Molex 207129 Series Manual de usuario

Tool Kit for Right Angle Board-In Crimp Terminals

Doc No: ATS-63 1169HM Release Date: 09-25-06 UNCONTROLLED COPY Page 1 of 9

Revision: E Revision Date: 03-27-14

Application Tooling

Specification Sheet

Tool Kit

Order No. 6 811-6970

Hand Crimp Tool

Order No. 6 811-6900

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 63 16-0300 Power Crimp Head which is installed

into the 63 16-0200 (110 V) or the 63 16-0250 (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, see conditions on page 2.

 This tool is RoHS compliant.

SCOPE

Products: 2.00/2.50mm (.079/.09 ") Right Angle Board-In Terminal, 22-30 AWG.

Terminal

Series No.

Terminal Order No.

Wire Size



Insulation Diameter

Strip Length







Reel

AWG

mm²

In.

35021

1201

35021

1310

24-30

0.20-0.05

1.01-1.50 .040-.059 1. 0-2.20

.071-.0 7

35021

1300

35021

1360

35021

1301

35021

1001

35021

1110

22-30

0.32-0.05

1.01-1.90 .040-.075 1. 0-2.20

.071-.0 7

35021

1100

35021

1160

35021

110



Customer to cut off terminal from reel: 0.

mm (.0

”) maximum Cut

off Tab.

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.

TYPE 2C

INSULATION

CRIMP

▲SEE NOTE

BRUSH

STRIP

LENGTH

BELL MOUTH

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP

TWISTING

CRIMP HEIGHT

Tool Kit for Right Angle Board-In Crimp Terminals

Doc No: ATS-63 1169HM Release Date: 09-25-06 UNCONTROLLED COPY Page 2 of 9

Revision: E Revision Date: 03-27-14

▲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

Pull Force

Minimum 



Profile

Height (Ref)

Width (Ref)

AWG

In.

Lb.

35021-12xx

and

35021-13xx

0.20

0.55

0.66

.022

.026

1.27

.050

29.

6.60

0.13

0.55

0.66

.022

.026

1.27

.050

19.6

4.40

0.0

0.55

0.66

.022

.026

1.27

.050

2.10

0.05

0.55

0.66

.022

.026

1.26

.049

4.9

1.30

35021-10xx

and

35021-11xx

0.35

0.55

0.66

.022

.026

1.2

.050

34.3

7.70

0.20

.55

0.66

.022

.026

1.27

.050

29.4

6.60

0.13

0.55

0.66

.022

.026

1.27

.050

19.6

4.40

0.0

0.55

0.66

.022

.026

1.27

.050

2.10

0.05

0.55

0.66

.022

.026

1.26

.049

4.9

1.30



To Achieve IPC

620 Class 2 Crimps, the following over

all wire insulation diameter ranges are recommended:

Profile A: 1.00-1.30mm (.039-.051”)

Profile B: 1.00-1.25mm (.039-.049”)

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 on this page.

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:

OVERLAP

INSULATION

CRIMP

OVERLAP FORM GEOMETRY

ANVIL

PUNCH

WIRE

Tool Kit for Right Angle Board-In Crimp Terminals

Doc No: ATS-63 1169HM Release Date: 09-25-06 UNCONTROLLED COPY Page 3 of 9

Revision: E Revision Date: 03-27-14

SWING

LOCATOR

OPEN

PRESS DOWN

ON THE BRASS

PIVOT SHAFT

LIFT UP ON

THE LOCATOR

Figure

ANVILS

POWER

CRIMP

HEAD

Figure

PUNCHES

M4 X 10 LONG

BHCS

M4 X 18 LONG

BHCS

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 1 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.

2. Swing the terminal locator away from the crimp tool shown in Figure 4.

3. When using the locator, press 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 or B

profile on the hand tool.

Figure

LOCATOR

JAWS OPEN

Tool Kit for Right Angle Board-In Crimp Terminals

Doc No: ATS-63 1169HM Release Date: 09-25-06 UNCONTROLLED COPY Page 4 of 9

Revision: E Revision Date: 03-27-14

LOCATOR

IN PLACE

WIRE STOP

TERMINAL

WIRE

WIRE STOP

WIRE AGAINST

STOP

Figure 5

TERMINAL

PUSH HERE TO

OPEN WIRE STOP

SWING OPEN

LOCATOR

TERMINAL IN PLACE

Figure 4

4. Return the locator to its original position.

5. Insert the proper wire over the terminal. 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.

Note: The tamper proof ratchet action will not release the tool until it has

been fully closed.

7. Remove the crimp 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.

. Visually inspect the crimped terminal for proper crimp location and

crimp height.

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 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.

SWING

LOCATOR

OPEN

PRESS DOWN ON

BRASS PIVOT SHAFT

LIFT UP LOCATOR

JAWS

OPEN

Figure 6

Tool Kit for Right Angle Board-In Crimp Terminals

Doc No: ATS-63 1169HM Release Date: 09-25-06 UNCONTROLLED COPY Page 5 of 9

Revision: E Revision Date: 03-27-14

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.

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.

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 .

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 (63 10-0101), 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 Right Angle Board-In Crimp Terminals

Doc No: ATS-63 1169HM Release Date: 09-25-06 UNCONTROLLED COPY Page 6 of 9

Revision: E Revision Date: 03-27-14

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, 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.

Tool Kit for Right Angle Board-In Crimp Terminals

Doc No: ATS-63 1169HM Release Date: 09-25-06 UNCONTROLLED COPY Page 7 of 9

Revision: E Revision Date: 03-27-14

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.

63 11-6970

63 1

0100

Hand Crimp Frame (Short)

N/A

63 1

Hand Crimp Frame (Long)

N/A

63 16

0200

Battery Power

Tool (110 V)

63 16

0300

Power Crimp Head

63 16

0250

Battery Power

Tool (220 V)

63 16

0300

Power Crimp Head

Applications for t

he Tool Kit

Hand Crimp Tool

Battery Powered Tool

Figure

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 Right Angle Board-In Crimp Terminals

Doc No: ATS-63 1169HM Release Date: 09-25-06 UNCONTROLLED COPY Page of 9

Revision: E Revision Date: 03-27-14

RATCHET

RELEASE SCREW

Figure 11

M4 X

LONG BHCS

M4 X 1

LONG BHCS

WITH TOOL KIT

LOCATOR ONLY

M4 X 12mm

LONG BHCS

HAND TOOL PARTS LIST

Item Number

Order Number

Description

Quantity

63 10

0100

Hand Crimp Frame (

Short

)

63 10

0101

Wrench Set (Not included)

63 10

0102

Locator Base

63 10

0103

Repair Kit (Not included)

63 11

6970

Tool Kit with

Locator

63 11

6975

Locator (only)

REF

Tool Kit for Right Angle Board-In Crimp Terminals

Doc No: ATS-63 1169HM Release Date: 09-25-06 UNCONTROLLED COPY Page 9 of 9

Revision: E Revision Date: 03-27-14

Figure 1

Long

BHCS

Long

BHCS

Long

BHCS

POWER HEAD PARTS LIST

Item

Order No

Engineering No.

Description

Quantity

63 16-0300 63 16-0300 Power Crimp Head 1

63 11-6970 63 11-6970 Tool Kit 1

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

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