Hand Crimp Tool for EdgeLock Crimp Terminals
Order Number
200218-2800
Application Tooling Specification
Type 4D
FEATURES
A full cycle ratcheting hand tool ensures complete crimps
Ergonomic soft grip handles for comfortable crimping
A precision user-friendly terminal locator wire stop holds terminals in the proper crimping position
Right- and left-handed applications
This tool is IPC/WHMA-A-620 Class 2 compliant, as indicated below and on page 2
This tool is RoHS compliant; however, RoHS compliance is not required
SCOPE
Products: EdgeLock Crimp Terminals, 24 AWG Stranded Wire.
Terminal
Series No.
200449
Terminal Order No.
Loose Piece
Reel (3)
—
200449-0001
Wire
Insulation Diameter
IPC/WHMA-A-620 (1)
Wire Type Wire Size
mm
In.
Terminal (2)
mm
In.
Strip Length
mm
In.
UL1061
24 AWG
1.15-1.35
.045-.053
1.10-1.50 .043-.059 1.60-2.30 .063-.090
UL1007
24 AWG
1.25-1.40
.049-.055
1.10-1.50 .043-.059 1.60-2.30 .063-.090
Insulation Diameter Notes
(1) Insulation diameter range for optimum (IPC/WHMA-A-620 Class 2) insulation crimps. Use tool profile specified on page 2.
(2) Insulation diameter range for the terminal product design.
Terminal Order No. Note
(3) Reeled terminals must be properly cut from the reel. 0.20mm (.008”) maximum cut-off tab.
Doc. No: 2002182800
Revision: A
Release Date: 10-23-20
Revision Date: 10-23-20
UNCONTROLLED COPY
Page 1 of 8
Hand Crimp Tool for EdgeLock Crimp Terminals
DEFINITION OF TERMS
K
K
L
L
SECTION K-K
SECTION L-L
CRIMP SPECIFICATIONS
The following crimp specifications are based on document 2004490001CS Revision B:
Feature
Requirement
1. Bend Up
3° Max
2. Bend Down
3° Max
3. Twist
3° Max
4. Roll
3° Max
5. Bell Mouth Rear
0.08-0.15mm (.003-.006”)
6. Bell Mouth Front
Not Applicable
7. Conductor Brush
0.30-1.00mm (.012-.039”)
8. Cut-Off Tab
Reeled terminals must be properly cut from the reel. 0.13mm (.005”) MAX cut-off tab.
Wire Type
Conductor Crimp
UL1061
UL1007
Wire Type
Insulation Crimp
UL1061
UL1007
Wire Type
Pull Force
Wire Size
24 AWG
Wire Size
24 AWG
Wire Size
9. Crimp Height
0.81-0.85mm
.032-.033 in.
10. Crimp Width
1.37-1.43mm
11. Crimp Height (Ref.)
1.50mm
.059 in.
1.60mm
.063 in.
Minimum Force
.054-.056 in.
12. Crimp Width
1.57-1.63mm
.062-.064 in.
Profile
A
B
UL1061
X
24 AWG
22.3 N
5 lb.
UL1007
X
To achieve IPC/WHMA-A-620 Class 2 crimps, the following overall wire insulation diameter ranges are recommended:
Profile A: 1.15-1.35 mm (.045-.053”) or UL1061
Profile B: 1.25-1.40 mm (.049-.055”) or UL1007
Tool Qualification Notes
1. (Ref) means that the dimension provided is approximate because of the wide range of wires,
conductor stranding, insulation diameter and insulation hardness.
2. An occasional conductor crimp height measurement should be performed. It must lie between
the minimum and maximum crimp height 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: 2002182800
Revision: A
Release Date: 10-23-20
Revision Date: 10-23-20
UNCONTROLLED COPY
Page 2 of 8
Hand Crimp Tool for EdgeLock Crimp Terminals
Notes
1. This tool should only be used for the terminals and wire gauges specified on this sheet.
2. Variations in tools, terminals, wire stranding and insulation types may affect crimp height.
3. This tool is intended for AWG conductor sizes. It may not give good insulation crimp support for
insulation sizes outside of the specified range.
4. Molex does not repair hand tools. See warranty on page 7. The replacement parts listed are the
only parts available for repair. If the handles or crimp tooling become damaged or worn, a new
tool must be purchased.
5. Conductor crimp height should be used as the final criterion for an acceptable crimp. Refer to
Molex Quality Crimping Handbook 63800-0029 for additional information on crimping and crimp
testing.
6. Molex does not certify hand crimp tools.
Bell Mouth Adjustment Notes
The 200218-2800 hand crimp tool features an adjustable locator that allows the operator to
increase or decrease the bell mouth and brush length specifications.
Note: The tool was set up in manufacturing and used to produce the included crimp samples,
but it may be necessary to adjust the tool because of variations in terminal production.
Use a 1.5mm hex wrench to adjust to bell mouth size and brush length.
The adjustment screw is accessible through the hole in
the side of the terminal locator on the back of the
hand crimp tool. See Figure 1.
To increase bell mouth and brush length, turn the
screw clockwise.
To decrease bell mouth and brush length, turn the
screw counterclockwise.
INCREASE
TERMINAL
LOCATOR
ADJUSTMENT
HOLE
DECREASE
Figure 1
When making an adjustment, turn the adjustment screw half a rotation or less, and then re-check
your bell mouth and brush length.
If you feel or hear a click during the rotation, you have reached the limits of the adjustment.
Once the bell mouth and brush length are properly adjusted, follow the tool operation instructions
listed below.
Doc. No: 2002182800
Revision: A
Release Date: 10-23-20
Revision Date: 10-23-20
UNCONTROLLED COPY
Page 3 of 8
Hand Crimp Tool for EdgeLock Crimp Terminals
OPERATION
CAUTION: Crimp only the Molex terminals listed in the scope for this tool. Do not crimp hardened
objects as damage can occur to the tool frame or crimp dies.
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 2.
HANDLE WILL
SPRING OPEN
Crimping Terminals
1. Select the desired terminal listed in the 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 3.
SQUEEZE HANDLES
TOGETHER
Figure 2
LOCATOR
IN DOWN
POSTION
3. While holding the locator button in, load the terminal into the proper
nest opening in the locator based on the wire insulation diameter
markings on the crimp jaws. See Figure 4.
LOCATOR
BUTTON
PUSHED IN
LOCATOR
PUSHED
THROUGH
TOOLING
LOCATOR
RELEASE
LOCATOR
BUTTON
PUSH ON
THE
LOCATOR
BUTTON
Figure 3
TOOLING
PARTIALLY CLOSED
Figure 4
PARTIALLY
CLOSE HANDLE
TERMINAL
TERMINAL
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 5.
6. Insert the properly stripped wire through the terminal and
against the wire stop. See Figure 6.
7. Crimp the terminal by squeezing the tool handles until the
ratchet mechanism cycle has been completed. Release the
handles to open the jaws.
OPEN
POSITION
FIRST RATCHET
POSITION
Figure 5
WIRE STOP IS PART
OF THE LOCATOR
WIRE AGAINST
THE
WIRE STOP
TERMINAL
WIRE
PRE-STRIPPED WIRE
Doc. No: 2002182800
Revision: A
Figure 6
Release Date: 10-23-20
Revision Date: 10-23-20
TERMINAL
UNCONTROLLED COPY
Page 4 of 8
Hand Crimp Tool for EdgeLock Crimp Terminals
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 then close the tool. See
Figure 7.
WIRE
STOP
TERMINAL
Figure 7
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 hand crimp tool.
2. Squeeze gently on the lower area shown
in Figure 7A with your thumb and index
finger. The lower tabs of the locator
should disengage from the hand tool.
3. Lift and pull away from the hand tool.
The top locator hooks should slip out of
the top slots easily. See Figure 8A.
4. To reinstall the new locator, make sure
the hand tool is in the open position.
5. Press the center of the locator down as
far as it will go as shown in Figure 8B.
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 tabs into the two bottom slots of
the hand tool. To secure the locator into
place, the lower tabs must snap into
place on the hand tool frame.
LOCATOR
SQUEEZE
HERE
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
SQUEEZE
HERE
Figure 8A
TOP SLOTS OF
HAND TOOL
TOP HOOKS
Figure 8B
LOWER TABS
Doc. No: 2002182800
Revision: A
Release Date: 10-23-20
Revision Date: 10-23-20
UNCONTROLLED COPY
Page 5 of 8
Hand Crimp Tool for EdgeLock Crimp Terminals
Right- or Left-Handed Operation
This hand tool can be converted from a right-handed application to a left-handed application. It is
necessary to reverse the tooling if using the left-handed application along with the locator. Follow
the steps below:
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 9 and 10.
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.
JAWS OPEN
PULL OPEN
TOOLING
TOOLING
M3 BHCS
Figure 9
PUSH ON
HANDLE
MATCH
UP MARKS
Figure 10
MAINTENANCE
FRONT
BACK
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. See Figure
11. 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 crimping. Light oil such as
30 weight automotive oil used at the oil points every 5,000 crimps
or 3 months will significantly enhance the tool life.
4. Wipe excess oil from hand tool, particularly from the crimping
area. Oil transferred from the crimping area onto certain
terminations may affect 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.
Doc. No: 2002182800
Revision: A
Release Date: 10-23-20
Revision Date: 10-23-20
LUBRICATION POINTS
(BOTH SIDES) LIGHT
OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
UNCONTROLLED COPY
Figure 11
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Hand Crimp Tool for EdgeLock Crimp Terminals
Miscrimps or Jams
RATCHET RELEASE
LEVER
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 12.
How to Adjust Tool Preload (See Figure 13)
Figure 12
Hand tool frame preload is factory preset to ensure crimp quality. 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:
SQUEEZE THE
1. Open the hand tool.
HANDLE CLOSED
HOLD THE HAND
LINK IN THE
2. Close the handle 2 ratchet clicks.
2 CLICKS
TOOL IN POSITION
HANDLE
3. Hold the hand tool in the palm of
your hand as shown in Figure 13.
Using your index finger, squeeze the
link toward the top of the hand tool
frame. This will release the preload
adjustment wheel.
4. Rotate the setting wheel
counterclockwise (CCW) to increase
handle force. The numbers will
display higher. To decrease handle
force, rotate the setting wheel
Figure 13
clockwise (CW).
SETTING
WHEEL
5. Release the link to lock the setting
wheel in place.
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, 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.
Doc. No: 2002182800
Revision: A
Release Date: 10-23-20
Revision Date: 10-23-20
UNCONTROLLED COPY
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Hand Crimp Tool for EdgeLock Crimp Terminals
PARTS LIST
Item Number
REF
1
2
3
Order Number
200218-2800
200218-2875
63810-0104
63810-0105
Description
Hand Crimp Tool
Locator Assembly (red)
Spring, Return
Spring, Ratchet
Quantity
Figure 14
1
1
1
2
1
3
Figure 14
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: 2002182800
Revision: A
Release Date: 10-23-20
Revision Date: 10-23-20
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