Molex 207129 Series Manual de usuario

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals

Doc No: ATS-638 98HM Release Date: 07-25-08 UNCONTROLLED COPY Page of 6

Revision: C Revision Date: -22- 0

CONDUCTOR

BRUSH

STRIP LENGTH

SEAM

CONDUCTOR

CRIMP

CUT-OFF

TAB

BELL MOUTH

BEND UP

TWISTING

ROLLING

BEND

DOWN

WIRE

SEAL

Application Tooling

Sp cification Sh t

Modular Crimp H ad

Ord r No. 63811-9870

Hand Crimp Tool

Ord r No. 63811-9800

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

% Modular Crimp Head is removable and can be use in the Air Powered Tool Order No.638 6-0 00,

accompanied by Air Powered Crimp Adapter (Order No. 638 6-0700).

% Can also be used in the Battery Powered Tool Order No.638 6-0200 ( 0 V) or 638 6-0250 (220 V),

accompanied by Battery Powered Crimp Adapter (Order No. 638 6-0600).

SCOPE

Products: CP 2.8 receptacle for 2.5 – 3.0 mm2 type ID and IR wire with 2.80mm (. 0"),

CMC Wire Seal Grey Receptacle.

T rminal S ri s No.

T rminal Ord r No. Wir Siz and Typ Insulation Diam t r Strip L ngth

Availabl in R l only AWG

mm² mm In. mm In.

989 0 989 0- 029

989 0- 29

--- 2.5 – 3.0 Type ID & IR

2.65 - 3.45

. 04 - . 36

4.90-5. 0

. 93-.20

989 0-2029

989 0-2 29

64324 64324- 029

64324- 29

64324-2029

64324-2 29

Customer to cut off terminal from reel: 0.30mm (.0 2”) maximum Cut-off Tab.

DEFINITION OF TERMS

TYPE 4A

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals

Doc No: ATS-638 98HM Release Date: 07-25-08 UNCONTROLLED COPY Page 2 of 6

Revision: C Revision Date: -22- 0

CRIMP SPECIFICATION

T rminal S ri s No. B ll Mouth B nd up B nd down Twist Roll Conductor Brush

mm In. D gr D gr mm In.

989 0 0. -0.5

.004-.020

2 2 2 3 0.2 - 0.6

.008-.024

64324 0. -0.5

.004-.020

2 2 2 3 0.2 - 0.6

.008-.024

S am: Seam shall not be open and no wire allowed out of the crimping area.

After crimping, the conductor profiles should measure the following (See notes on page 4).

T rminal

S ri s No.

Wir Siz

Conductor Insulation Pull Forc

Minimum Profil

Crimp H ight

(R f)

Crimp Width

(R f)

Crimp H ight

(R f)

Crimp Width

(R f)

AWG

mm2

mm In. mm In. mm In. mm In. N Lb 2.5mm2

3mm2

989 0 - 2.50

.80- .90

.07 -.075

2.89

. 4 4.80-5.00

. 99-.2

5.02 . 98 235

52.80 X

- 3.00

.95-2.05

.077-.08

2.90

. 4 5. 0-5.30

.207-.2 5

5.05 . 99 260

58.42 X

64324 - 2.50

.80- .90

.07 -.075

2.89

. 4 4.80-5.00

. 99-.2

5.02 . 98 235

52.80 X

- 3.00

.95-2.05

.077-.08

2.90

. 4 5. 0-5.30

.207-.2 5

5.05 . 99 260

58.42 X

CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects - damage can

occur to the tool or die.

ΤΤ

Τ Tool Qualification Notes:

. 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 T rminals

. Lift up the wire stop blade.

2. Insert the terminal fully into the correct profile until the

terminal is fully seated and stops.

3. Bring down the wire stop blade.

4. Slide the pre-stripped wire with the seal into the wire stop blade. See Figure .

5. Be sure to hold the wire in place until the terminal is fully crimped. See Figure 2.

6. Close the tool until the ratchet releases. The tool handles will then spring open.

7. Lift up the wire stop blade if it is still in down position.

8. Carefully remove the crimped terminal.

TERMINAL

PRE-STRIPPED

WIRE WITH SEAL Figur 1

WIRE STOP

BLADE

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals

Doc No: ATS-638 98HM Release Date: 07-25-08 UNCONTROLLED COPY Page 3 of 6

Revision: C Revision Date: -22- 0

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

Not : To maintain a good brush control and a consistent bell mouth the crimping instructions must be

followed.

Maint nanc

It is recommended that each operator of the tool

be made aware of, and responsible for, the

following maintenance steps:

. 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.

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 lifting the ratchet release lever. See Figure 6.

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.

Figur 2

CONDUCTOR

PUNCH

WIRE

LOCATOR

TERMINAL

INSULATION

PUNCH

INSULATION ANVIL

CONDUCTOR

ANVIL

WIRE STOP

BLADE

SEAL

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals

Doc No: ATS-638 98HM Release Date: 07-25-08 UNCONTROLLED COPY Page 4 of 6

Revision: C Revision Date: -22- 0

CAUTIONS:

. 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.

Not s:

. 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.

4. 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 ( /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.

Applications for th Modular Crimp H ad

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.

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals

Doc No: ATS-638 98HM Release Date: 07-25-08 UNCONTROLLED COPY Page 5 of 6

Revision: C Revision Date: -22- 0

MODULAR

CRIMP

HEAD

BATTERY

POWER

CRIMP

ADAPTER

LOCKING

PINS

LOCKING PINS

BATTERY

POWERED

TOOL

AIR

POWER

TOOL

MODULAR

CRIMP HEAD

LOCKING

PINS

LOCKING

PINS

AIR

POWER

CRIMP

ADAPTER

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

Modular Crimp H ad

Ord r No.

Tool

Ord r no.

Tool

D scription

Adapt r

Ord r No.

Adapt r

D scription

Figur

No.

638 -9870

638 6-0000

Hand Crimp Frame (Short) N/A N/A 3

638 6-0050

Hand Crimp Frame (Long) N/A N/A 3

638 6-0200

Battery Power Tool ( 0 V)

638 6-0600

Battery Power Crimp Adapter

638 6-0250

Battery Power Tool (220 V)

638 6-0600

Battery Power Crimp Adapter

638 6-0 00

Air Power Tool 638 6-0700

Air Power Crimp Adapter 5

Applications for th Modular Crimp H ad

Hand Crimp Tool Batt ry Pow r d Tool Air Pow r d Tool

Figur 3 Figur 4 Figur 5

MODULAR

CRIMP

HEAD

LOCKING

PINS

HAND CRIMP

FRAME LONG

OR SHORT

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals

Doc No: ATS-638 98HM Release Date: 07-25-08 UNCONTROLLED COPY Page 6 of 6

Revision: C Revision Date: -22- 0

RATCHET

RELEASE LEVER

HANDLE

SPRING

CRIMPING

SPRING (2)

Figur 6

M4 X 14mm

LONG BHCS

M4 FLAT

WASHER

PARTS LIST

Hand Crimp Tool 63811-9800

It m

Ord r Numb r

D scription Quantity

638 -9870 Modular Crimp Head (Ref)

2 638 6-0050 Hand Crimp Frame (Long)

(Ref)

3 638 -9875 Locator

4 638 6-000 Locking Pin 2

5 63600-0525 Handle Spring

6 63600-0520 Crimping Spring 2

http://www.molex.com

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