molex 207129 Series User manual

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
mm
In.
mm
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
mm
In.
mm
In.
mm
In.
mm
In.
N
Lb.
A
B
5556
22
0.35
0.76-0.86
.030-.034
1.44
.057
1.72
.068
1.61
.063
40.0
9.00
X
24
0.20
0.69-0.79
.027-.031
1.44
.057
1.72
.068
1.61
.063
31.1
7.00
X
26
0.12
0.64-0.74
.025-.029
1.44
.057
1.43
.056
1.57
.062
22.2
5.00
X
28
0.08
0.61-0.71
.024-.028
1.44
.057
1.43
.056
1.57
.062
13.3
3.00
X
5558
22
0.35
0.76-0.86
.030-.034
1.44
.057
1.72
.068
1.61
.063
40.0
9.00
X
24
0.20
0.69-0.79
.027-.031
1.44
.057
1.72
.068
1.61
.063
31.1
7.00
X
26
0.12
0.64-0.74
.025-.029
1.44
.057
1.43
.056
1.57
.062
22.2
5.00
X
28
0.08
0.61-0.71
.024-.028
1.44
.057
1.43
.056
1.57
.062
13.3
3.00
X
44485
22
0.35
0.76-0.86
.030-.034
1.44
.057
1.72
.068
1.61
.063
40.0
9.00
X
24
0.20
0.69-0.79
.027-.031
1.44
.057
1.72
.068
1.61
.063
31.1
7.00
X
26
0.12
0.64-0.74
.025-.029
1.44
.057
1.43
.056
1.57
.062
22.2
5.00
X
28
0.08
0.61-0.71
.024-.028
1.44
.057
1.43
.056
1.57
.062
13.3
3.00
X
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
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
5.
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
OR
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
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
10
63816-0250
Battery Power Tool (220 V)
63816-0300
Power Crimp Head
10
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
1
3
M4 X 6mm
LONG BHCS
M4 X 12mm
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
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
5
63811-5170
Tool Kit with Locator
1
6
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
1
2
2
M4 by 8 Long
BHCS
M4 by 18 Long
BHCS
M4 by 10 Long
BHCS
1
POWER HEAD PARTS LIST
Item
Order No
Engineering No.
Description
Quantity
1
63816-0300
63816-0300
Power Crimp Head
1
2
63811-5170
63811-5170
Tool Kit
1
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