Molex 207129 Series Bedienungsanleitung

Tool Kit for SPOX™ Crimp Terminals

Doc No: ATS-63811 2HM Release Date: 04-03-06 UNCONTROLLED COPY Page 1 of 9

Revision: D Revision Date: 06-30-11

Application Tooling

Specification Sheet

Tool Kit

Order No. 6 811-5270

Hand Crimp Tool

Order No. 6 811-5200

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

 Tool kits are easily installed into the Hand Crimp Tool or the 63816-0300 Power Crimp Head which is installed

into the 63816-0200 (110 V) or the 63816-02 0 (220 V) Battery Powered Tool.

 Many different Tool kits can be used with a single Battery Powered Tool.

 This tool is IPC/WHMA-A-620 Class 2 and RoHS compliant.

SCOPE

Products: 2. 0mm (.098”) Pitch SPOX™ Wire-to-Board and Wire-to-Wire Crimp Terminal, 22-28 AWG.

Terminal

Series No.

Terminal Order No. Wire Size Insulation Diameter Strip Length

Loose Piece Reel AWG mm² mm In. mm In.

103

08-70-00 7 08-70-00 6 39-00-0188

22-28 0.3 -0.08 1.1 -1.90 .04 -.07 3.30-3.80 .130-.1 0

08-70-00 9 08-70-00 8 39-00-0387

39-00-0189 08-700-0 69 39-00-0388

08-700-0 89 39-00-0389

39-00-0390

263

08-70-1040 08-70-1039 39-00-01 1

22-28 0.3 -0.08 1.1 -1.90 .04 -.07 3.30-3.80 .130-.1 0 08-70-1046 08-70-104 39-00-01 9

39-00-01 2 39-00-0160

4 627 4 627-1002 4 627-0002 22-24 0.3 -0.20 1.1 -1.90 .04 -.07 3.30-3.80 .130-.1 0

4 627-9002

0802 0802-8100 0802-8000 22-24 0.3 -0.20 1.1 -1.90 .04 -.07 3.30-3.80 .130-.1 0

0802-9101 0802-9001

Customer to cut off terminal from reel: 0.30mm (.012”) maximum Cut-off Tab.

See Conditions on page 2.

TYPE 2C

Tool Kit for SPOX™ Crimp Terminals

Doc No: ATS-63811 2HM Release Date: 04-03-06 UNCONTROLLED COPY Page 2 of 9

Revision: D Revision Date: 06-30-11

INSULATION

CRIMP

▲

SEE NOTE

BRUSH

STRIP

LENGTH

BELL MOUTH

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP

TWISTING

CRIMP HEIGHT

OVERLAP

INSULATION

CRIMP

OVERLAP FORM

GEOMETRY

ANVIL

PUNCH

WIRE

DEFINITION OF TERMS

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

scope.

▲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.

Hand

Tool

Locator

Wire Size Conductor Crimp Insulation Crimp Pull Force

Minimum  Profile

Height (Ref.) Width (Ref.)

Height (Ref.)

Width (Ref.)

AWG

mm2

mm In. mm In. mm In. mm In. N Lb. A B C

103

1 22 0.3 0.73-0.80

.029-.031

1.40 .0 1.68 .066 1.90 .07 44.48

10.0

1 24 0.20 0.67-0.74

.026-.029

1.40 .0 1. 7 .062 1.90 .07 28.91

6. X

1 26 0.12 0.63-0.69

.02 -.027

1.40 .0 1.42 .0 6 1. 0 .0 9 17.79

4.0 X

1 28 0.08 0.61-0.67

.024-.026

1.40 .0 1.42 .0 6 1. 0 .0 9 11.12

2. X

263

1 22 0.3 0.73-0.80

.029-.031

1.40 .0 1.68 .066 1.90 .07 44.48

10.0

1 24 0.20 0.67-0.74

.026-.029

1.40 .0 1. 7 .062 1.90 .07 28.91

6. X

1 26 0.12 0.63-0.69

.02 -.027

1.40 .0 1.42 .0 6 1. 0 .0 9 17.79

4.0 X

1 28 0.08 0.61-0.67

.024-.026

1.40 .0 1.42 .0 6 1. 0 .0 9 11.12

2. X

0802

1 22 0.3 0.73-0.80

.029-.031

1.40 .0 1.68 .066 1.90 .07 44.48

10.0

1 24 0.20 0.67-0.74

.026-.029

1.40 .0 1. 7 .062 1.90 .07 28.91

6. X

1 26 0.12 0.63-0.69

.02 -.027

1.40 .0 1.42 .0 6 1. 0 .0 9 17.79

4.0 X

1 28 0.08 0.61-0.67

.024-.026

1.40 .0 1.42 .0 6 1. 0 .0 9 11.12

2. X

4 627 2 22 0.3 0.73-0.80

.029-.031

1.40 .0 1.68 .066 1.90 .07 44.48

10.0

2 24 0.20 0.67-0.74

.026-.029

1.40 .0 1. 7 .062 1.90 .07 28.91

6. X



To Achieve IPC-A-620 Class 2 crimps. The following over-all wire insulation diameter ranges are recommended:

1. Profile A: 1.20-1.90mm (.047-.07 inch)

2. Profile B: 1.20-1. mm (.047-.061 inch)

Profile C: 1.1 -1.30mm (.04 -.0 1 inch)

Tool Kit for SPOX™ Crimp Terminals

Doc No: ATS-63811 2HM Release Date: 04-03-06 UNCONTROLLED COPY Page 3 of 9

Revision: D Revision Date: 06-30-11

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

destructive, pull force test should be preformed to check hand tool crimp. Pull Force value must exceed the

minimum pull force specifications listed.

CAUTION: Install 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.

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. Make sure that the proper locator is mounted on the

tool.

Figure

LOCATOR

JAWS OPEN

TERMINAL

PUSH HERE

TO OPEN

WIRE STOP

SWING OPEN

LOCATOR

LOCATOR TERMINAL

IN PLACE

Figure 4

Tool Kit for SPOX™ Crimp Terminals

Doc No: ATS-63811 2HM Release Date: 04-03-06 UNCONTROLLED COPY Page 4 of 9

Revision: D Revision Date: 06-30-11

2. Swing the terminal locator away from the crimp tool shown in Figure

4. 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, press down on the wire stop on the locator

as shown in Figure 4. Insert the proper terminal into the proper nest

opening. Make sure when choosing the nest opening, it will

correspond with the A, B, or C profile on the hand tool.

4. Return the locator to its original position.

. 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 .

6. Compress the terminal by squeezing the tool handles until the

ratchet mechanism cycle has been completed. Release handles to

open the jaws.

7. Return the locator to its original position.

8. 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 .

9. Compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.

Release handles to open the jaws.

10. 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.

11. Visually inspect the crimped terminal for proper crimp location.

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

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.

Locator Change Over and Replacement

Multiple styles of locators maybe provided with the crimp

hand tool. They are different colors for easy identification.

See the parts list on the last page of the document. Make

sure the desired style of locator is installed for the proper

terminal and wire. Follow the steps below to change the

locators.

1. Open the crimp hand tool.

2. Swing the existing locator open and away from the hand tool.

LOCATOR

IN PLACE

WIRE STOP

TERMINAL

WIRE AGAINST

STOP Figure 5

WIRE STOP

WIRE

SWING

LOCATOR

OPEN

PRESS DOWN ON

BRASS PIVOT SHAFT

LIFT UP LOCATOR

JAWS OPEN

Figure 6

Tool Kit for SPOX™ Crimp Terminals

Doc No: ATS-63811 2HM Release Date: 04-03-06 UNCONTROLLED COPY Page of 9

Revision: D Revision Date: 06-30-11

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 desired locator by putting

over the brass pivot shaft and snapping it into

place.

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 ,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.

. 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 the ratchet release lever. See Figure 8.

How to Adjust Tool Preload

(See Figure 8)

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. 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.

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

Figure 7B

LUBRICATION

POINTS

(BOTH SIDES)

LIGHT OIL

(EVERY MONTH

5,000 CRIMPS)

Figure 7A

Tool Kit for SPOX™ Crimp Terminals

Doc No: ATS-63811 2HM Release Date: 04-03-06 UNCONTROLLED COPY Page 6 of 9

Revision: D Revision Date: 06-30-11

4. Replace the locking screw, aligning the nearest notch in the setting wheel to locking screw.

. 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, 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 commercial grade 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.

The chart below shows all applications for this Tool Kit.

Tool Kit

Order No.

Tool

Order no.

Tool

Description

Power Head

Order No.

Adapter

Description

Figure

No.

63811- 270

63810-0100

Hand Crimp Frame (Short) N/A N/A 9

63810-0400

Hand Crimp Frame (Long) N/A N/A 9

63816-0200

Battery Power Tool (110 V)

63816-0300 Power Crimp Head

63816-02 0

Battery Power Tool (220 V)

63816-0300 Power Crimp Head

Tool Kit for SPOX™ Crimp Terminals

Doc No: ATS-63811 2HM Release Date: 04-03-06 UNCONTROLLED COPY Page 7 of 9

Revision: D Revision Date: 06-30-11

Applications for the Tool Kit

Hand Crimp Tool Battery Powered Tool

Figure 9 Figure 10

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

TOOLING KIT

HAND CRIMP

FRAME LONG

AND SHORT

TOOLING

KIT

Tool Kit for SPOX™ Crimp Terminals

Doc No: ATS-63811 2HM Release Date: 04-03-06 UNCONTROLLED COPY Page 8 of 9

Revision: D Revision Date: 06-30-11

RATCHET

RELEASE SCREW

Figure 11

M4 X 6mm

LONG BHCS

M4 X 12mm

LONG BHCS

WITH TOOL KIT

LOCATOR ONLY

M4 X 12mm

LONG BHCS

5 WITH TOOL KIT

LOCATOR ONLY

HAND TOOL PARTS LIST

Item Number Order Number Description Quantity

1 63810-0100 Hand Crimp Frame (Short) 1

2 63810-0101 Wrench Set (Not included) 0

3 63810-0102 Locator Base 1

4 63810-0103 Repair Kit (Not included) 0

63811- 270 Tool Kit with Locator 1

6 63811- 27 Locator #1-Black 1

7 63811- 276 Locator #2-Gray 1

Tool Kit for SPOX™ Crimp Terminals

Doc No: ATS-63811 2HM Release Date: 04-03-06 UNCONTROLLED COPY Page 9 of 9

Revision: D Revision Date: 06-30-11

Figure 12

M4 by 8 Long

BHCS

M4 by 18 Long

BHCS

M4 by 10 Long

BHCS

POWER HEAD PARTS LIST

Item Order No Engineering No. Description Quantity

63816-0300 63816-0300 Power Crimp Head 1

63811- 270 63811- 270 Tool Kit 1

http://www.molex.com

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