Molex 207129 Series Bedienungsanleitung

Tool Kit for Mini-Fit Jr. ™ Crimp Terminals

Doc No: ATS-6381151HM Release Date: 04-03-06 UNCONTROLLED COPY Page 1 of 9

Revision: D Revision Date: 10-04-10

Application Tooling

Specification Sheet

Tool Kit

Order No. 63811-5170

Hand Crimp Tool

Order No. 63811-5100

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 63816-0250 (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 and RoHS compliant.

SCOPE

Products: Mini-Fit Jr. ™ Male, and Female Crimp Terminals, 22-28 AWG.

Terminal

Series No.

Terminal Order No.

Wire Size

Insulation

Diameter

Maximum

Strip Length

Loose Piece

Reel

AWG

mm²

In.

5556

39-00-0047

39-00-0172

39-00-0046

39-00-0171

22-28

0.35-0.08

1.80

.071

2.79-3.30

.110-.130

39-00-0066

39-00-0178

39-00-0065

39-00-0177

39-00-0086

39-00-0184

39-00-0085

39-00-0183

39-00-0092

39-00-0197

39-00-0091

39-00-0196

39-00-0111

39-00-0203

39-00-0110

39-00-0202

39-00-0117

39-00-0210

39-00-0116

39-00-0209

39-00-0140

39-00-0216

39-00-0139

39-00-0215

39-00-0156

39-00-0435

39-00-0155

39-00-0434

39-00-0166

39-00-0165

5558

39-00-0049

39-00-0129

39-00-0048

39-00-0128

22-28

0.35-0.08

1.80

.071

2.79-3.30

.110-.130

39-00-0068

39-00-0146

39-00-0067

39-00-0145

39-00-0088

39-00-0222

39-00-0087

39-00-0221

39-00-0098

39-00-0433

39-00-0097

39-00-0432

39-00-0123

39-00-0122

44485

39-00-2212

39-00-2412

39-00-2211

39-00-2411

22-28

0.35-0.08

1.80

.071

2.79-3.30

.110-.130

39-00-2312

39-00-2311

Customer to cut off terminal from reel: 0.20mm (.008”) maximum Cut-off Tab.

See Conditions on page 2

TYPE 2C

Tool Kit for Mini-Fit Jr. ™ Crimp Terminals

Doc No: ATS-6381151HM Release Date: 04-03-06 UNCONTROLLED COPY Page 2 of 9

Revision: D Revision Date: 10-04-10

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

Wire Size

Conductor Crimp

Insulation Crimp

Pull Force

Minimum

Profile

Height (Ref.)

Width (Ref.)

Height (Ref.)

Width (Ref.)

AWG

mm2

In.

Lb.

5556

0.35

0.76-0.86

.030-.034

1.44

.057

1.72

.068

1.61

.063

40.0

9.00

0.20

0.69-0.79

.027-.031

1.44

.057

1.72

.068

1.61

.063

31.1

7.00

0.12

0.64-0.74

.025-.029

1.44

.057

1.43

.056

1.57

.062

22.2

5.00

0.08

0.61-0.71

.024-.028

1.44

.057

1.43

.056

1.57

.062

13.3

3.00

5558

0.35

0.76-0.86

.030-.034

1.44

.057

1.72

.068

1.61

.063

40.0

9.00

0.20

0.69-0.79

.027-.031

1.44

.057

1.72

.068

1.61

.063

31.1

7.00

0.12

0.64-0.74

.025-.029

1.44

.057

1.43

.056

1.57

.062

22.2

5.00

0.08

0.61-0.71

.024-.028

1.44

.057

1.43

.056

1.57

.062

13.3

3.00

44485

0.35

0.76-0.86

.030-.034

1.44

.057

1.72

.068

1.61

.063

40.0

9.00

0.20

0.69-0.79

.027-.031

1.44

.057

1.72

.068

1.61

.063

31.1

7.00

0.12

0.64-0.74

.025-.029

1.44

.057

1.43

.056

1.57

.062

22.2

5.00

0.08

0.61-0.71

.024-.028

1.44

.057

1.43

.056

1.57

.062

13.3

3.00

To Achieve IPC-A-620 Class 2 Crimps, the following over-all wire insulation diameter ranges are recommended:

1. Profile A: 1.12-1.80mm (.044-.071 inch)

2. Profile B: 0.90-1.30mm (.035-.051 inch)

INSULATION

CRIMP

▲SEE NOTE

BRUSH

STRIP

LENGTH

BELL MOUTH

CRIMP HEIGHT

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP

TWISTING

OVERLAP

INSULATION

CRIMP

OVERLAP FORM GEOMETRY

ANVIL

PUNCH

WIRE

Tool Kit for Mini-Fit Jr. ™ Crimp Terminals

Doc No: ATS-6381151HM Release Date: 04-03-06 UNCONTROLLED COPY Page 3 of 9

Revision: D Revision Date: 10-04-10

SWING

LOCATOR

OPEN

PRESS DOWN

ON THE BRASS

PIVOT SHAFT

LIFT UP ON

THE LOCATOR

Figure 2

ANVILS

POWER

CRIMP

HEAD

Figure 1

PUNCHES

M4 X 10 LONG

BHCS

M4 X 18 LONG

BHCS

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.

Figure 3

LOCATOR

JAWS OPEN

Tool Kit for Mini-Fit Jr. ™ Crimp Terminals

Doc No: ATS-6381151HM Release Date: 04-03-06 UNCONTROLLED COPY Page 4 of 9

Revision: D Revision Date: 10-04-10

TERMINAL

PUSH HERE TO

OPEN WIRE STOP

SWING OPEN

LOCATOR

TERMINAL IN PLACE

Figure 4

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.

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

Figure 4. Gently press on the locator to open the wire stop.

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 or B 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

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

ratchet mechanism cycle has been completed. Release

handles to open the jaws.

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

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.

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.

WIRE

LOCATOR

IN PLACE

WIRE STOP

TERMINAL

WIRE STOP

WIRE

AGAINST STOP

Figure 5

Tool Kit for Mini-Fit Jr. ™ Crimp Terminals

Doc No: ATS-6381151HM Release Date: 04-03-06 UNCONTROLLED COPY Page 5 of 9

Revision: D Revision Date: 10-04-10

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.

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 8.

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:

Figure 7B

LUBRICATION

POINTS

(BOTH SIDES)

LIGHT OIL

(EVERY MONTH

5,000 CRIMPS)

Figure 7A

SWING

LOCATOR

OPEN

PRESS DOWN

ON BRASS PIVOT

SHAFT

LIFT UP

LOCATOR

JAWS

OPEN

Figure 6

Tool Kit for Mini-Fit Jr. ™ Crimp Terminals

Doc No: ATS-6381151HM Release Date: 04-03-06 UNCONTROLLED COPY Page 6 of 9

Revision: D Revision Date: 10-04-10

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.

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.

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

Tool Kit for Mini-Fit Jr. ™ Crimp Terminals

Doc No: ATS-6381151HM Release Date: 04-03-06 UNCONTROLLED COPY Page 7 of 9

Revision: D Revision Date: 10-04-10

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.

63811-5170

63810-0100

Hand Crimp Frame (Short)

N/A

63810-0400

Hand Crimp Frame (Long)

N/A

63816-0200

Battery Power Tool (110 V)

63816-0300

Power Crimp Head

63816-0250

Battery Power Tool (220 V)

63816-0300

Power Crimp Head

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 Mini-Fit Jr. ™ Crimp Terminals

Doc No: ATS-6381151HM Release Date: 04-03-06 UNCONTROLLED COPY Page 8 of 9

Revision: D Revision Date: 10-04-10

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

HAND TOOL PARTS LIST

Item Number

Order Number

Description

Quantity

63810-0100

Hand Crimp Frame (Short)

63810-0101

Wrench Set (Not included)

63810-0102

Locator Base

63810-0103

Repair Kit (Not included)

63811-5170

Tool Kit with Locator

63811-5175

Locator (only)

REF

Tool Kit for Mini-Fit Jr. ™ Crimp Terminals

Doc No: ATS-6381151HM Release Date: 04-03-06 UNCONTROLLED COPY Page 9 of 9

Revision: D Revision Date: 10-04-10

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

Power Crimp Head

63811-5170

Tool Kit

http://www.molex.com

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