Molex 207129 Series Manual de usuario

Hand Crimp Tool for Ulti-Mate™ Commercial Micro D Crimp Terminals

Doc No: ATS-63811 8HM Release Date: 0 -0 -05 UNCONTROLLED COPY Page 1 of 7

Revision: D Revision Date: 07-26-10

Application Tooling

Specification Sheet

Modular Crimp ead

Order No. 63811-4870

and Crimp Tool

Order No. 63811-4800

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

% A-620 Class 3 compliant and RoHS compliant

% Modular Crimp Head is removable and can be use in the Air Powered Tool Order No.63816-0100,

accompanied by Air Powered Crimp Adapter (Order No. 63816-0700).

% Can also be used in the Battery Powered Tool Order No.63816-0200 (110 V) or 63816-0250 (220 V),

accompanied by Battery Powered Crimp Adapter (Order No. 63816-0600).

SCOPE

Products: 1.27mm (.050") Pitch Ulti-Mate™ Commercial Micro D, 26-28 AWG.

Terminal

Series No.

Terminal Order No. Wire Size Insulation Diameter

Strip Length

Loose Piece





Reel AWG

mm²

mm In. mm In.

83000

83000-0083 83000-9502

83000-9558

26 0.12 0.89-1.02 .035-.0 0 1.30-1.60

.051-.063

83000-0106 83000-9503

83000-9559

83000-0110 83000-95 7

83000-9561

83000-9560 83000-9550

83000-9562

83000-9557

83000-0083 83000-9502

83000-9558

28 0.08 0.50-1.00 .020-.039 1.30-1.60

.051-.063

83000-0106 83000-9503

83000-9559

83000-0110 83000-95 7

83000-9561

83000-9560 83000-9550

83000-9562

83000-9557

 Customer to cut off terminal from reel: 0.15mm (.006”) maximum Cut-Off Tab.

Insulation diameters below 0.63mm (.029”) may not provide A-620 Class 3 compliant insulation crimps.

Customer to determine suitability for these applications.

TYPE 4A

Hand Crimp Tool for Ulti-Mate™ Commercial Micro D Crimp Terminals

Doc No: ATS-63811 8HM Release Date: 0 -0 -05 UNCONTROLLED COPY Page 2 of 7

Revision: D Revision Date: 07-26-10

INSULATION

CRIMP

BRUS

STRIP

LENGT

BELL

MOUT

CRIMP EIG T

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP

TWISTING

CUT-OFF

TAB

SEAM

DEFINITION OF TERMS

The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the scope.

CRIMP SPECIFICATION

After crimping, the conductor profile should measure the following.

Terminal Order No. Wire Size Tool Wire

Insulation Diameter

Crimp Conductor (REF)

eight Width

AWG

mm2

mm In. mm In. mm In.

83000-0083, 83000-9502

83000-9503, 83000-9550

26 0.12 0.89-1.02

.035-.0 0

0.5 -0.58

.021-.023

0.81

.031

28 0.08 0.76-1.00

.030-.039

0. 1-0. 6

.016-.018

0.81

.031

28 0.08 0.50-0.75

.020-.029

0. 1-0. 6

.016-.018

0.81

.031

83000-0106

83000-95 7

83000-9557

26 0.12 0.89-1.02

.035-.0 0

0.5 -0.58

.021-.023

0.81

.031

28 0.08 0.76-1.00

.030-.039

0. 1-0. 6

.016-.018

0.81

.031

28 0.08 0.50-0.75

.020-.029

0. 1-0. 6

.016-.018

0.81

.031

83000-0110

83000-9558

83000-9559

26 0.12 0.89-1.02

.035-.0 0

0.5 -0.58

.021-.023

0.81

.031

28 0.08 0.76-1.00

.030-.039

0. 1-0. 6

.016-.018

0.81

.031

28 0.08 0.50-0.75

.020-.029

0. 1-0. 6

.016-.018

0.81

.031

83000-9560

83000-9561

83000-9562

26 0.12 0.89-1.02

.035-.0 0

0.5 -0.58

.021-.023

0.81

.031

28 0.08 0.76-1.00

.030-.039

0. 1-0. 6

.016-.018

0.81

.031

28 0.08 0.50-0.75

.020-.029

0. 1-0. 6

.016-.018

0.81

.031

Terminal

Order No.

Wire Size Pull Force Minimum

Profile

Locator Color

26 AWG

28 AWG

Large Insulation

28 AWG

Small Insulation

AWG

mm2

N Lb. A B C

83000-0083, 83000-9502

83000-9503, 83000-9550

26 0.12 13. 3.00 X

Blue 28 0.08 9.8 2.20 X

28 0.08 9.8 2.20 X

83000-0106

83000-95 7

83000-9557

26 0.12 13. 3.00 X

Red 28 0.08 9.8 2.20 X

28 0.08 9.8 2.20 X

83000-0110

83000-9558

83000-9559

26 0.12 13. 3.00 X

Yellow 28 0.08 9.8 2.20 X

28 0.08 9.8 2.20 X

83000-9560

83000-9561

83000-9562

26 0.12 13. 3.00 X

Yellow 28 0.08 9.8 2.20 X

28 0.08 9.8 2.20 X

Hand Crimp Tool for Ulti-Mate™ Commercial Micro D Crimp Terminals

Doc No: ATS-63811 8HM Release Date: 0 -0 -05 UNCONTROLLED COPY Page 3 of 7

Revision: D Revision Date: 07-26-10

INSULATION

OF T E WIRE

STOPS ERE INSULATION

PUNC

TERMINAL

LOCATOR

INSULATION

STOP

Figure 2

CONDUCTOR

PUNC

Figure 3

PUNC

TERMINAL

LOCATOR

INSULATION

STOP

ANVIL

INSULATION

OF T E WIRE

STOPS ERE

ΤΤ

Τ 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.

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. With the hand tool in the open position, pivot the terminal

locator open. See Figure 1.

2. Insert the terminal fully into the correct profile until the terminal is fully seated and stops.

3. Gently pivot the locator closed.

. Slide the pre-stripped wire into the insulation stop. See Figure 2. The wire strands pass thru the

insulation stop slot, while the end of the insulation touches the stop. Be sure to hold the wire in place until

the terminal is fully crimped. See Figure 3.

5. Close the tool until the ratchet releases.

6. Carefully remove the crimped terminal.

Note: The tamper proof ratchet action will not release the tool until it has been fully closed.

Note: To maintain good brush control and a consistent bell mouth the crimping instructions must be followed.

TERMINAL

SEATED IN

LOCATOR

OPEN

Figure 1

AND TOOL

OPEN

Hand Crimp Tool for Ulti-Mate™ Commercial Micro D Crimp Terminals

Doc No: ATS-63811 8HM Release Date: 0 -0 -05 UNCONTROLLED COPY Page of 7

Revision: D Revision Date: 07-26-10

INCORRECT

Figure 5

CORRECT INCORRECT

Terminal Locator Replacement/Change Over

This section describes the procedure for changing locators.

Removal

1. With the tool in the open position, pivot the terminal locator outward.

2. Remove the M BHCS. See Figure .

Installation

1. Place the proper locator, (See Chart on page 2), on the hand tool.

Install the M BHCS. See Figure .

2. Tighten the screw enough to hold the locator. Make sure the

locator can still float freely with hand pressure.

3. Insert the proper terminal fully into the correct profile slot until the terminal is fully seated and stops. Then

gently pivot the locator closed.

. With hand pressure, slowly slide the locator to the correct position. See Figure 5.

5. Gently pivot the locator open without disturbing the location.

6. Hold the locator firmly in place and slowly tighten the M 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 5,000 crimps or 3 months, will significantly enhance the tool life.

. 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 lifting the ratchet release lever. See Figure 9.

M4 B CS

PIVOT LOCATOR

Figure 4

Hand Crimp Tool for Ulti-Mate™ Commercial Micro D Crimp Terminals

Doc No: ATS-63811 8HM Release Date: 0 -0 -05 UNCONTROLLED COPY Page 5 of 7

Revision: D Revision Date: 07-26-10

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: 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.

. Use only the Molex terminals specified for crimping with this tool.

Notes:

1. This tool should only be used for the terminals and wire gauges specified on this sheet.

2. This tool is not adjustable for crimp height; however crimp force is adjustable (See instructions above).

Variations in tools, terminals, wire stranding, and insulation types may affect crimp height.

3. This tool is intended for standard conductor sizes. It may not give a good insulation crimp support for all

insulation sizes.

. 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.

5. Pull force should be used as the final criteria for an acceptable crimp. Pull force is measured with no

influence from the insulation crimp. The insulation should be stripped long (1/2 in.) so the insulation grips

on the terminal do not grip the wire insulation or the conductor. Refer to Molex Quality Crimping

Handbook 63800-0029 for additional information on crimping and crimp testing.

6. Molex does not certify crimp hand tools.

CAUTION: Molex crimp specifications are valid only when used with Molex terminals and tooling.

Hand Crimp Tool for Ulti-Mate™ Commercial Micro D Crimp Terminals

Doc No: ATS-63811 8HM Release Date: 0 -0 -05 UNCONTROLLED COPY Page 6 of 7

Revision: D Revision Date: 07-26-10

MODULAR

CRIMP

EAD

BATTERY

POWER

CRIMP

ADAPTER

LOCKING

PINS

LOCKING PINS

BATTERY

POWERED

TOOL

AIR

POWER

TOOL

MODULAR

CRIMP EAD

LOCKING

PINS

LOCKING

PINS

AIR POWER

CRIMP

ADAPTER

Applications for the Modular Crimp ead

WARNING: NEVER operate, service, install, or adjust this Modular Crimp Head without proper instruction

and without first reading and understanding the instructions in the proper Manual or Specification Sheet.

See Chart below for the correct Manual or Specification Sheet.

WARNING: NEVER install tooling or service this tool while it is into any power source. Disconnect the

power by unplugging or turn off the Actuator from its power source.

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.

The chart below shows all applications for this Modular Crimp Head.

Modular Crimp ead

Order No.

Tool

Order no.

Tool

Description

Adapter

Order No.

Adapter

Description

Figure

No.

63811- 870

63816-0000

Hand Crimp Frame (Short) N/A N/A 6

63816-0050

Hand Crimp Frame (Long) N/A N/A 6

63816-0200

Battery Power Tool (110 V)

63816-0600

Battery Power Crimp Adapter

63816-0250

Battery Power Tool (220 V)

63816-0600

Battery Power Crimp Adapter

63816-0100

Air Power Tool 63816-0700

Air Power Crimp Adapter 8

Applications for the Modular Crimp ead

and Crimp Tool Battery Powered Tool Air Powered Tool

Figure 6 Figure 7 Figure 8

MODULAR

CRIMP

EAD

LOCKING

PINS

AND CRIMP

FRAME LONG

OR S ORT

Hand Crimp Tool for Ulti-Mate™ Commercial Micro D Crimp Terminals

Doc No: ATS-63811 8HM Release Date: 0 -0 -05 UNCONTROLLED COPY Page 7 of 7

Revision: D Revision Date: 07-26-10

RATC ET

RELEASE LEVER

ANDLE

SPRING

CRIMPING

SPRING (2)

LOCATOR

Figure 9

M4 X 6mm

LONG B CS

3 5

PARTS LIST

and Crimp Tool 63811-4800

Item

Order Number

Description Quantity

1 63811- 870 Modular Crimp Head 1

2 63816-0000 Hand Crimp Frame (Short)

3 63811- 875 Locator-Blue 1

63811- 876 Locator-Red 1

5 63811- 877 Locator-Yellow 1

6 63816-0001 Locking Pin 2

7 63600-0525 Handle Spring 1

8 63600-0520 Crimping Spring 2

http://www.molex.com

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