Hand Crimp Tool for Micro-Fit Terminals
Order Number
200218-5900
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 holds terminals in the proper crimping position
Right- or left-handed operation
Dies and locator from this tool can be used in the Battery Powered Tool Order No. 63816-0270
(110 V) or 63816-0280 (220 V), with the use of the 63816-0800 Crimp Head
This tool is IPC/WHMA-A-620 Class 2 compliant, as indicated on page 2
SCOPE
Products: Micro-Fit + Female and Micro-Fit TPA Male Crimp Terminals, 24 AWG, UL1007 and UL1061
wires.
Terminal
Series No.
Terminal Order No.
Reel
Loose
Wire Size
AWG
Insulation Diameter
▲IPC/WHMA-A-620 (1)
Terminal (2)
mm
In.
mm
In.
Strip Length
mm
In.
206460
43031
206460-0021*
—
43031-5003 43031-5013
43031-5004 43031-5014
24
1.12-1.58
.044-.062 0.90-1.85 .035-.073 2.50-2.90 .098-.114
43031-5005 43031-5015
43031-5006 43031-5016
(1) To achieve optimum IPC/WHMA-A-620 insulation crimps, use this insulation OD range.
(2) Overall insulation OD specification for terminal.
* Not available in loose-piece. Cut terminal from reel with 0.15mm max cut-off tab.
DEFINITION OF TERMS
BEND UP
BRUSH
BELL MOUTH
CONDUCTOR
CRIMP
INSULATION
CRIMP
▲SEE NOTE
ROLL
TWIST
STRIP
LENGTH
BEND
DOWN
CRIMP HEIGHT
Doc. No: 2002185900
Revision: A
Release Date: 12-04-18
Revision Date: 12-04-18
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Hand Crimp Tool for Micro-Fit Terminals
▲ Insulation Crimp Note
OVERLAP FORM
GEOMETRY
PUNCH
Due to the terminal’s insulation grip design or
insulation diameter range, this tool uses overlap
form geometry in the insulation punch. This
produces an overlap insulation crimp (A-620compliant). Although 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.
OVERLAP
INSULATION
CRIMP
WIRE
ANVIL
CONDITIONS
After crimping, the crimped profile should measure as follows:
Terminal Series No.
Conductor Crimp
Height
Width
mm
In.
mm
In.
Wire Size
AWG
206460
43031
24
0.79-0.84
.031-.033
1.35-1.45
Insulation Crimp
Terminal Series No.
Wire Size
Height (Ref.)
Width (Ref.)
.053-.057
Profile
Pull Force
Minimum
A
B
C
D
mm
In.
mm
In.
N
Lb. 24 24 24 24
1.85-1.95 .073-.077 1.55-1.65 .061-.065
X
206460
1.80-1.95 .071-.077 1.50-1.60 .059-.063
X
24
28.5 6.4
1.85-1.95 .073-.077 1.55-1.65 .061-.065
X
43031
1.80-1.95 .071-.077 1.50-1.60 .059-.063
X
▲To achieve IPC/WHMA-A-620 Class 2 Crimps, the following overall wire insulation diameter ranges are recommended:
Profile A: 1.12-1.40mm (.044-.055”) or UL1061
Profile C: 1.28-1.58mm (.050-.077”) or UL1007
Profile B: 1.28-1.58mm (.050-.077”) or UL1007
Profile D: 1.12-1.40mm (.044-.055”) or UL1061
AWG
Crimp attribute specifications:
Terminal
Series No.
Wire Size
Bell Mouth
Brush
AWG
mm
In.
mm
In.
24
0.05-0.35
.002-.014
0-0.80
0-.031
206460
43031
Bend Up
Bend
Down
Twist
Roll
8°
8°
6°
10°
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: 2002185900
Revision: A
Release Date: 12-04-18
Revision Date: 12-04-18
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Hand Crimp Tool for Micro-Fit 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 6. 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 crimp hand tools.
Note
The crimp height chart is provided with this document as reference only. Due to the wide range of
wires, strands, insulation diameters and insulation hardness available, actual crimp height
measurements may vary slightly. An occasional destructive pull force test should be performed to
verify the conductor crimp. The pull force value must exceed the minimum pull force specifications
listed.
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 1.
Crimping Terminals
1. Select the desired terminal listed from the
preceding charts. Then, install it in the
proper locator. See chart above and see
Locator Installation section on page 5.
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 in the locator button, 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.
LOCATOR
PUSHED THROUGH
TOOLING
LOCATOR
IN DOWN
POSTION
HANDLE WILL
SPRING OPEN
SQUEEZE
HANDLES
TOGETHER
Figure 2
PUSH ON THE
LOCATOR
BUTTON
Figure 1
RELEASE
LOCATOR BUTTON
LOCATOR
LOCATOR
BUTTON
PUSHED IN
TERMINAL
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Revision: A
Figure 3
Release Date: 12-04-18
Revision Date: 12-04-18
TERMINAL
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Hand Crimp Tool for Micro-Fit Terminals
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.
6. Insert the properly stripped wire through the terminal and
against the wire stop. See Figure 5.
WIRE AGAINST THE
WIRE STOP
WIRE STOP IS PART
OF THE LOCATOR
TERMINAL
TOOLING
PARTIALLY
CLOSED
PARTIALLY
CLOSE HANDLE
OPEN
POSITION
PRE-STRIPPED
WIRE
FIRST RATCHET
POSITION
Figure 4
Figure 5
WIRE
TERMINAL
7. Crimp the terminal by squeezing the tool handles until the ratchet mechanism cycle has been
completed. Release the handles to open the jaws.
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
Locator Replacement
LOCATOR
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 7A.
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
7B.
Doc. No: 2002185900
Revision: A
Release Date: 12-04-18
Revision Date: 12-04-18
SQUEEZE
HERE
SQUEEZE
HERE
Figure 7A
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
TOP SLOTS OF
HAND TOOL
TOP HOOKS
Figure 7B
LOWER TABS
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Hand Crimp Tool for Micro-Fit Terminals
6. Holding onto the lower part of the locator with your thumb and index finger, insert the
locator’s top hooks into the hand tool’s 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.
Right- or Left-Handed Operation
This hand tool has an added feature that can be
converted from a right-handed application to a
left-handed application. It is necessary to reverse
the tooling along with the locator if using the lefthanded application. Follow the steps below:
JAWS OPEN
PULL OPEN
TOOLING
TOOLING
M3 BHCS
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.
Figure 8
PUSH ON
HANDLE
MATCH
UP MARKS
Figure 9
FRONT
MAINTENANCE
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. 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. See
Figure 10.
4. Wipe excess oil from the 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: 2002185900
Revision: A
Release Date: 12-04-18
Revision Date: 12-04-18
LUBRICATION POINTS
(BOTH SIDES) LIGHT
OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
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Figure 10
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Hand Crimp Tool for Micro-Fit 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 11.
How to Adjust Tool Preload (See Figure 12)
Figure 11
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:
SQUEEZE THE
1. Hold the hand tool in the palm of
LINK IN THE
RATCHET
HANDLE
your hand as shown in Figure 12.
RELEASE LEVER
Using your index finger, squeeze the
link toward the top of the hand tool
frame. This will release the preload
adjustment wheel.
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.
SETTING WHEEL
4. Check the crimp specifications or
conduct a pull test after tool handle preload force is adjusted.
HOLD THE HAND
TOOL IN POSITION
Figure 12
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: 2002185900
Revision: A
Release Date: 12-04-18
Revision Date: 12-04-18
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Hand Crimp Tool for Micro-Fit Terminals
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 (.50”) 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
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: 2002185900
Revision: A
Release Date: 12-04-18
Revision Date: 12-04-18
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Hand Crimp Tool for Micro-Fit Terminals
PARTS LIST
Item Number
REF
1
2
3
Order Number
200218-5900
200218-5975
63810-0104
63810-0105
Description
Hand Crimp Tool
Locator Assembly (Red)
Spring, Return
Spring, Ratchet
Quantity
Figure 13
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: 2002185900
Revision: A
Release Date: 12-04-18
Revision Date: 12-04-18
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