Molex 207129 Series Manual de usuario

Hand Crimp Tool For Cluster Block Terminal

Doc No: ATS-6382 0200 Release Date: 02-08-12 UNCONTROLLED COPY Page 1 of 8

Revision: A Revision Date: 02-08-12

INSULATION

CRIMP

BRUSH

STRIP

LENGTH

CONDUCTOR

CRIMP HEIGHT

CUT-OFF TAB

SEAM

BELL MOUTH

WIRE

TYPE 4D

HAND CRIMP

TOOL

Application Toolin

Specification Sheet Order No. 63825-0200

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

 Right and Left handed applications

 This tool is IPC/WHMA A-620 Class 2 compliant as indicated

 This tool is RoHS compliant, however RoHS compliant is not required

SCOPE

Products: Cluster Block Terminal for 18 AWG UL Style 048 Wire.

Terminal

Series No.

Terminal Order No.

Reel Form only

Wire Size

Insulation Diameter

Strip Len th

IPC/WHMA-A620 (1)

Terminal (2)

Insulation ran e

AWG

mm²

mm In. mm In. mm In.

7920 7920-6002 18 0.82 2.30-2.4

.091-.097

2.1 -2.4

.08 -.097

.00- . 0

.197-.217

Note: This terminal will accommodate the UL Style 048 wire.

(1) To achieve optimum IPC-A620 insulation crimps, use this insulation OD range.

(2) Overall insulation OD specification for terminal.

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

DEFINITION OF TERMS

Hand Crimp Tool For Cluster Block Terminal

Doc No: ATS-6382 0200 Release Date: 02-08-12 UNCONTROLLED COPY Page 2 of 8

Revision: A Revision Date: 02-08-12

▲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).

CRIMP SPECIFICATIONS

After crimping, the crimp profiles should measure the following:

Terminal Series No. Bell mouth Conductor Brush

mm In. mm In.

7920 0.20-0. 0 .008-.020 0. 0-1.00 .020-.039

Terminal Series No. Bend up Bend down Twist Roll Seam

Seam shall not be open and no wire

Allowed out of the crimping area

De ree De ree

7920 3 3 3

Terminal

Series No.

Wire Size Conductor Crimp Insulation Crimp Pull Force

Minimum

Hei ht Width (Ref)

Hei ht Maximum

Width Maximum

AWG

mm2

mm In. mm In. mm In. mm In. N Lb.

7920 18 0.82

1.4 -1.

.0 7-.061

2.40

.09

3.80 .1 0 3. 0 .138 107.8

24.2

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

occur to the tool or die.





 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 available,

actual crimp height measurements may very slightly. An occasional, destructive,

pull force test should be performed to check hand tool crimp. Pull Force value

Must exceed the Minimum pull force specifications listed.

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.

See Figure 1.

OVERLAP

INSULATION

CRIMP

OVERLAP FORM GEOMETRY

ANVIL

PUNCH

WIRE

SQUEEZE

HANDLES

TOGETHER

HANDLE WILL

SPRING OPEN

Fi ure 1

Hand Crimp Tool For Cluster Block Terminal

Doc No: ATS-6382 0200 Release Date: 02-08-12 UNCONTROLLED COPY Page 3 of 8

Revision: A Revision Date: 02-08-12

PRE

STRIPPED WIRE

TERMINAL

Fi ure 5

TERMINAL

WIRE AGAINST

THE WIRE

STOP

WIRE

WIRE STOP IS

PART OF

THE LOCATOR

Crimpin Terminals

1. Select the desired terminal listed in the preceding charts.

2. Make sure the locator is attached behind the lower tooling and is above all the

anvils surfaces.

3. The spring loaded wire stop should be clear of the locator’s cavity, if not push up

on the red tab to move the wire stop out of the way while inserting the terminal.

See Figure 3.

4. Load the terminal into the proper nest opening in the locator based on the wire

gauge or terminal type markings on the hand tooling. See Figure 3.

. Partially close the tool handle until the first ratchet position engages, and

holds the terminal in place. See Figure 4.

6. Insert the properly stripped wire through the terminal and against the wire

stop. See Figure .

7. Crimp the terminal by squeezing the tool handles until the ratchet

mechanism cycle has been completed. Release the handles to open the

jaws.

TERMINAL

Fi ure 3 TERMINAL

PUSH UP

ON THE

RED TAB

PARTIALLY

CLOSE HANDLE

TOOLING

PARTIALLY

CLOSED

Fi ure 4

FIRST

RATCHET

POSITION

OPEN

POSITION

LOCATOR

IN DOWN

POSTION

RED

TAB

Fi ure 2

Hand Crimp Tool For Cluster Block Terminal

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Revision: A Revision Date: 02-08-12

SQUEEZE

HERE

SQUEEZE

HERE

LOCATOR

Fi ure 7

TOP HOOKS

TOP SLOTS OF

HANDTOOL

LOWER TABS

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

8. Remove the crimped terminal from the terminal

locator by pulling on the wire.

9. Visually inspect the crimped terminal for proper

crimp location.

10. On some large O.D. wires, it may not be possible

to insert the wire with the tool partially closed.

Those wires should be inserted with the hand tool

in the open position. Insert the wire above the

terminal in the punch and against the wire stop

then close the tool. See Figure 6.

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. Squeeze gently on the lower area shown in Figure 7 with your thumb

and index finger. The lower tabs of the locator should disengage from

the hand tool.

3. Lift and pull away from the hand tool. The top locator hooks should

slip out of the top slots easily. See Figure 7.

4. To reinstall the new locator, make sure the hand tool is in the open

position.

. Holding onto the lower part of the locator with your thumb and index

finger, insert the locators top hooks (2) into the hand tool top slots.

6. Rotate the locator down and press the lower tabs into the two bottom

slots of the hand tool. To secure the locator into place, the lower tabs

must snap into place on the hand tool frame.

Ri ht or Left Hand Operation

This hand tool has an added feature that can be converted from a right handed application to a left handed

application. It is necessary to reverse the tooling if using the left handed application along with the locator. Follow

the steps below:

1. The locator must be removed before reversing the tooling.

2. Remove the M3 BHCS which is holding the upper tooling.Flip the upper tooling to the opposite side and

replace the M3 BHCS. Make sure the small markings on the front and back of the hand tool frame, match up

and are on the outside of the hand tool frame. See Figure 8 and 9.

3. Do the same thing with the lower tooling and tighten the M3 screws. Be sure the small markings line up.

4. Reinstall the locator by following the Instructions in the locator replacement section.

TERMINAL

Fi ure 6

WIRE

WIRE STOP

Hand Crimp Tool For Cluster Block Terminal

Doc No: ATS-6382 0200 Release Date: 02-08-12 UNCONTROLLED COPY Page of 8

Revision: A Revision Date: 02-08-12

MATCH

UP MARKS

FRONT BACK

Fi ure 9

Fi ure 8

PUSH ON

HANDLE

JAWS OPEN

PULL OPEN

TOOLING TOOLING

M3 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 ,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.

. 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 up on the ratchet release lever in the movable handle. See Figure 11.

RATCHET RELEASE

LEVER

Fi ure 11

LUBRICATION

POINTS

(BOTH SIDES)

LIGHT OIL

(EVERY 3 MONTHS OR

5,000 CRIMPS)

Fi ure 10

Hand Crimp Tool For Cluster Block Terminal

Doc No: ATS-6382 0200 Release Date: 02-08-12 UNCONTROLLED COPY Page 6 of 8

Revision: A Revision Date: 02-08-12

Fi ure 12

SQUEEZE

THE LINK IN

THE HANDLE

HOLD THE HAND

TOOL IN POSITION

SETTING

WHEEL

RATCHET

RELEASE LEVER

How to Adjust Tool Preload

(See Fi ure 12)

This hand tool is factory preset to 2 -4

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. Hold the hand tool in the palm of your

hand as shown in Figure 12. Using

the index finger squeeze the link

towards the top of the hand tool

frame. This will release the preload

adjustment wheel.

2. Rotate the setting wheel counter-clockwise (CCW) to increase handle force. The numbers will display higher.

To decrease handle force rotate the setting wheel clockwise (CW).

3. Release the link to lock the setting wheel in place.

4. 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.

Hand Crimp Tool For Cluster Block Terminal

Doc No: ATS-6382 0200 Release Date: 02-08-12 UNCONTROLLED COPY Page 7 of 8

Revision: A Revision Date: 02-08-12

Certification

Molex does not certify or re-certify 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

2 mm (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 Cluster Block Terminal

Doc No: ATS-6382 0200 Release Date: 02-08-12 UNCONTROLLED COPY Page 8 of 8

Revision: A Revision Date: 02-08-12

RATCHET

RELEASE LEVER

Fi ure 13

PARTS LIST

Item Number Order Number Description Quantity

REF 6382 -0200 Hand Crimp Tool Figure 13

1 6382 -027 Locator Assembly 1

2 63810-0104 Spring, Return 1

3 63810-010 Spring, Ratchet 1

http://www.molex.com

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