shaft with your thumb, while
pulling the locator up. Slip the locator off the top of the brass
pivot shaft. See Figure 4.
4. Replace it with the desired locator by putting over the brass pivot
shaft and snapping it into place.
LOCATOR
IN PLACE
WIRE STOP
TERMINAL
WIRE AGAINST
STOP Figure 3
WIRE STOP
WIRE
SWING
LOCATOR
OPEN
PRESS DOWN ON
BRASS PIVOT SHAFT
LIFT UP LOCATOR
JAWS OPEN
Figure 4

Hand Crimp Tool for SPOX™Terminals
Doc No. 63811-5200 Release Date: 04-03-06 UNCONTROLLED COPY Page 4 of 6
Revision: A Revision Date: 04-03-06
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.
This tool 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. Light oil such as 30 weight automotive oil
used at the oil points shown in Figure 6, 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 the ratchet release lever. See Figure 6.
How To Adjust Tool Preload (See Figure 6)
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:
1. Remove or fold back the handle grip from the handle to
expose the eccentric axle and setting wheel.
2. Remove the locking screw with a 2mm hex wrench. The
wrench set (63810-0101), is not supplied. It is sold
separately from the hand tool.
3. Turn the eccentric axle and setting wheel with the
wrench or pliers Counter-clockwise (CCW) will increase
handle force.
4. Replace the locking screw, aligning the nearest notch in the setting wheel to locking screw.
5. Replace the handle grip.
6. Check the crimp specifications or conduct a pull test after tool handle preload force is adjusted.
RATCHET
RELEASE LEVER
Figure 6
HANDLE
GRIP
REMOVED
ECCENTRIC AXLE
HANDLE
GRIP
LOCKING
SCREW
WRENCH SET
(SOLD
SEPERATELY)
PRELOAD
CHECK POINT
25.4MM
SETTING WHEEL
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figure 5

Hand Crimp Tool for SPOX™Terminals
Doc No. 63811-5200 Release Date: 04-03-06 UNCONTROLLED COPY Page 5 of 6
Revision: A Revision Date: 04-03-06
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.
Certification
Molex does not certify or re-certify commercial grade 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 25mm (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 SPOX™Terminals
Doc No. 63811-5200 Release Date: 04-03-06 UNCONTROLLED COPY Page 6 of 6
Revision: A Revision Date: 04-03-06
RATCHET
RELEASE LEVER
2
Figure 7
M4 X 5LG
BHCS
3
4
1
3
5
PARTS LIST
Item Number Order Number Description Quantity
1 63810-0101 Wrench Set (Not included) 0
2 63810-0102 Locator Base Assembly 1
3 63810-0103 Repair Kit (Not included) 0
4 63811-5275 Locator #1-Black 1
5 63811-5276 Locator #2-Gray 1
Molex Application Tooling Group
2200 Wellington Court
Lisle, IL 60532
Tel: [phone]
Fax: [phone]
Visit our Web site at http://www.molex.com