Molex 213309-1400 User manual

Hand Crimp Tool for Mega-Fit Crimp Terminals

Doc. No: 2133091400 Release Date: 04-15-20 UNCONTROLLED COPY Page 1 of 8

Revision: A Revision Date: 04-15-20

INSULATION

CRIMP

▲SEE NOTE

BRUSH

STRIP

LENGTH

BELL MOUTH

CRIMP HEIGHT

BEND

DOWN

BEND UP

ROLL

CONDUCTOR

CRIMP

TWIST

Application Tooling Specification

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: Mega-Fit Crimp Terminals, 16 AWG, UL1007 and UL1015 Wire.

Terminal Series

No.

Terminal Order No.

(Reel)

Wire

Insulation Diameter

Strip Length

Terminal

Wire Type

Wire Size

In.

76823

76823-0344

UL1015

16 AWG

2.30-3.58

.091-.141

4.60-5.20

.181-.205

UL1007

172063

172063-0334

172063-1334

UL1015

16 AWG

UL1007

105417

105417-0334

UL1015

16 AWG

UL1007

105418

105418-0314

105418-1314

UL1015

16 AWG

UL1007

Insulation diameter range for the terminal product design.

Customer to cut off terminals from reel: 0.20mm (.008”) maximum cut-off tab.

DEFINITION OF TERMS

The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed

in the scope.

Order Number

213309-1400

TYPE 4D

Hand Crimp Tool for Mega-Fit Crimp Terminals

Doc. No: 2133091400 Release Date: 04-15-20 UNCONTROLLED COPY Page 2 of 8

Revision: A Revision Date: 04-15-20

▲Insulation Crimp Note

Due to the terminal’s insulation grip design or

insulation diameter range, this tool uses the overlap

form geometry in the insulation punch. This produces

an overlap insulation crimp (A-620-compliant).

Although the insulation punch profile may appear

lopsided, this is a normal condition for this tool. See

figure to the right. This tool only uses the overlap form

geometry on profile B.

CONDITIONS

After crimping, the crimped profile should measure as follows:

Terminal Series

No.

Terminal Locator

Wire Size

Conductor Crimp

Height

Width (Ref.)

Order No.

Color

AWG

In.

76823

172063

213309-1475

Red

1.45-1.55

.057-.061

2.60

.102

105417

105418

213309-1476

Yellow

To achieve IPC/WHMA-A-620 Class 2 insulation crimps, use the appropriate tool profile for the

insulation diameter:

Terminal

Series No.

Wire

Insulation Diameter

Insulation Crimp

Pull Force

Minimum

Profile

IPC/WHMA-A-620

Height (Ref.)

Width (Ref.)

Wire Type

Wire Size

In.

Lb.

76823

172063

105417

105418

UL1007

16 AWG

2.30-2.85

.090-.112

3.45

.136

2.90

.114

200.0

45.0

UL1015

16 AWG

3.00-3.45

.118-.136

3.55

.140

3.60

.142

200.0

45.0

Crimp attribute specifications are as follows:

Terminal

Series No.

Wire Size

Bell Mouth

Brush

Bend Up

Bend Down

Twist

Roll

AWG

In.

76823

172063

105417

105418

0.20-0.80

.008-.032

0.10-0.80

.004-.032

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.

OVERLAP

INSULATION

CRIMP

OVERLAP FORM GEOMETRY

ANVIL

PUNCH

WIRE

Hand Crimp Tool for Mega-Fit Crimp Terminals

Doc. No: 2133091400 Release Date: 04-15-20 UNCONTROLLED COPY Page 3 of 8

Revision: A Revision Date: 04-15-20

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 from the preceding charts. Then, 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

PUSH ON THE

LOCATOR BUTTON

Figure 2

SQUEEZE

HANDLES

TOGETHER

HANDLE WILL

SPRING OPEN

Figure 1

Hand Crimp Tool for Mega-Fit Crimp Terminals

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Revision: A Revision Date: 04-15-20

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.

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.

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.

PARTIALLY

CLOSE HANDLE

TOOLING

PARTIALLY

CLOSED

Figure 4

FIRST RATCHET

POSITION

OPEN

POSITION

TERMINAL

Figure 6

WIRE

STOP

RELEASE

LOCATOR

BUTTON

TERMINAL

Figure 3

LOCATOR

PUSHED THROUGH

TOOLING

TERMINAL

LOCATOR

BUTTON

PUSHED IN

LOCATOR

TERMINAL

PRE-STRIPPED

WIRE

Figure 5

TERMINAL

WIRE AGAINST THE

WIRE STOP

WIRE

WIRE STOP IS PART

OF THE LOCATOR

Hand Crimp Tool for Mega-Fit Crimp Terminals

Doc. No: 2133091400 Release Date: 04-15-20 UNCONTROLLED COPY Page 5 of 8

Revision: A Revision Date: 04-15-20

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 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.

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.

Figure 8

PUSH ON

HANDLE

JAWS OPEN

PULL OPEN

TOOLING

M3 BHCS

SQUEEZE

HERE

SQUEEZE

HERE

LOCATOR

Figure 7A

TOP HOOKS

TOP SLOTS OF

HAND TOOL

LOWER TABS

MAKE SURE

CENTER OF

LOCATOR

IS IN THE

DOWN POSITION

Figure 7B

MATCH

UP MARKS

FRONT

BACK

Figure 9

Hand Crimp Tool for Mega-Fit Crimp Terminals

Doc. No: 2133091400 Release Date: 04-15-20 UNCONTROLLED COPY Page 6 of 8

Revision: A Revision Date: 04-15-20

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.

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 11.

How to Adjust Tool Preload (See Figure 12)

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:

1. 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.

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.

4. Check the crimp specifications or

conduct a pull test after tool handle preload force is adjusted.

Figure 12

SQUEEZE THE

LINK IN THE

HANDLE

HOLD THE HAND

TOOL IN POSITION

SETTING WHEEL

RATCHET

RELEASE LEVER

RATCHET RELEASE

LEVER

Figure 11

LUBRICATION POINTS

(BOTH SIDES) LIGHT

OIL

(EVERY 3 MONTHS OR

5,000 CRIMPS)

Figure 10

Hand Crimp Tool for Mega-Fit Crimp Terminals

Doc. No: 2133091400 Release Date: 04-15-20 UNCONTROLLED COPY Page 7 of 8

Revision: A Revision Date: 04-15-20

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 (.500”) 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.

Hand Crimp Tool for Mega-Fit Crimp Terminals

Doc. No: 2133091400 Release Date: 04-15-20 UNCONTROLLED COPY Page 8 of 8

Revision: A Revision Date: 04-15-20

PARTS LIST

Item Number

Order Number

Description

Quantity

REF

213309-1400

Hand Crimp Tool

Figure 13

213309-1475

Locator Assembly (Red)

213309-1476

Locator Assembly (Yellow)

63810-0104

Spring, Return

63810-0105

Spring, Ratchet

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.

Figure 13

Mouser Electronics

Authorized Distributor

Click to View Pricing, Inventory, Delivery & Lifecycle Information:

Molex:

213309-1476 213309-1400 213309-1475

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