Molex 207129 Series Manuel utilisateur

Hand Crimp Tool for EdgeLock™ Crimp Terminal

Doc No: ATS-638279000 Release Date: 09-30-15 UNCONTROLLED COPY Page 1 of 7

Revision: A Revision Date: 09-30-15

INSULATION CRIMP

BRUSH

STRIP LENGTH

BELL MOUTH

CUT-OFF

TAB

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP HEIGHT

TWISTING

SEAM

WIRE

HAND CRIMP

TOOL

Application Tooling

Specification Sheet

Order No. 63827-9000

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

Dies and Locator from this tool can be used in the Battery Powered Tool Order No.63816-0200 (110 V) or

63816-0250 (220 V), with the use of the 63816-0800 Crimp Head

Many different tool kits can be used with a single Battery Powered Crimp Tool

This tool is IPC/WHMA A-620 Class 2 compliant

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

SCOPE

Products: EdgeLock™ Crimp Terminal, 24AWG wire, UL1007 and UL1061 insulation.

Terminal Series No.

Terminal Order No.

Wire Size

Insulation Diameter

Strip Length

Loose Piece

Reel

AWG

mm²

In.

200449

---

200449-0001

---

1.10 –1.50

0.043 –0.059

1.50 –1.90

0.059 –0.075

Customer to cut off terminal from reel: 0.20mm (0.008”) maximum Cut-off Tab.

DEFINITION OF TERMS

TYPE 4D

Hand Crimp Tool for EdgeLock™ Crimp Terminal

Doc No: ATS-638279000 Release Date: 09-30-15 UNCONTROLLED COPY Page 2 of 7

Revision: A Revision Date: 09-30-15

CONDITIONS:

After crimping, the conductor profiles should measure the following.

Terminal Series No.

Wire Size

Conductor Crimp

Height

Conductor Crimp

Width (REF)

Pull Force

Minimum

Profile

AWG

mm2

In.

Lb.

1007

1061

200449

24AWG UL1007

---

0.81 –0.85

0.032 –0.033

1.40

0.055

22.3

5.0

24AWG UL1061

---

Terminal Series No.

Wire Size

Insulation Crimp Height (Ref)

Insulation Crimp Width (Ref)

AWG

mm2

In.

200449

24AWG UL1007

---

1.65

0.065

1.65

0.065

24AWG UL1061

---

1.55

0.061

1.55

0.061

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 document 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

CAUTION: Crimp only the Molex terminals

listed in the scope for this tool. Do not

crimp hardened objects as damage can

occur to the tool frame and/or crimp dies.

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.

Crimping Terminals

1. Select the desired terminal listed in the

preceding charts.

2. Make sure the center of the locator is in the down position. With the locator attached, push the locator button

on the back of the hand tool to bring the locator forward through the tooling. See Figure 2.

3. While holding the locator button in, 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.

LOCATOR

IN DOWN

POSTION

PUSH ON THE

LOCATOR BUTTON

Figure 2

SQUEEZE

HANDLES

TOGETHER

HANDLE WILL

SPRING OPEN

Figure 1

Hand Crimp Tool for EdgeLock™ Crimp Terminal

Doc No: ATS-638279000 Release Date: 09-30-15 UNCONTROLLED COPY Page 3 of 7

Revision: A Revision Date: 09-30-15

LOCATOR

PUSHED THRU

TOOLING

TERMINAL

RELEASE

LOCATOR BUTTON

Figure 3

TERMINAL

LOCATOR

BUTTON

PUSHED IN

LOCATOR

PRE-STRIPPED

WIRE

TERMINAL

Figure 5

TERMINAL

WIRE AGAINST

THE WIRE

STOP

WIRE

WIRE STOP IS

PART OF

THE LOCATOR

4. Release the locator button, allowing the locator to return to the

crimping position.

5. Close the tool handle until the first ratchet position engages. See

Figure 4.

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

the wire stop. See Figure 5.

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

mechanism cycle has been completed. Release the handles to

open the jaws.

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.

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 6A 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

6A.

PARTIALLY

CLOSE HANDLE

TOOLING

PARTIALLY CLOSED

Figure 4

FIRST RATCHET

POSITION

OPEN

POSITION

Hand Crimp Tool for EdgeLock™ Crimp Terminal

Doc No: ATS-638279000 Release Date: 09-30-15 UNCONTROLLED COPY Page 4 of 7

Revision: A Revision Date: 09-30-15

Figure 7

PUSH ON

HANDLE

JAWS OPEN

PULL OPEN

TOOLING

M3 BHCS

MATCH

UP MARKS

FRONT

BACK

Figure 8

4. To reinstall the new locator, make sure

the hand tool is in the open position.

5. Press the red insert down as far as it will

go as shown in Figure 6B.

6. 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.

7. 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.

Right 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.

3. 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 7 and 8.

4. Do the same thing with the lower tooling and

tighten the M3 screws. Be sure the small

markings line up.

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

MAKE SURE

CENTER OF LOCATOR

IS IN THE

DOWN POSITION

Figure 6B

SQUEEZE

HERE

SQUEEZE

HERE

LOCATOR

Figure 6A

TOP HOOKS

TOP SLOTS OF

HANDTOOL

LOWER TABS

Hand Crimp Tool for EdgeLock™ Crimp Terminal

Doc No: ATS-638279000 Release Date: 09-30-15 UNCONTROLLED COPY Page 5 of 7

Revision: A Revision Date: 09-30-15

Figure 11

SQUEEZE

THE LINK IN

THE HANDLE

HOLD THE HAND

TOOL IN POSITION

SETTING

WHEEL

RATCHET

RELEASE LEVER

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 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 pressing up

on the ratchet release lever in the movable handle. See Figure 10.

How to Adjust Tool Preload (See Figure 11)

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. Hold the hand tool in the palm of your

hand as shown in Figure 11. 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.

LUBRICATION POINTS

(BOTH SIDES) LIGHT OIL

(EVERY 3 MONTHS OR

5,000 CRIMPS)

Figure 9

RATCHET RELEASE

LEVER

Figure 10

Hand Crimp Tool for EdgeLock™ Crimp Terminal

Doc No: ATS-638279000 Release Date: 09-30-15 UNCONTROLLED COPY Page 6 of 7

Revision: A Revision Date: 09-30-15

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.

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

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.

Hand Crimp Tool for EdgeLock™ Crimp Terminal

Doc No: ATS-638279000 Release Date: 09-30-15 UNCONTROLLED COPY Page 7 of 7

Revision: A Revision Date: 09-30-15

RATCHET

RELEASE LEVER

Figure 12

PARTS LIST

Item Number

Order Number

Description

Quantity

REF

63827-9000

Hand Crimp Tool

Figure 12

63827-9075

Locator Assembly

63810-0104

Spring, Return

63810-0105

Spring, Ratchet

Visit our Web site at http://www.molex.com

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