Molex 207129 Series Manuel utilisateur

Hand Crimp Tool for 2.00/2.50mm (.079/.098") Board-In Crimp Terminals

Do No: ATS-6381177HM Release Date: 08-29-07 UNCONTROLLED COPY Page 1 of 7

Revision: B Revision Date: 08-02-10

INSULATION

CRIMP

▲

SEE NOTE

BRUSH

STRIP

LENGTH

BELL MOUTH

CRIMP HEIGHT

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP

TWISTING

Application Tooling

Speci ication Sheet

Modular Crimp Head

Order No. 63811-7770

Hand Crimp Tool

Order No. 63811-7700

FEATURES

% A full y le rat heting hand tool ensures omplete rimps

% Ergonomi ally designed soft handles

% Pre isely designed rimping profiles with simple onta t positioning

% Easy handling due to outstanding for e ratio

% A-620 Class 3 ompliant and RoHS ompliant

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

a ompanied 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),

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

SCOPE

Produ ts: 2.00/2.50mm (.079/.098") Board-In Terminal, 22-28 AWG.

Terminal

Series No.

Terminal Order No.





 Reel

Wire Size Insulation Diameter

Strip Length

AWG

mm² mm In. mm In.

35044

35044-9101

35044-9160

24-28

0.20-0.08

0.90-1.50 .035-.059 3.00-3.50

.118-.138

35044-9102

35044-9210

35044-9110

35044-9260

35044

35044-9103

35044-9360

22-28

0.35-0.08

1.20-1.90 .047-.075 3.00-3.50

.118-.138

35044-9104

35044-9410

35044-9310

35044-9460

Follow the Cut-Off Tab spe ifi ations on Appli ator spe ifi ation sheets

See Conditions on page 2.

DEFINITION OF TERMS

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

TYPE 4A

Hand Crimp Tool for 2.00/2.50mm (.079/.098") Board-In Crimp Terminals

Do No: ATS-6381177HM Release Date: 08-29-07 UNCONTROLLED COPY Page 2 of 7

Revision: B Revision Date: 08-02-10

▲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 pun h. This

produ es an overlap insulation rimp (A620 –

ompliant). While the insulation pun h profile may

appear “lopsided”, this is a normal ondition for this

tool. See figure to the right. (Some tools with

multiple rimp po kets may not have the “overlap”

profile on all po kets).

CRIMP SPECIFICATION

After rimping, the rimp profiles should measure the following (see notes on page 4).

Terminal

Order No.

Wire Size

Conductor Crimp Insulation Crimp Pull Force

Minimum 



Pro ile

Height (Re ) Width (Re )

Height (Re )

Width (Re )

AWG

mm2

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

35044-9101

35044-9102

35044-9110

35044-9160

35044-9210

35044-9260

26 0.12

0.64-0.74

.025-.029

1.30

.051

1.50 .059 1.50

.059

19.6

4.40

28 0.08

0.64-0.74

.025-.029

1.30

.051

1.50 .059 1.50

.059

9.8 2.20

35044-9103

35044-9104

35044-9310

35044-9360

35044-9410

35044-9460

26 0.12

0.64-0.74

.025-.029

1.30

.051

1.60 .063 1.90

.075

19.6

4.40

28 0.08

0.64-0.74

.025-.029

1.30

.051

1.60 .063 1.90

.075

9.8 2.20

35044-9101

35044-9102

35044-9110

35044-9160

35044-9210

35044-9260

24 0.20

0.77-0.87

.030-.034

1.30

.051

1.65 .065 1.50

.059

29.4

6.60

35044-9103

35044-9104

35044-9310

35044-9360

35044-9410

35044-9460

22 0.35

0.77-0.87

.030-.034

1.30

.051

1.90 .075 1.90

.075

39.1

8.80

24 0.20

0.77-0.87

.030-.034

1.30

.051

1.90 .075 1.90

.075

29.4

6.60

To A hieve IPC-A-620 Class 3 Crimps, the following over-all wire insulation diameter ranges are re ommended:

Profile A: 0.90mm (.035”) maximum-Up to the maximum terminal rating 1.50mm (.059”).

Profile B: 1.20-1.90mm (.047-.075”)

Profile C: 0.90-1.50-1.90mm (.035-.059”)

Profile D: 1.20-1.90mm (.047-.075”)

ΤΤ

Τ Tool Qualifi ation Notes:

1. Pull For e should be measured with no influen e from the insulation rimp.

2. The above spe ifi ations are guidelines to an optimum rimp.

OVERLAP

INSULATION

CRIMP

OVERLAP FORM GEOMETRY

ANVIL

PUNCH

WIRE

Hand Crimp Tool for 2.00/2.50mm (.079/.098") Board-In Crimp Terminals

Do No: ATS-6381177HM Release Date: 08-29-07 UNCONTROLLED COPY Page 3 of 7

Revision: B Revision Date: 08-02-10

Figure 3

WIRE

TERMINAL

LOCATOR INSULATION

PUNCH

INSULATION

ANVIL

WIRE STOP

BLADE

CONDUCTOR

ANVIL

CONDUCTOR PUNCH

WIRE

CONDUCTOR

PUNCH

TERMINAL

WIRE STOP

BLADE

Figure 2

OPERATION

Open the tool by squeezing the handles together,

at the end of the losing stroke, the rat het

me hanism will release the handles, and the

hand tool will spring open.

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

the terminal lo ator open by pulling up on the

lo ator knob and lift the wire stop blade up.

See Figure 1.

2. Insert the terminal into the orre t profile until

the terminal is fully seated and stops. Make

sure the wire stop blade is fully seated on the

terminal behind the ondu tor grip se tion.

3. Gently pivot the lo ator losed.

4. Bring down the wire stop blade.

5. Slide the pre-stripped wire into the terminal; make sure to aim the wire brush towards the tip point on the

wire stop blade. See Figure 2. Align the wire so that it is parallel and sitting into the terminal. Maintain a

light and onstant pressure on the wire that is seated in the terminal at all times. (Do not let go of the

wire.) Be sure to hold the wire and terminal in pla e until the terminal is fully rimped. See Figure 3.

6. Close the tool until the rat het releases.

7. Lift the wire stop blade up.

8. Carefully remove the rimped terminal.

Note: To maintain good brush ontrol and a onsistent bell mouth the rimping instru tions must be

followed.

Note: The tamper proof rat het a tion will not release the tool until it has been fully losed.

Note: To maintain good brush ontrol and a onsistent bell mouth the rimping instru tions must be followed.

TERMINAL

SEATED IN

LOCATOR

SWING

LOCATOR

OPEN

Figure 1

HAND TOOL

OPEN

WIRE

STOP BLADE

Hand Crimp Tool for 2.00/2.50mm (.079/.098") Board-In Crimp Terminals

Do No: ATS-6381177HM Release Date: 08-29-07 UNCONTROLLED COPY Page 4 of 7

Revision: B Revision Date: 08-02-10

INCORRECT

Figure 5

CORRECT INCORRECT

Terminal Locator Replacement/Change Over

This se tion des ribes the pro edure for hanging lo ators.

Removal

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

2. Remove the M4 BHCS. See Figure 4.

Installation

1. Pla e the proper lo ator, (See Chart on page 2), on the hand tool.

Install the M4 BHCS. See Figure 4.

2. Tighten the s rew enough to hold the lo ator. Make sure the lo ator

an still float freely with hand pressure.

3. Insert the proper terminal fully into the orre t profile slot until the

terminal is fully seated and stops. Then gently pivot the lo ator

losed.

4. With hand pressure, slowly slide the lo ator to the orre t position. See Figure 5.

5. Gently pivot the lo ator open without disturbing the lo ation.

6. Hold the lo ator firmly in pla e and slowly tighten the M4 BHCS.

Maintenance

It is re ommended that ea h operator of the tool be made

aware of, and responsible for, the following maintenan e

steps:

1. Remove dust, moisture, and other ontaminants with a

lean brush, or soft, lint free loth.

2. Do not use any abrasive materials that ould damage the

tool.

3. Make ertain all pins; pivot points and bearing surfa es

are prote ted with a thin oat of high quality ma hine oil.

Do not oil ex essively. The tool was engineered for

durability but like any other equipment it needs leaning and lubri ation for a maximum servi e life of trouble

free rimping. Light oil (su h as 30 weight automotive oil) used at the oil points, every 5,000 rimps or 3

months, will signifi antly enhan e the tool life.

4. Wipe ex ess oil from hand tool, parti ularly from rimping area. Oil transferred from the rimping area onto

ertain terminations may affe t the ele tri al hara teristi s of an appli ation.

5. When tool is not in use, keep the handles losed to prevent obje ts from be oming lodged in the rimping dies,

and store the tool in a lean, dry area.

Miscrimps or Jams

Should this tool ever be ome stu k or jammed in a partially losed position, Do Not for e the handles open or

losed. The tool will open easily by lifting the rat het release lever. See Figure 9.

Warranty

This tool is for ele tri al terminal rimping purposes only. This tool is made of the best quality materials. All vital

omponents are long life tested. All tools are warranted to be free of manufa turing defe ts for a period of 30

days. Should su h a defe t o ur, we will repair or ex hange the tool free of harge. This repair or ex hange will

M4 BHCS

PIVOT LOCATOR

Figure 4

Hand Crimp Tool for 2.00/2.50mm (.079/.098") Board-In Crimp Terminals

Do No: ATS-6381177HM Release Date: 08-29-07 UNCONTROLLED COPY Page 5 of 7

Revision: B Revision Date: 08-02-10

not be appli able to altered, misused, or damaged tools. This tool is designed for hand use only. Any lamping,

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

produ tion use. Repetitive use of this tool should be avoided.

2. Insulated rubber handles are not prote tion against ele tri al sho k.

3. Wear eye prote tion at all times.

4. Use only the Molex terminals spe ified for rimping with this tool.

Notes:

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

2. This tool is not adjustable for rimp height; however rimp for e is adjustable (See instru tions above).

Variations in tools, terminals, wire stranding, and insulation types may affe t rimp height.

3. This tool is intended for standard ondu tor sizes. It may not give a good insulation rimp support for all

insulation sizes.

4. Molex does not repair hand tools (see warranty above). The repla ement parts listed are the only parts

available for repair. If the handles or rimp tooling is damaged or worn, a new tool must be pur hased.

5. Pull for e should be used as the final riteria for an a eptable rimp. Pull for e is measured with no

influen e from the insulation rimp. The insulation should be stripped long (1/2 in.) so the insulation grips

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

Handbook 63800-0029 for additional information on rimping and rimp testing.

6. Molex does not ertify rimp hand tools.

CAUTION: Molex rimp spe ifi ations are valid only when used with Molex terminals and tooling.

Applications or the Modular Crimp Head

WARNING: NEVER operate, servi e, install, or adjust this Modular Crimp Head without proper instru tion

and without first reading and understanding the instru tions in the proper Manual or Spe ifi ation Sheet.

See Chart below for the orre t Manual or Spe ifi ation Sheet.

WARNING: NEVER install tooling or servi e this tool while it is into any power sour e. Dis onne t the

power by unplugging or turn off the A tuator from its power sour e.

CAUTION: Keep fingers away from the rimping area when operating this tool. It may ause severe injury.

CAUTION: Wear safety glasses when operating or serving this tool.

Hand Crimp Tool for 2.00/2.50mm (.079/.098") Board-In Crimp Terminals

Do No: ATS-6381177HM Release Date: 08-29-07 UNCONTROLLED COPY Page 6 of 7

Revision: B Revision Date: 08-02-10

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 hart below shows all appli ations for this Modular Crimp Head.

Modular Crimp Head

Order No.

Tool

Order no.

Tool

Description

Adapter

Order No.

Adapter

Description

Figure

No.

63811-7770

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 or the Modular Crimp Head

Hand Crimp Tool Battery Powered Tool Air Powered Tool

Figure 6 Figure 7 Figure 8

MODULAR

CRIMP

HEAD

LOCKING

PINS

HAND CRIMP

FRAME LONG

OR SHORT

Hand Crimp Tool for 2.00/2.50mm (.079/.098") Board-In Crimp Terminals

Do No: ATS-6381177HM Release Date: 08-29-07 UNCONTROLLED COPY Page 7 of 7

Revision: B Revision Date: 08-02-10

RATCHET

RELEASE LEVER

HANDLE

SPRING

CRIMPING

SPRING (2)

LOCATOR

Figure 9

M4 X 8mm

LONG BHCS

PARTS LIST

Hand Crimp Tool 63811-7700

Item

Order Number

Description Quantity

1 63811-7770 Modular Crimp Head 1

2 63816-0000 Hand Crimp Frame (Short)

3 63811-7775 Lo ator 1

4 63816-0001 Lo king Pin 2

5 63600-0525 Handle Spring 1

6 63600-0520 Crimping Spring 2

http://www.molex. om

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