Molex 200218-4500 User guide

Hand Crimp Tool for Micro-Lock Plus 2.0mm Pitch Wire-to-Board Receptacle Crimp Terminals

Doc. No: 20021845HM Release Date: 01-16-19 UNCONTROLLED COPY Page 1 of 7

Revision: A Revision Date: 01-16-19

INSULATION CRIMP

BRUSH

STRIP LENGTH

BELL MOUTH

CUT-OFF

TAB

BEND

DOWN

BEND UP

ROLL

CONDUCTOR

CRIMP HEIGHT

TWIST

SEAM

WIRE

Application Tooling Specification

FEATURES

A full cycle ratcheting hand tool ensures complete crimps

Ergonomically designed soft handles

Precisely designed crimping profiles with simple contact positioning

Easy handling due to outstanding force ratio

IPC/WHMA-A-620 Class 2 compliant as indicated below

Modular crimp head is removable and can be used in the Electric Crimp Machine (Order No.

63816-1500), accompanied by Battery Powered Crimp Adapter (Order No. 63816-0600)

Can also be used in the Battery Powered Tool Order No. 63816-0270 (110 V) or 63816-0280

(220 V), accompanied by Battery Powered Crimp Adapter (Order No. 63816-0600)

SCOPE

Products: Micro-Lock Plus 2.0mm Pitch Wire-to-Board Receptacle Crimp Terminal. 0.22mm²

CIVUS, 0.30mm² CAVUS, and 0.30mm² AVSS wire.

Terminal

Series No.

Terminal Order No.

Wire Size

Insulation Diameter

Strip Length

IPC/WHMA-A-620 ♦

Terminal ♦♦

Reel (1)

Loose Piece

AWG

mm2

In.

505572

505572-1000

505572-1100

—

0.22

1.00-1.20

.039-.047

0.90-1.50

.035-.059

1.90-2.10

.075-.083

—

0.30

1.15-1.50

.045-.059

(1) Customer to cut off terminal from reel: 0.10mm (.004”) maximum cut-off tab.

♦To achieve optimum IPC/WHMA-A-620 insulation crimps, use this insulation OD range.

♦♦ Overall insulation OD specification for terminal.

DEFINITION OF TERMS

Order Number

200218-4500

Type 4A

Hand Crimp Tool for Micro-Lock Plus 2.0mm Pitch Wire-to-Board Receptacle Crimp Terminals

Doc. No: 20021845HM Release Date: 01-16-19 UNCONTROLLED COPY Page 2 of 7

Revision: A Revision Date: 01-16-19

CRIMP SPECIFICATION

After crimping, the crimp profiles should measure the following:

Terminal Series No.

Bell Mouth

Conductor Brush

In.

505572

0.10-0.45

.004-.018

0.10-0.65

.004-.026

Terminal Series

No.

Bend Up

Bend Down

Twist

Roll

Seam

Degree Max.

505572

Seam shall not be open and no

wire allowed out of the crimping

area

Terminal

Series No.

Wire Size

Conductor

Insulation

Pull Force

Minimum

Profile

Crimp Height

Crimp Width

(Ref)

Crimp Height

Crimp

Width

(Ref)

AWG

mm2

In.

Lb.

505572

—

0.22

0.70-0.75

.028-.030

1.25

.049

1.60-1.66

.063-.065

1.45

.057

29.4

6.61

—

0.30

0.78-0.83

.031-.033

1.25

.049

1.70-1.76

.067-.070

1.50

.059

39.2

8.81

—

0.30

0.78-0.83

.031-.033

1.25

.049

1.82-1.90

.072-.075

1.58

.062

39.2

8.81

♦To achieve optimum IPC/WHMA-A-620 Class 2 crimps, the following overall insulation diameter ranges are recommended:

Profile A: 1.00-1.20mm CIVUS wire

Profile B: 1.15-1.30mm CAVUS wire

Profile C: 1.25-1.50mm AVSS wire

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 5. 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.

Hand Crimp Tool for Micro-Lock Plus 2.0mm Pitch Wire-to-Board Receptacle Crimp Terminals

Doc. No: 20021845HM Release Date: 01-16-19 UNCONTROLLED COPY Page 3 of 7

Revision: A Revision Date: 01-16-19

WIRE

PUNCH

TERMINAL

WIRE STOP

BLADE

Figure 2

Figure 3

WIRE

TERMINAL

LOCATOR

INSULATION

PUNCH

INSULATION

ANVIL

WIRE STOP

BLADE

CONDUCTOR

ANVIL

CONDUCTOR

PUNCH

OPERATION

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.

1. With the hand tool in the open position, pivot the

terminal locator open by pulling up on the locator

knob, and lift the wire stop blade. See Figure 1.

2. Insert the terminal into the correct profile until the

terminal is fully seated and stops. See Locator Note

below. Make sure the wire stop blade is fully seated

on the terminal behind the conductor grip section.

3. Gently pivot the locator closed.

4. Bring down the wire stop blade.

5. Slide the pre-stripped wire into the terminal,

making sure to aim the wire brush toward the tip

point on the wire stop blade. See Figure 2. Align

the wire so that it is parallel and sitting into the

terminal. Maintain a light and constant pressure

on the wire that is seated in the terminal at all

times. (Do not let go of the wire.) Be sure to hold

the wire and terminal in place until the terminal

is fully crimped. See Figure 3.

6. Close the tool until the ratchet releases.

7. Lift the wire stop blade.

8. Carefully remove the crimped terminal.

Locator Note

This three-pocket hand tool features offset crimp

profiles. The terminal locator for this tool includes a

fourth, unused profile (pocket). Do not use this

profile. See Figure 4.

TERMINAL

SEATED IN

LOCATOR

SWING

LOCATOR

OPEN

Figure 1

HAND TOOL

OPEN

WIRE

STOP

BLADE

UPPER

TOOLING

LOWER

TOOLING

TERMINAL

LOCATOR

DO NOT USE

OFFSET CRIMP

PROFILES

Figure 4

Hand Crimp Tool for Micro-Lock Plus 2.0mm Pitch Wire-to-Board Receptacle Crimp Terminals

Doc. No: 20021845HM Release Date: 01-16-19 UNCONTROLLED COPY Page 4 of 7

Revision: A Revision Date: 01-16-19

INCORRECT

Figure 6

CORRECT

INCORRECT

M4 BHCS

PIVOT

LOCATOR

Figure 5

Note: The tamper-proof ratchet action will not release the tool until it has been fully closed.

Note: To maintain good brush control and a consistent bell mouth, the crimping instructions must

be followed.

TERMINAL LOCATOR REPLACEMENT

This section describes the procedure for changing locators:

Removal

1. With the tool in the open position, pivot the terminal locator outward.

2. Remove the M4 BHCS. See Figure 5.

Installation

1. Place the locator on the hand tool. Install the M4 BHCS. See Figure 5.

2. Tighten the screw just enough to hold the locator. Make sure the locator can still float freely

with hand pressure.

3. Insert the proper terminal fully into the correct profile slot until the terminal is fully seated

and stops. Then, gently pivot the locator closed.

4. With hand pressure, slowly slide the locator to the correct position. See Figure 6.

5. Gently pivot the locator open without disturbing the location.

6. Hold the locator firmly in place, and slowly tighten the M4 BHCS.

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.

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.

Hand Crimp Tool for Micro-Lock Plus 2.0mm Pitch Wire-to-Board Receptacle Crimp Terminals

Doc. No: 20021845HM Release Date: 01-16-19 UNCONTROLLED COPY Page 5 of 7

Revision: A Revision Date: 01-16-19

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 lifting the ratchet release lever. See Figure 10.

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: Repetitive use of this tool should be avoided.

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.

CAUTION: Molex crimp specifications are valid only when used with Molex terminals and

tooling.

Hand Crimp Tool for Micro-Lock Plus 2.0mm Pitch Wire-to-Board Receptacle Crimp Terminals

Doc. No: 20021845HM Release Date: 01-16-19 UNCONTROLLED COPY Page 6 of 7

Revision: A Revision Date: 01-16-19

APPLICATIONS FOR THE MODULAR CRIMP HEAD

WARNING: NEVER operate, service, install or adjust this modular crimp head without proper

instruction and without first reading and understanding the instructions in the proper manual

or specification sheet. See chart below for the correct manual or specification sheet.

WARNING: NEVER install tooling or service this tool while it is plugged into any power

source. Disconnect the power by unplugging, or turn off the actuator from its power source.

CAUTION: Keep fingers away from the crimping area when operating this tool. It may cause

severe injury.

CAUTION: Wear safety glasses when operating or servicing this tool.

The chart below shows all applications for this modular crimp head:

Tool Order No.

Tool Description

Adapter Order No.

Adapter Description

Figure No.

63816-0000

Hand Crimp Frame (Short)

—

63816-0050

Hand Crimp Frame (Long)

—

63816-0270

Battery Power Tool (110 V)

63816-0600

Battery Power Crimp Adapter

63816-0280

Battery Power Tool (220 V)

63816-0600

Battery Power Crimp Adapter

63816-1500

Electric Crimp Machine

63816-0600

Battery Power Crimp Adapter

Applications for the Modular Crimp Head

Hand Crimp Tool

Battery Powered Tool

Electric Crimp Machine

Figure 7

Figure 8

Figure 9

MODULAR

CRIMP

HEAD

LOCKING

PINS

HAND CRIMP

FRAME LONG

OR SHORT

MODULAR

CRIMP

HEAD

BATTERY

POWERED

CRIMP

ADAPTER

LOCKING

PINS

LOCKING

PINS

BATTERY

POWERED

TOOL

ELECTRIC

CRIMP

MACHINE

MODULAR

CRIMP HEAD

BATTERY

POWER CRIMP

ADAPTER

Hand Crimp Tool for Micro-Lock Plus 2.0mm Pitch Wire-to-Board Receptacle Crimp Terminals

Doc. No: 20021845HM Release Date: 01-16-19 UNCONTROLLED COPY Page 7 of 7

Revision: A Revision Date: 01-16-19

PARTS LIST

Item

Order Number

Description

Quantity

63816-0000

Hand Crimp Frame (Short)

200218-4575

Locator

63816-0001

Locking Pin

63600-0525

Handle Spring

63600-0520

Crimping Spring

Application Tooling Support

Phone: (402) 458-TOOL (8665)

E-Mail: [email protected]

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.

HANDLE

SPRING

CRIMPING

SPRING (2)

M4 X 8mm

LONG BHCS

LOCATOR

Figure 10

RATCHET

RELEASE LEVER

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