Molex 207129 Series Manual de usuario

Tool Kit for , Micro SPOX™ Crimp Terminals

Doc No: ATS-63 1167HM Release Date: 0 -02-06 UNCONTROLLED COPY Page 1 of 9

Revision: C Revision Date: 10-04-10

INSULATION

CRIMP

▲

SEE NOTE

BRUSH

STRIP

LENGTH

BELL MOUTH

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP

TWISTING

CRIMP HEIGHT

Application Tooling

Speci ication Sheet

Tool Kit

Order No. 63811-6770

Hand Crimp Tool

Order No. 63811-6700

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

 Tool kits are easily installed into the Hand Crimp Tool or the 63 16-0300 Power Crimp Head which is installed

into the 63 16-0200 (110 V) or the 63 16-0250 (220 V) Battery Powered Tool.

 Many different Tool kits can be used with a single Battery Powered Tool.

 This tool is IPC/WHMA-A-620 Class 2 and RoHS compliant.

SCOPE

Products: 2.00mm (.079") Pitch, Micro SPOX™ Crimp Terminals, 22-30 AWG.

Terminal

Series No.

Terminal Order No. Wire Size Insulation Diameter Strip Length

Loose Piece





Reel AWG

mm² mm In. mm In.

5230 0 -70-0073 0 -70-0072

22-30

0.35-0.05

1.10-1.50

.043-.060

2.54-3.17

.100-.125

Customer to cut off terminal from reel: 0.40mm (.016”) maximum Cut-off Tab.

DEFINITION OF TERMS

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

scope.

TYPE 2C

Tool Kit for , Micro SPOX™ Crimp Terminals

Doc No: ATS-63 1167HM Release Date: 0 -02-06 UNCONTROLLED COPY Page 2 of 9

Revision: C Revision Date: 10-04-10

▲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 (Re )

Pull Force

Minimum Pro ile

AWG

mm2 mm In. N Lb. A B

5230

22 0.35 0. 4-0. 9 .033-.035 39.1 . 0

24 0.20 0.76-0. 1 .030-.032 29.3 6.60

26 0.12 0.69-0.74 .027-.029 19.6 4.40

2 0.0 0.66-0.71 .026-.02 9. 2.20

30 0.05 0.63-0.6 .025-.027 4.9 1.10

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.

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.

CAUTION: Install 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 1 long BHCS and tighten in place. See

Figure 1.

OVERLAP

INSULATION

CRIMP

OVERLAP FORM GEOMETRY

ANVIL

PUNCH

WIRE

Tool Kit for , Micro SPOX™ Crimp Terminals

Doc No: ATS-63 1167HM Release Date: 0 -02-06 UNCONTROLLED COPY Page 3 of 9

Revision: C Revision Date: 10-04-10

SWING

LOCATOR

OPEN

PRESS DOWN

ON THE BRASS

PIVOT SHAFT

LIFT UP ON

THE LOCATOR

Figure 2

ANVILS

POWER

CRIMP

HEAD

Figure 1

PUNCHES

M4 X 10 LONG

BHCS

M4 X 18 LONG

BHCS

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.

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. 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 4. 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.

Figure 3

LOCATOR

JAWS OPEN

Tool Kit for , Micro SPOX™ Crimp Terminals

Doc No: ATS-63 1167HM Release Date: 0 -02-06 UNCONTROLLED COPY Page 4 of 9

Revision: C Revision Date: 10-04-10

SWING

LOCATOR

OPEN

PRESS DOWN

ON BRASS PIVOT

SHAFT

LIFT UP

LOCATOR

JAWS

OPEN

Figure 6

TERMINAL

PUSH HERE TO

OPEN WIRE STOP

SWING OPEN

LOCATOR LOCATOR

TERMINAL IN PLACE

Figure 4

LOCATOR

IN PLACE

WIRE STOP

TERMINAL

WIRE

WIRE STOP

WIRE

AGAINST STOP Figure 5

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.

. Visually inspect the

crimped terminal for

proper crimp location.

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

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.

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.

Tool Kit for , Micro SPOX™ Crimp Terminals

Doc No: ATS-63 1167HM Release Date: 0 -02-06 UNCONTROLLED COPY Page 5 of 9

Revision: C Revision Date: 10-04-10

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.

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.

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 .

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 (63 10-0101), is not supplied. It is sold

separately from the hand tool.

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

Figure 7B

LUBRICATION

POINTS

(BOTH SIDES)

LIGHT OIL

(EVERY MONTH

5,000 CRIMPS)

Figure 7A

Tool Kit for , Micro SPOX™ Crimp Terminals

Doc No: ATS-63 1167HM Release Date: 0 -02-06 UNCONTROLLED COPY Page 6 of 9

Revision: C Revision Date: 10-04-10

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, 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.

Certi ication

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.

Tool Kit for , Micro SPOX™ Crimp Terminals

Doc No: ATS-63 1167HM Release Date: 0 -02-06 UNCONTROLLED COPY Page 7 of 9

Revision: C Revision Date: 10-04-10

The chart below shows all applications for this Tool Kit.

Tool Kit

Order No.

Tool

Order no.

Tool

Description

Power Head

Order No.

Adapter

Description

Figure

No.

63 11-6770

63 10-0100

Hand Crimp Frame (Short) N/A N/A 9

63 10-0400

Hand Crimp Frame (Long) N/A N/A 9

63 16-0200

Battery Power Tool (110 V)

63 16-0300 Power Crimp Head

63 16-0250

Battery Power Tool (220 V)

63 16-0300 Power Crimp Head

Applications or the Tool Kit

Hand Crimp Tool Battery Powered Tool

Figure 9 Figure 10

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

TTERY

POWERED

TOOL

TOOLING KIT

HAND CRIMP

FRAME LONG

AND SHORT

TOOLI

KIT

Tool Kit for , Micro SPOX™ Crimp Terminals

Doc No: ATS-63 1167HM Release Date: 0 -02-06 UNCONTROLLED COPY Page of 9

Revision: C Revision Date: 10-04-10

RATCHET

RELEASE SCREW

Figure 11

M4 X 6mm

LONG BHCS

M4 X 12mm

LONG BHCS

WITH TOOL KIT

LOCATOR ONLY

M4 X 12mm

LONG BHCS

HAND TOOL PARTS LIST

Item Number Order Number Description Quantity

1 63 10-0100 Hand Crimp Frame (Short) 1

2 63 10-0101 Wrench Set (Not included) 0

3 63 10-0102 Locator Base 1

4 63 10-0103 Repair Kit (Not included) 0

5 63 11-6770 Tool Kit with Locator 1

6 63 11-6775 Locator (only) REF

Tool Kit for , Micro SPOX™ Crimp Terminals

Doc No: ATS-63 1167HM Release Date: 0 -02-06 UNCONTROLLED COPY Page 9 of 9

Revision: C Revision Date: 10-04-10

Figure 12

M4 by 8 Long

BHCS

M4 by 18 Long

BHCS

M4 by 10 Long

BHCS

POWER HEAD PARTS LIST

Item Order No Engineering No. Description Quantity

63 16-0300 63 16-0300 Power Crimp Head 1

63 11-6770 63 11-6770 Tool Kit 1

http://www.molex.com

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