0638280200

Hand Crimp Tool for Micro-Fit 3.0 Crimp Terminals HAND CRIMP TOOL Application Tooling Specification Sheet TYPE 4D Order No. 63828-0200 FEATURES A full cycle ratcheting hand tool ensures complete crimps Ergonomic soft grip handles for comfortable crimping A precision user-friendly terminal locator with wire stop holds terminals in the proper crimping position Dies and locator from this tool can be used in the Battery Powered Tool Order No. 63816-0200 (110 V) or 63816-0250 (220 V) with the use of the 63816-0800 Crimp Head Many different tool kits can be used with a single Battery Powered Crimp Tool This tool is IPC/WHMA A-620 Class 2 compliant (see Scope table) This tool is RoHS compliant; however, RoHS compliance is not required SCOPE Products: Micro-Fit 3.0 Crimp Terminals, 0.75mm² and 18AWG (UL1061) wires. Terminal Series No. Terminal Order No. Wire Size AWG mm² ►Insulation Diameter IPC/WHMA-A620 (1) Terminal (2) mm In. mm In. Strip Length mm In. 43030 43030-0038 43031-0021 43031 18 0.75 43031-0022 1.60-1.85 .063-.073 0.90-1.85 .035-.073 2.54-2.92 .100-.115 ● (3) 43031-0023 45807-0003 45807 18 N/A 45807-0005 ►Insulation Diameter Notes (1) Insulation OD range for optimum (IPC/WHMA-A620 Class 2) insulation crimps (2) Insulation OD range for the terminal product design ● Terminal Locator Note (3) Separate terminal locator is needed for 43031 series (see Page 2). If locator is missing it can be ordered (see Page 8) DEFINITION OF TERMS BELL MOUTH BEND UP STRIP LENGTH ROLLING CONDUCTOR BRUSH SEAM TWISTING BEND DOWN CUT-OFF TAB CONDUCTOR CRIMP INSULATION CRIMP Doc No: ATS-638280200 Revision: B Release Date: 03-15-16 Revision Date: 09-11-17 UNCONTROLLED COPY Page 1 of 8 Hand Crimp Tool for Micro-Fit 3.0 Crimp Terminals CONDITIONS After crimping to the wire, the crimped terminal should measure as follows: Terminal No. 43030-0038 43031-0021 43031-0022 43031-0023 45807-0003 45807-0005 AWG 18 N/A 18 N/A 18 N/A 18 N/A mm2 N/A 0.75 N/A 0.75 N/A 0.75 N/A 0.75 Conductor Crimp Height mm In. 1.00-1.10 0.039-0.043 0.85-0.95 0.033-0.037 1.00-1.10 0.039-0.043 0.85-0.95 0.033-0.037 1.00-1.10 0.039-0.043 0.85-0.95 0.033-0.037 1.00-1.10 0.039-0.043 0.85-0.95 0.033-0.037 18 N/A 1.00-1.10 Wire Size Terminal Series 43030 43031 45807 0.039-0.043 Wire Size AWG mm2 18 0.75 Conductor Crimp Width (Ref) mm In. Pull Force Minimum N Lb. Tool Profile 18 X 0.75mm2 X Locator Order No. Color 63828-0275 Red 63828-0276 Yellow 63828-0275 Red X 1.65 0.065 89 20 X X X X X 1.65 0.065 Insulation Crimp Height (Ref) mm In. 1.90 .075 89 20 X Insulation Crimp Width (Ref) mm In. 2.00 .078 Tool Qualification Notes 1. (Ref) means the dimension provided is approximate due to the wide range of wires, conductor stranding, insulation diameter, and insulation hardness. 2. An occasional pull force test should be performed. It must exceed the minimum pull force specification. 3. Pull force should be measured with no influence from the insulation crimp. To ensure this, strip the wire long enough so the terminal insulation grips do not contact the wire insulation. Doc No: ATS-638280200 Revision: B Release Date: 03-15-16 Revision Date: 09-11-17 UNCONTROLLED COPY Page 2 of 8 Hand Crimp Tool for Micro-Fit 3.0 Crimp Terminals OPERATION CAUTION: Crimp only the Molex terminals listed in the scope for this tool. Do not crimp hardened objects because damage can occur to the tool frame or crimp dies. HANDLE WILL SPRING OPEN LOCATOR IN DOWN POSTION SQUEEZE HANDLES TOGETHER PUSH ON THE 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. See Figure 1. Figure 2 Crimping Terminals LOCATOR BUTTON 1. Select the desired terminal listed in the Figure 1 preceding charts. 2. Make sure the center of the locator is in the down position. With the locator attached, push the locator button on the back of the hand tool to bring the locator forward through the tooling. See Figure 2. 3. While holding the locator button in, load the terminal into the proper nest opening in the locator based on the wire gauge or terminal type markings on the hand tooling. See Figure 3. RELEASE LOCATOR BUTTON LOCATOR LOCATOR PUSHED THROUGH TOOLING LOCATOR BUTTON PUSHED IN TERMINAL TERMINAL Figure 3 4. Release the locator button, allowing the locator to return to the crimping position. 5. Close the tool handle until the first ratchet position engages. See Figure 4. TOOLING PARTIALLY CLOSED PARTIALLY CLOSE HANDLE OPEN POSITION FIRST RATCHET POSITION Figure 4 Doc No: ATS-638280200 Revision: B Release Date: 03-15-16 Revision Date: 09-11-17 UNCONTROLLED COPY Page 3 of 8 Hand Crimp Tool for Micro-Fit 3.0 Crimp Terminals 6. Insert the properly stripped wire through the terminal and against the wire stop. See Figure 5. 7. Crimp the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed. Release the handles to open the jaws. TERMINAL WIRE AGAINST THE WIRE STOP WIRE STOP IS PART OF THE LOCATOR PRE-STRIPPED WIRE Figure 5 WIRE TERMINAL Note: The tamper-proof ratchet action will not release the tool until it has been fully closed. WIRE 8. Remove the crimped terminal from the terminal locator by pulling on the wire. 9. Visually inspect the crimped terminal for proper crimp location. 10. On some large O.D. wires, it may not be possible to insert the wire with the tool partially closed. Those wires should be inserted with the hand tool in the open position. Insert the wire above the terminal in the punch and against the wire stop, and then close the tool. See Figure 6. WIRE STOP TERMINAL Figure 6 Doc No: ATS-638280200 Revision: B Release Date: 03-15-16 Revision Date: 09-11-17 UNCONTROLLED COPY Page 4 of 8 Hand Crimp Tool for Micro-Fit 3.0 Crimp Terminals Locator Installation Depending on the terminal to be crimped, the locator may need to be changed. Follow the steps below to remove and install the locator: LOCATOR 1. Open the crimp hand tool. SQUEEZE 2. Squeeze gently on the lower area shown in HERE Figure 7A with your thumb and index finger. The lower tabs of the locator should SQUEEZE disengage from the hand tool. HERE 3. Lift and pull away from the hand tool. The Figure 7A TOP SLOTS OF top locator hooks should slip out of the top HANDTOOL slots easily. See Figure 7A. 4. To reinstall the new locator, make sure the TOP HOOKS hand tool is in the open position. 5. Press the red insert down as far as it will go as shown in Figure 7B. 6. Holding onto the lower part of the locator with your thumb and index finger, insert the locator’s top hooks (2) into the hand tool top slots. 7. Rotate the locator down and press the lower LOWER TABS tabs into the two bottom slots of the hand tool. To secure the locator into place, the lower tabs JAWS OPEN must snap into place on the hand tool frame. Right or Left Hand Operation This hand tool has an added feature in that it can be converted from a right-handed application to a lefthanded application. It is necessary to reverse the tooling if using the left-handed application along with the locator. Follow the steps below: MAKE SURE CENTER OF LOCATOR IS IN THE DOWN POSITION Figure 7B PULL OPEN TOOLING TOOLING M3 BHCS Figure 8 1. The locator must be removed before reversing the tooling. 2. Remove the M3 BHCS, which is holding the upper tooling. 3. Flip the upper tooling to the opposite side and replace the M3 BHCS. Make sure the small markings on the front and back of the hand tool frame match up and are on the outside of the hand tool frame. See Figures 8 and 9. 4. Do the same thing with the lower tooling and tighten the M3 screws. Be sure the small markings line up. 5. Reinstall the locator by following the instructions in the locator replacement section. Doc No: ATS-638280200 Revision: B Release Date: 03-15-16 Revision Date: 09-11-17 PUSH ON HANDLE MATCH UP MARKS Figure 9 FRONT UNCONTROLLED COPY BACK Page 5 of 8 Hand Crimp Tool for Micro-Fit 3.0 Crimp Terminals 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 a 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 other equipment, it needs cleaning and lubrication for a maximum service life of trouble-free LUBRICATION POINTS crimping. Light oil (such as 30 weight automotive oil) used at the oil (BOTH SIDES) LIGHT OIL points every 5,000 crimps or 3 months will significantly enhance the tool (EVERY 3 MONTHS OR life. 5,000 CRIMPS) 4. Wipe excess oil from hand tool, particularly from crimping area. Oil transferred from the crimping area onto certain terminations may affect Figure 10 the electrical characteristics of an application. 5. When the 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. RATCHET RELEASE LEVER 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 up on the ratchet release lever in the movable handle. See Figure 11. How to Adjust Tool Preload (See Figure 12) This hand tool is factory preset to 25-45 pounds. 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. Hold the hand tool in the palm of your hand as shown in Figure 10. Using your index finger, squeeze the link toward the top of the hand tool frame. This will release the preload adjustment wheel. Doc No: ATS-638280200 Revision: B RATCHET RELEASE LEVER SQUEEZE THE LINK IN THE HANDLE Figure 11 HOLD THE HAND TOOL IN POSITION Figure 12 SETTING WHEEL Release Date: 03-15-16 Revision Date: 09-11-17 UNCONTROLLED COPY Page 6 of 8 Hand Crimp Tool for Micro-Fit 3.0 Crimp Terminals 2. Rotate the setting wheel counterclockwise (CCW) to increase handle force. The numbers will display higher. To decrease handle force, rotate the setting wheel clockwise (CW). 3. Release the link to lock the setting wheel in place. 4. 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, Molex 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 use 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 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 that has been stripped 12.7mm (1/2”) long so that 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 website 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 should be 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. Doc No: ATS-638280200 Revision: B Release Date: 03-15-16 Revision Date: 09-11-17 UNCONTROLLED COPY Page 7 of 8 Hand Crimp Tool for Micro-Fit 3.0 Crimp Terminals PARTS LIST Item Number REF 1 1 2 3 Order Number 63828-0200 63828-0275 63828-0276 63810-0104 63810-0105 Description Hand Crimp Tool Locator Assembly (Red) Locator Assembly (Yellow) Spring, Return Spring, Ratchet Quantity Figure 13 1 1 1 1 2 1 3 Figure 13 Application Tooling Support Phone: (402) 458-TOOL (8665) E-Mail: applicationtooling@molex.com Website: www.molex.com/applicationtooling Molex is a registered trademark of Molex, LLC in the United States of America and may be registered in other countries; all other trademarks listed herein belong to their respective owners. Doc No: ATS-638280200 Revision: B Release Date: 03-15-16 Revision Date: 09-11-17 UNCONTROLLED COPY Page 8 of 8