Molex 207129 Series Bedienungsanleitung

Hand Crimp Tool for SPOX™ Terminals

Doc No. 63811-5200 Release Date: 04-03-06 UNCONTROLLED COPY Page 1 of 6

Revision: A Revision Date: 04-03-06

INSULATION

CRIMP

BRUSH

STRIP

LENGTH

BELL MOUTH

CRIMP HEIGHT

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP

TWISTING

TYPE 2C

HAND CRIMP TOOL

SPECIFICATION SHEET

Order No. 63811-5200

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



This tool is WHMA-IPCA620 Class 2 and RoHS compliant

SCOPE

SPOX™, 2.50mm (.098") Pitch Crimp Terminal, 22 - 28 AWG.

Wire Size ✴ Insulation Diameter Strip Length

Terminal Series No. Terminal Order No. AWG mm² mm In. mm In.

08-70-0057 22-28 0.35-0.08 1.15-1.90 .045-.075 3.30-3.80 .130-.150

5103 08-70-0059 22-28 0.35-0.08 1.15-1.90 .045-.075 3.30-3.80 .130-.150

08-70-1040 22-28 0.35-0.08 1.15-1.90 .045-.075 3.30-3.80 .130-.150

08-70-1046 22-28 0.35-0.08 1.15-1.90 .045-.075 3.30-3.80 .130-.150

5263

39-00-0152 22-28 0.35-0.08 1.15-1.90 .045-.075 3.30-3.80 .130-.150

45627 45627-0002 22-24 0.35-0.20 1.15-1.90 .045-.075 3.30-3.80 .130-.150

✴ See Conditions on page 2.

DEFINITION OF TERMS

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

Hand Crimp Tool for SPOX™Terminals

Doc No. 63811-5200 Release Date: 04-03-06 UNCONTROLLED COPY Page 2 of 6

Revision: A Revision Date: 04-03-06

CONDITIONS:

After crimping, the conductor profiles should measure the following (see notes on page 5).

Conductor Crimp Insulation Crimp

Wire Size Height (Ref.) Width (Ref.) Height (Ref.) Width (Ref.) Pull Force Min. ✴ Profile

Terminal

Series No

Hand

Tool

Locator AWG mm2mm In. mm In. mm In. mm In. N Lb. A B C

5103 1 22 0.35 0.73-0.80 .029-.031 1.40 .055 1.68 .066 1.90 .075 44.48 10.0 X

5103 1 24 0.20 0.67-0.74 .026-.029 1.40 .055 1.57 .062 1.90 .075 28.91 6.5 X

5103 1 26 0.12 0.63-0.69 .025-.027 1.40 .055 1.42 .056 1.50 .059 17.79 4.0 X

5103 1 28 0.08 0.61-0.67 .024-.026 1.40 .055 1.42 .056 1.50 .059 11.12 2.5 X

5263 1 22 0.35 0.73-0.80 .029-.031 1.40 .055 1.68 .066 1.90 .075 44.48 10.0 X

5263 1 24 0.20 0.67-0.74 .026-.029 1.40 .055 1.57 .062 1.90 .075 28.91 6.5 X

5263 1 26 0.12 0.63-0.69 .025-.027 1.40 .055 1.42 .056 1.50 .059 17.79 4.0 X

5263 1 28 0.08 0.61-0.67 .024-.026 1.40 .055 1.42 .056 1.50 .059 11.12 2.5 X

45627 2 22 0.35 0.73-0.80 .029-.031 1.40 .055 1.68 .066 1.90 .075 44.48 10.0 X

45627 2 24 0.20 0.67-0.74 .026-.029 1.40 .055 1.57 .062 1.90 .075 28.91 6.5 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-.075 inch)

2. Profile B: 1.20-1.55mm (.047-.061 inch)

3. Profile C: 1.15-1.30mm (.045-.051 inch)

OPERATION

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

the tool or die.

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.

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

2. 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.

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 3.

6. Compress the terminal by squeezing the tool handles until the ratchet mechanism cycle

has been completed. Release handles to open the jaws.

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

Figure 1

LOCATOR

JAWS OPEN

Hand Crimp Tool for SPOX™Terminals

Doc No. 63811-5200 Release Date: 04-03-06 UNCONTROLLED COPY Page 3 of 6

Revision: A Revision Date: 04-03-06

TERMINAL

PUSH HERE TO

OPEN WIRE STOP

SWING OPEN

LOCATOR

LOCATOR TERMINAL IN PLACE

Figure 2

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.

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 on page 2.

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.

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 4.

4. Replace it with the desired locator by putting over the brass pivot

shaft and snapping it into place.

LOCATOR

IN PLACE

WIRE STOP

TERMINAL

WIRE AGAINST

STOP Figure 3

WIRE STOP

WIRE

SWING

LOCATOR

OPEN

PRESS DOWN ON

BRASS PIVOT SHAFT

LIFT UP LOCATOR

JAWS OPEN

Figure 4

Hand Crimp Tool for SPOX™Terminals

Doc No. 63811-5200 Release Date: 04-03-06 UNCONTROLLED COPY Page 4 of 6

Revision: A Revision Date: 04-03-06

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.

This 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. Light oil such as 30 weight automotive oil

used at the oil points shown in Figure 6, 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 the ratchet release lever. See Figure 6.

How To Adjust Tool Preload (See Figure 6)

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) will 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.

RATCHET

RELEASE LEVER

Figure 6

HANDLE

GRIP

REMOVED

ECCENTRIC AXLE

HANDLE

GRIP

LOCKING

SCREW

WRENCH SET

(SOLD

SEPERATELY)

PRELOAD

CHECK POINT

25.4MM

SETTING WHEEL

LUBRICATION POINTS

(BOTH SIDES) LIGHT OIL

(EVERY 3 MONTHS OR

5,000 CRIMPS)

Figure 5

Hand Crimp Tool for SPOX™Terminals

Doc No. 63811-5200 Release Date: 04-03-06 UNCONTROLLED COPY Page 5 of 6

Revision: A Revision Date: 04-03-06

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 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 SPOX™Terminals

Doc No. 63811-5200 Release Date: 04-03-06 UNCONTROLLED COPY Page 6 of 6

Revision: A Revision Date: 04-03-06

RATCHET

RELEASE LEVER

Figure 7

M4 X 5LG

BHCS

PARTS LIST

Item Number Order Number Description Quantity

1 63810-0101 Wrench Set (Not included) 0

2 63810-0102 Locator Base Assembly 1

3 63810-0103 Repair Kit (Not included) 0

4 63811-5275 Locator #1-Black 1

5 63811-5276 Locator #2-Gray 1

Molex Application Tooling Group

2200 Wellington Court

Lisle, IL 60532

Tel: 630-969-4550

Fax: 630-505-0049

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

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