2133091075

Hand Crimp Tool for 2.00mm (.079”) Pitch Pico-Lock Crimp Terminals Order Number 213309-1000 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 compliant, as indicated on page 2 SCOPE Products: 2.00mm (.079") Pitch Pico-Lock Crimp Terminals, 20-22 AWG Wire. Terminal Series No. Terminal Order No.  Reel Wire Size AWG 205342 205342-5028 20-22 Insulation Diameter mm In. 1.20-1.50 .047-.059 Strip Length mm In. 2.20-2.60 .087-.102  Customer to cut off terminal from reel: 0.10mm (.004”) maximum cut-off tab. Crimp terminals to copper stranded wire only. DEFINITION OF TERMS BEND UP ROLL STRIP LENGTH CONDUCTOR BRUSH SEAM BELL MOUTH TWIST WIRE BEND DOWN CUT-OFF TAB CONDUCTOR CRIMP HEIGHT Doc No: 2133091000 Revision: A Release Date: 03-11-20 Revision Date: 03-11-20 ▲ INSULATION CRIMP UNCONTROLLED COPY Page 1 of 7 Hand Crimp Tool for 2.00mm (.079”) Pitch Pico-Lock Crimp Terminals CONDITIONS After crimping, the conductor profiles should measure the following: Terminal Wire Size Series No. AWG 205342 Conductor Crimp Height Width (Ref.) mm In. mm In. Insulation Crimp Height (Ref.) Width (Ref.) mm In. mm In. Pull Force Minimum N Lb. 20 0.90-0.98 .035-.038 1.45 .057 1.85 (Max) .073 (Max) 1.60 .063 58.8 13.22 22 0.81-0.86 .031-.033 1.45 .057 1.75 .069 1.60 .063 39.2 8.81 Profile 20 22 X X ▲ To achieve IPC/WHMA-A-620 Class 2 crimps, the following overall wire insulation diameter ranges are recommended: Profile 20: 1.40-1.50mm (.055-.059”) Profile 22: 1.30-1.50mm (.051-.059”) Crimp attribute specifications: Terminal Series No. 205342 Wire Size AWG mm2 20 — 22 — Bell Mouth Conductor Brush mm In. mm In. 0.20-0.45 .008-.018 0.10-0.70 .004-.028 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. 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 hand crimp tools. Note A crimp height chart is provided with this document as reference only. Because of the wide range of wires, strands, insulation diameters and durometers available, actual crimp height measurements may very slightly. An occasional destructive pull force test should be performed to check hand tool crimp. Pull force value must exceed the minimum pull force specifications listed. Doc No: 2133091000 Revision: A Release Date: 03-11-20 Revision Date: 03-11-20 UNCONTROLLED COPY Page 2 of 7 Hand Crimp Tool for 2.00mm (.079”) Pitch Pico-Lock 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. 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. 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. 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 4. LOCATOR IN DOWN POSTION HANDLE WILL SPRING OPEN SQUEEZE HANDLES TOGETHER Figure 3 PUSH ON THE LOCATOR BUTTON Figure 2 RELEASE LOCATOR BUTTON LOCATOR LOCATOR PUSHED THROUGH TOOLING LOCATOR BUTTON PUSHED IN TERMINAL Figure 4 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 locator. 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. TOOLING PARTIALLY CLOSED PARTIALLY CLOSE HANDLE OPEN POSITION TERMINAL LOCATOR FIRST RATCHET POSITION PRE-STRIPPED WIRE Figure 5 TERMINAL WIRE AGAINST THE LOCATOR Figure 6 Doc No: 2133091000 Revision: A Release Date: 03-11-20 Revision Date: 03-11-20 UNCONTROLLED COPY Page 3 of 7 Hand Crimp Tool for 2.00mm (.079”) Pitch Pico-Lock 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 locator, and then close the tool. See Figure 7. LOCATOR TERMINAL Figure 7 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: SQUEEZE HERE MAKE SURE CENTER OF LOCATOR IS IN THE DOWN POSITION 1. Open the hand crimp tool. 2. Squeeze gently on the lower area shown SQUEEZE in Figure 8A with your thumb and index HERE finger. The lower tabs of the locator Figure 8A TOP SLOTS OF should disengage from the hand tool. HAND TOOL 3. Lift and pull away from the hand tool. The top locator hooks should slip out of the TOP HOOKS 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 Figure 8B with your thumb and index finger, insert the locator’s top hooks into the hand tool’s top slots. LOWER TABS 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 can be converted from a righthanded 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 Doc No: 2133091000 Revision: A Release Date: 03-11-20 Revision Date: 03-11-20 JAWS OPEN PULL OPEN TOOLING TOOLING M3 BHCS Figure 9 PUSH ON HANDLE UNCONTROLLED COPY Page 4 of 7 Hand Crimp Tool for 2.00mm (.079”) Pitch Pico-Lock Crimp Terminals 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. MATCH UP MARKS Figure 10 MAINTENANCE BACK FRONT 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 LUBRICATION POINTS trouble-free crimping. Light oil (such as 30 weight automotive oil) (BOTH SIDES) LIGHT used at the oil points every 5,000 crimps or 3 months will OIL significantly enhance the tool life. See Figure 11. (EVERY 3 MONTHS OR 4. Wipe excess oil from the hand tool, particularly from the crimping 5,000 CRIMPS) area. Oil transferred from the crimping area onto certain terminations may affect the electrical characteristics of an Figure 11 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. 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 12. RATCHET RELEASE LEVER Figure 12 Doc No: 2133091000 Revision: A Release Date: 03-11-20 Revision Date: 03-11-20 UNCONTROLLED COPY Page 5 of 7 Hand Crimp Tool for 2.00mm (.079”) Pitch Pico-Lock Crimp Terminals How to Adjust Tool Preload (See Figure 13) 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 1. Hold the hand tool in the palm HOLD THE HAND THE LINK IN of your hand as shown in TOOL IN POSITION RATCHET THE HANDLE Figure 13. Using your index RELEASE LEVER 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). Figure 13 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. 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. 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 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: 2133091000 Revision: A Release Date: 03-11-20 Revision Date: 03-11-20 UNCONTROLLED COPY Page 6 of 7 Hand Crimp Tool for 2.00mm (.079”) Pitch Pico-Lock Crimp Terminals PARTS LIST Item Number REF 1 2 3 Order Number 213309-1000 213309-1075 63810-0104 63810-0105 Description Hand Crimp Tool Locator Assembly 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: 2133091000 Revision: A Release Date: 03-11-20 Revision Date: 03-11-20 UNCONTROLLED COPY Page 7 of 7