molex 207129 Series User manual

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
mm
In.
mm
In.
35021
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
1

Customer to cut off terminal from reel: 0.
35
mm (.0
14
”) 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
mm
2
mm
In.
mm
In.
N
Lb.
A
B
35021-12xx
and
35021-13xx
24
0.20
0.55
-
0.66
.022
-
.026
1.27
.050
29.
4
6.60
X
26
0.13
0.55
-
0.66
.022
-
.026
1.27
.050
19.6
4.40
X
2
0.0
0.55
-
0.66
.022
-
.026
1.27
.050
9.
2.10
X
30
0.05
0.55
-
0.66
.022
-
.026
1.26
.049
4.9
1.30
X
35021-10xx
and
35021-11xx
22
0.35
0.55
-
0.66
.022
-
.026
1.2
.050
34.3
7.70
X
24
0.20
0
.55
-
0.66
.022
-
.026
1.27
.050
29.4
6.60
X
26
0.13
0.55
-
0.66
.022
-
.026
1.27
.050
19.6
4.40
X
2
0.0
0.55
-
0.66
.022
-
.026
1.27
.050
9.
2.10
X
30
0.05
0.55
-
0.66
.022
-
.026
1.26
.049
4.9
1.30
X

To Achieve IPC
-
A
-
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
2
ANVILS
POWER
CRIMP
HEAD
Figure
1
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
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
OR
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
0
-
0100
Hand Crimp Frame (Short)
N/A
N/A
9
63 1
0
-
04
0
0
Hand Crimp Frame (Long)
N/A
N/A
9
63 16
-
0200
Battery Power
Tool (110 V)
63 16
-
0300
Power Crimp Head
10
63 16
-
0250
Battery Power
Tool (220 V)
63 16
-
0300
Power Crimp Head
10
Applications for t
he 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 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
1
M4 X
6
mm
LONG BHCS
M4 X 1
2
mm
LONG BHCS
5
6
WITH TOOL KIT
LOCATOR ONLY
M4 X 12mm
LONG BHCS
4
4
2
5
HAND TOOL PARTS LIST
Item Number
Order Number
Description
Quantity
1
63 10
-
0100
Hand Crimp Frame (
Short
)
1
2
63 10
-
0101
Wrench Set (Not included)
0
3
63 10
-
0102
Locator Base
1
4
63 10
-
0103
Repair Kit (Not included)
0
5
63 11
-
6970
Tool Kit with
Locator
1
6
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
2
1
2
2
M
4
by
8
Long
BHCS
M
4
by
18
Long
BHCS
M
4
by
10
Long
BHCS
1
POWER HEAD PARTS LIST
Item
Order No
Engineering No.
Description
Quantity
1
63 16-0300 63 16-0300 Power Crimp Head 1
2
63 11-6970 63 11-6970 Tool Kit 1
Visit our Web site at http://www.molex.com