Molex 207129 Series Manual de usuario

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

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

In.

Lb.

2578

0.35

.94-1.04

.037-.041

1.56

.061

1.94

.076

44.0

10.0

0.20

.84-.94

.033-.037

1.56

.061

1.56

.061

29.0

6.5

0.12

.84-.94

.033-.037

1.56

.061

1.56

.061

18.0

4.0

5168

0.35

.94-1.04

.037-.041

1.56

.061

1.94

.076

44.0

10.0

0.20

.84-.94

.033-.037

1.56

.061

1.56

.061

29.0

6.5

0.12

.84-.94

.033-.037

1.56

.061

1.56

.061

18.0

4.0

7258

0.35

.94-1.04

.037-.041

1.56

.061

1.94

.076

44.0

10.0

0.20

.84-.94

.033-.037

1.56

.061

1.56

.061

29.0

6.5

0.12

.84-.94

.033-.037

1.56

.061

1.56

.061

18.0

4.0

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

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

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

---

63816-0270

Battery Power Tool (110 V)

63816-1915

Power Crimp Head

63816-0280

Battery Power Tool (220 V)

63816-1915

Power Crimp Head

63816-1900

Electric Crimp Machine

63816-1915

Power Crimp Head

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

M4 X 6mm

LONG BHCS

M4 X 12mm

LONG BHCS

LOCATOR

M4 X 12mm

LONG BHCS

HAND TOOL PARTS LIST

Item Number

Order Number

Description

Quantity

REF

63811-7400

Hand Crimp Tool

Figure 12

---

Hand Crimp Frame

---

Tool Kit

63811-7475

Locator

63810-0102

Locator Base

63810-0103

Repair Kit (Not included)

63810-0101

Wrench Set (Not included)

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.

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