molex 207129 Series User manual

Tool Kit for KK® Crimp Terminals
Doc No: ATS-6381174HM Release Date: 10-31-06 UNCONTROLLED COPY Page 1 of 8
Revision: D Revision Date: 06-30-23
Order No.
63811-7400
Application Tooling
Specification Sheet
FEATURES
A full cycle ratcheting hand tool ensures complete crimps
Ergonomic soft grip handles for comfortable crimping
Easy handling due to outstanding force ratio
A precision user-friendly terminal locator with wire stop that holds terminals in the proper crimping position
This tool is IPC/WHMA-A-620 compliant
Tooling can be installed in the 63816-1915 Power Crimp Head, which is installed into the 63816-0270 (110 V)
or 63816-0280 (220 V) Battery Powered Tools and the 63816-1900 Electric Crimp Machine
This tool is RoHS compliant; however, RoHS compliance is not required
SCOPE
Products: 3.96mm (.156") Pitch KK® Crimp Terminal for 22-26 AWG.
Terminal
Series No.
Terminal Order No.
Wire Size
Insulation Diameter
Strip Length
Loose Piece
Reel
AWG
mm²
mm
In.
mm
In.
2578
08-50-0019
08-56-0122
08-50-0018
08-56-0161
22 - 26
0.35-0.12
1.20-1.52
.047-.060
2.54-3.17
.100-.125
08-50-0062
08-56-0163
08-50-0061
08-56-0162
08-50-0066
08-58-0126
08-50-0065
08-58-0125
08-50-0108
08-60-0004
08-50-0107
08-59-0101
08-50-0112
08-65-0107
08-50-0111
08-60-0003
08-50-0134
08-65-0111
08-50-0133
08-65-0108
08-52-0117
08-65-0117
08-50-0504
08-65-0109
08-55-0106
40-01-1119
08-52-0116
08-65-0110
08-55-0132
40-07-1106
08-55-0105
08-65-0116
08-56-0108
50-29-1878
08-55-0121
40-01-1117
08-55-0123
40-07-1105
08-55-0137
50-29-1767
08-56-0107
50-29-1877
08-56-0121
5168
08-70-0019
08-70-0099
08-70-0018
08-70-0098
22 - 26
0.35-0.12
1.20-1.52
.047-.060
2.54-3.17
.100-.125
7258
08-50-0185
08-58-0134
08-04-0001
08-56-0181
22 - 26
0.35-0.12
1.20-1.52
.047-.060
2.54-3.17
.100-.125
08-52-0125
08-65-0122
08-50-0183
08-58-0133
08-56-0124
08-65-0127
08-50-0283
08-65-0121
08-56-0182
08-52-0124
08-65-0126
08-56-0123
Customer to cut off terminal from reel: .2.80mm (.110”) maximum Cut-off Tab center.
See Conditions on page 2.
TYPE 2C

Tool Kit for KK® Crimp Terminals
Doc No: ATS-6381174HM Release Date: 10-31-06 UNCONTROLLED COPY Page 2 of 8
Revision: D Revision Date: 06-30-23
INSULATION CRIMP ▲SEE NOTE
BRUSH
STRIP LENGTH
BELL
MOUTH
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLLING
LOCKING
TANG HEIGHT
TWISTING
CUT-OFF
TAB
SEAM
CONDUCTOR CRIMP
DEFINITION OF TERMS
▲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).
CONDITIONS:
After crimping, the conductor profiles should measure the following (see notes below).
Terminal Series No.
Wire Size
Conductor
Crimp Height (Ref)
Punch Width (Ref)
Pull Force
Minimum
Profile
Conductor
Insulation
AWG
mm2
mm
In.
mm
In.
mm
In.
N
Lb.
A
B
2578
22
0.35
.94-1.04
.037-.041
1.56
.061
1.94
.076
44.0
10.0
X
24
0.20
.84-.94
.033-.037
1.56
.061
1.56
.061
29.0
6.5
X
26
0.12
.84-.94
.033-.037
1.56
.061
1.56
.061
18.0
4.0
X
5168
22
0.35
.94-1.04
.037-.041
1.56
.061
1.94
.076
44.0
10.0
X
24
0.20
.84-.94
.033-.037
1.56
.061
1.56
.061
29.0
6.5
X
26
0.12
.84-.94
.033-.037
1.56
.061
1.56
.061
18.0
4.0
X
7258
22
0.35
.94-1.04
.037-.041
1.56
.061
1.94
.076
44.0
10.0
X
24
0.20
.84-.94
.033-.037
1.56
.061
1.56
.061
29.0
6.5
X
26
0.12
.84-.94
.033-.037
1.56
.061
1.56
.061
18.0
4.0
X
OVERLAP
INSULATION
CRIMP
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
WIRE

Tool Kit for KK® Crimp Terminals
Doc No: ATS-6381174HM Release Date: 10-31-06 UNCONTROLLED COPY Page 3 of 8
Revision: D Revision Date: 06-30-23
SWING
LOCATOR
OPEN
PRESS DOWN
ON THE BRASS
PIVOT SHAFT
LIFT UP ON
THE LOCATOR
Figure 2
POWER
CRIMP
HEAD
Figure 1
PUNCHES
M4 X 10 LONG
BHCS
M4 X 18 LONG
BHCS
Tool Qualification Notes:
1. (Ref) means that the dimension provided is approximate because of the wide range of wires, conductor
stranding, insulation diameter and insulation hardness.
2. An occasional conductor crimp height measurement should be performed, and it should be used as the final
criterion for an acceptable crimp. It must lie between the minimum and maximum crimp height specification.
Refer to Molex Quality Crimping Handbook 63800-0029 for additional information on crimping and crimp
testing.
3. In addition, an occasional pull force test may be performed. It must exceed the minimum pull force
specification. Pull force should be measured with no influence from the insulation crimp. To ensure this, strip
the wire long enough so the terminal insulation grips do not contact the wire insulation.
Notes:
1. This tool should only be used for the terminals and wire gauges specified on this document.
2. Variations in tools, terminals, wire stranding and insulation types may affect crimp height.
3. This tool is intended for the conductor sizes specified on this document. It may not give good insulation
crimp support for insulation sizes outside of the specified range.
4. Molex does not repair hand tools. See warranty on page 6. The replacement parts listed are the only parts
available for repair. If the handles or crimp tooling become damaged or worn, a new tool must be
purchased.
CAUTION: Crimp only Molex terminals listed above with this tool. Do not crimp hardened objects as damage
can occur to the tool or die.
INSTALLATION
To install the Tool Kit into the Power Crimp Head follow the steps below:
Anvils and Punches Installation
1. Insert the Anvils into the bottom slots of the nest. Install the M4 x 10 long BHCS and tighten in place.
2. Insert the Punches into the top slots of the nest. Install the M4 x 18 long BHCS and tighten in place. See
Figure 1.
Locator Installation and Removal
Follow the steps below to install or replace the locator. See Figure 2.
To install the locator
1. Position the locator with the hole
over the brass pivot shaft
and snap it into place.
ANVILS

Tool Kit for KK® Crimp Terminals
Doc No: ATS-6381174HM Release Date: 10-31-06 UNCONTROLLED COPY Page 4 of 8
Revision: D Revision Date: 06-30-23
SWING OPEN
TERMINAL
PUSH HERE TO
OPEN WIRE STOP
LOCATOR
LOCATOR
TERMINAL IN PLACE
Figure 4
LOCATOR
IN PLACE
WIRE STOP
TERMINAL
WIRE
WIRE STOP
WIRE
AGAINST STOP
Figure 5
To remove the locator
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.
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 Terminals
1. Select the desired terminal listed in the preceding charts.
2. Swing the terminal locator away from the crimp tool shown in
Figure 4. Gently press on the locator to open the wire stop.
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, swing the locator away from the crimp tool, and gently press the locator against the
tool frame as shown in Figure 4. The wire stop will automatically open. Insert the proper terminal into the
proper nest opening. Make sure when choosing the nest opening, it will correspond with the A or B 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 5.
6. Compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.
Release handles to open the jaws.
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.
Figure 3
LOCATOR
JAWS OPEN

Tool Kit for KK® Crimp Terminals
Doc No: ATS-6381174HM Release Date: 10-31-06 UNCONTROLLED COPY Page 5 of 8
Revision: D Revision Date: 06-30-23
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
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. 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 6.
4. Replace it with the proper locator by putting over the brass
pivot shaft and snapping it into place.
For the Battery Power Tool:
1. Cycle the Battery Power Tool to crimp the terminal to the wire.
2. 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.
3. Visually inspect the crimped terminal for proper crimp location.
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 fine piece of
equipment it needs cleaning and
lubrication for a maximum service life of trouble free crimping. Use a 30 weight automotive (light) oil used at
the oil points, every 5,000 crimps or 3 months, shown in Figure 7A or 7B 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.
SWING
LOCATOR
OPEN
PRESS DOWN
ON BRASS PIVOT
SHAFT
LIFT UP
LOCATOR
JAWS
OPEN
Figure 6
Figure 7B
LUBRICATION
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY MONTH
OR
5,000 CRIMPS)
Figure 7A

Tool Kit for KK® Crimp Terminals
Doc No: ATS-6381174HM Release Date: 10-31-06 UNCONTROLLED COPY Page 6 of 8
Revision: D Revision Date: 06-30-23
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 8.
How to Adjust Tool Preload
(See Figure 8)
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) to 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.
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, Molex 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.
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.
CAUTION: Molex crimp specifications are valid only when used with Molex terminals and tooling.
RATCHET
RELEASE LEVER
Figure 8
HANDLE
GRIP
REMOVED
ECCENTRIC AXLE
HANDLE
GRIP
LOCKING
SCREW
WRENCH SET
(SOLD
SEPERATELY)
PRELOAD
CHECK POINT
25.4MM
SETTING WHEEL

Tool Kit for KK® Crimp Terminals
Doc No: ATS-6381174HM Release Date: 10-31-06 UNCONTROLLED COPY Page 7 of 8
Revision: D Revision Date: 06-30-23
HAND
CRIMP
FRAME
TOOL KIT
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 or determine tool life:
1. When the hand tool is no longer capable of achieving minimum conductor crimp height, it should be taken out of
service and replaced.
2. The tool frame is very difficult to disassemble and reassemble. Customer repair is not recommended.
APPLICATIONS FOR THE TOOL KIT AND POWER CRIMP HEAD
The chart below shows all applications for this Tool Kit and Power Crimp Head:
Tool
Order No.
Tool
Description
Crimp Head
Order No.
Crimp Head
Description
Figure
No.
63811-7400
Hand Crimp Tool
---
---
9
63816-0270
Battery Power Tool (110 V)
63816-1915
Power Crimp Head
10
63816-0280
Battery Power Tool (220 V)
63816-1915
Power Crimp Head
10
63816-1900
Electric Crimp Machine
63816-1915
Power Crimp Head
11
Applications for the Tool Kit and Power Crimp Head
Hand Crimp Tool
Battery Powered Tool
Electric Crimp Machine
Figure 9
Figure 10
Figure 11
WARNING: NEVER operate service, install tool kits, or adjust the Power Crimp Head without proper
instruction and without first reading and understanding the instructions in the proper Manual or
Specification Sheet. See Chart above for the correct Manual or Specification Sheet.
WARNING: NEVER install tooling or service this tool while it is into any power source. Make sure the
power is turned off.
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.
POWER
CRIMP
HEAD
LOCKING PINS
BATTERY
POWERED
TOOL
TOOL KIT
LOCATOR
POWER CRIMP
HEAD
ELECTRIC CRIMP MACHINE
LOCATOR

Tool Kit for KK® Crimp Terminals
Doc No: ATS-6381174HM Release Date: 10-31-06 UNCONTROLLED COPY Page 8 of 8
Revision: D Revision Date: 06-30-23
RATCHET
RELEASE SCREW
Figure 12
1
4
M4 X 6mm
LONG BHCS
M4 X 12mm
LONG BHCS
3
LOCATOR
M4 X 12mm
LONG BHCS
5
5
6
2
HAND TOOL PARTS LIST
Item Number
Order Number
Description
Quantity
REF
63811-7400
Hand Crimp Tool
Figure 12
1
---
Hand Crimp Frame
1
2
---
Tool Kit
1
3
63811-7475
Locator
1
4
63810-0102
Locator Base
1
5
63810-0103
Repair Kit (Not included)
0
6
63810-0101
Wrench Set (Not included)
0
Application Tooling Support
E-Mail: [email protected]
Website: www.molex.com/applicationtooling
Molex is a registered trademark of Molex, LLC in the United States of America and may be registered in other countries; all other
trademarks listed herein belong to their respective owners.