2133094475

Hand Crimp Tool for Micro-Fit Plus Crimp Terminals Order Number 213309-4400 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 Plus Pin and Receptacle Crimp Terminals, 16 and 18 AWG, UL1061 Wire. Terminal Series No. 206460 215953 Terminal Order No. Wire Size Insulation Diameter (1) *Reel 206460-0031 206460-0032 206460-0033 206460-0041 206460-0042 206460-0043 215953-0031 215953-0032 215953-0033 215953-0041 215953-0042 215953-0043 AWG mm In. 18 1.58–1.78 .062–.070 16 1.93–2.03 .076–.080 18 1.58–1.78 .062–.070 16 1.93–2.03 .076–.080 Strip Length mm In. 2.50–2.90 .098–.114 (1) To achieve optimum IPC/WHMA-A-620 insulation crimps, use this insulation OD range. See page 2 for more information. *Not available in loose piece. Cut terminal from reel with 0.15mm max cut-off tab. Doc. No: 2133094400 Revision: A Release Date: 07-21-21 Revision Date: 07-21-21 UNCONTROLLED COPY Page 1 of 8 Hand Crimp Tool for Micro-Fit Plus Crimp Terminals DEFINITION OF TERMS CRIMP/TRANSITION K K L L SECTION K-K SECTION L-L CONDITIONS After crimping, the crimped profile should measure as follows: Feature 1. Bend Up 2. Bend Down 3. Twist 4. Roll 5. Bell Mouth Rear 6. Bell Mouth Front 7. Conductor Brush Conductor Crimp Insulation Crimp Pull Force Requirement 3° Max 3° Max 4° Max 8° Max 0.05-0.40mm (.002-.016”) Not Applicable 0.20-0.80mm (.008-.031”) Terminal Series No. Wire Size 18 AWG 206460 215953 16 AWG Terminal Series No. Wire Size 18 AWG 206460 215953 16 AWG Terminal Series No. Wire Size 206460 215953 18 AWG 16 AWG 8. Crimp Height 1.00-1.10mm .039-.043 In. 1.25-1.35mm .049-.053 In. 10. Crimp Height (Ref.) 2.05-2.15mm .081-.085 In. 2.30-2.40mm .091-.094 In. Minimum Force 89 N 89 N 20 lb. 20 lb. 9. Crimp Width 1.55-1.65mm .061-.065 In. 1.90-2.00mm .075-.079 In. 11. Crimp Width (Ref.) 1.85-1.95mm .073.077 In. 2.30-2.40mm .091-.094 In. Profile A B X X ▲To achieve IPC/WHMA-A-620 Class 2 crimps, the following overall wire insulation diameter ranges are recommended: Profile A: 1.58-1.78mm (.062-.070”) or UL1061 Profile B: 1.93-2.03mm (.076-.080”) or UL1061 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: 2133094400 Revision: A Release Date: 07-21-21 Revision Date: 07-21-21 UNCONTROLLED COPY Page 2 of 8 Hand Crimp Tool for Micro-Fit Plus 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. 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 and install it in the proper locator. See chart above and see Locator Replacement 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. LOCATOR IN DOWN POSTION HANDLE WILL SPRING OPEN SQUEEZE HANDLES TOGETHER Figure 2 PUSH ON THE LOCATOR BUTTON Figure 1 Doc. No: 2133094400 Revision: A Release Date: 07-21-21 Revision Date: 07-21-21 UNCONTROLLED COPY Page 3 of 8 Hand Crimp Tool for Micro-Fit Plus Crimp Terminals 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 RELEASE LOCATOR BUTTON LOCATOR LOCATOR BUTTON PUSHED IN TERMINAL Figure 3 TOOLING PARTIALLY CLOSED PARTIALLY CLOSE HANDLE 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 4. 6. Insert the properly stripped wire through the terminal and against the wire stop. See Figure 5. WIRE AGAINST THE WIRE STOP OPEN POSITION WIRE STOP IS PART OF THE LOCATOR FIRST RATCHET POSITION Figure 4 TERMINAL PRE-STRIPPED WIRE 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. 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 WIRE STOP TERMINAL Figure 6 Doc. No: 2133094400 Revision: A Release Date: 07-21-21 Revision Date: 07-21-21 UNCONTROLLED COPY Page 4 of 8 Hand Crimp Tool for Micro-Fit Plus Crimp Terminals 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: 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. 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. 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 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 along with the locator if using the left-handed application. Follow the steps below: 1. The locator must be removed before reversing the tooling. 2. Remove the M3 BHCS that 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. JAWS OPEN PULL OPEN TOOLING TOOLING M3 BHCS Figure 8 PUSH ON HANDLE MATCH UP MARKS Figure 9 FRONT Doc. No: 2133094400 Revision: A Release Date: 07-21-21 Revision Date: 07-21-21 BACK UNCONTROLLED COPY Page 5 of 8 Hand Crimp Tool for Micro-Fit Plus 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 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. LUBRICATION POINTS (BOTH SIDES) LIGHT OIL (EVERY 3 MONTHS OR 5,000 CRIMPS) Figure 10 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 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 HANDLE CLOSED 1. Open the hand tool. LINK IN THE 2 CLICKS HANDLE 2. Close the handle 2 ratchet clicks. 3. Hold the hand tool in the palm of your hand as shown in Figure 12. 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 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 adjusted. Doc. No: 2133094400 Revision: A Release Date: 07-21-21 Revision Date: 07-21-21 UNCONTROLLED COPY HOLD THE HAND TOOL IN POSITION Figure 12 force is Page 6 of 8 Hand Crimp Tool for Micro-Fit Plus Crimp Terminals 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 (.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: 2133094400 Revision: A Release Date: 07-21-21 Revision Date: 07-21-21 UNCONTROLLED COPY Page 7 of 8 Hand Crimp Tool for Micro-Fit Plus Crimp Terminals PARTS LIST Item Number REF 1 2 3 Order Number 213309-4400 213309-4475 63810-0104 63810-0105 Description Hand Crimp Tool Locator Assembly 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: 2133094400 Revision: A Release Date: 07-21-21 Revision Date: 07-21-21 UNCONTROLLED COPY Page 8 of 8