Molex 63828-0200 Manual de usuario

Hand Crimp Tool for Micro-Fit 3.0 Crimp Terminals

Doc. No: ATS-638280200 Release Date: 03-15-16 UNCONTROLLED COPY Page 1 of 7

Revision: C Revision Date: 06-18-19

CONDUCTOR

BRUSH

STRIP LENGTH

CONDUCTOR

CRIMP

CUT-OFF

TAB

BELL

MOUTH

BEND UP

TWIST

ROLL

BEND

DOWN

SEAM

INSULATION

CRIMP

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 with wire stop holds terminals in the proper crimping

position

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

Many different tool kits can be used with a single Battery Powered Crimp Tool

This tool is IPC/WHMA A-620 Class 2 compliant (see Scope table)

This tool is RoHS compliant; however, RoHS compliance is not required

SCOPE

Products: Micro-Fit 3.0 Crimp Terminals, 0.75mm2and 18 AWG (UL1061) wires.

Terminal

Series No.

Terminal

Order No.

Wire Size

►Insulation Diameter

Strip Length

IPC/WHMA-A-620 (1)

Terminal (2)

AWG

mm²

In.

43030

43030-0038

0.75

1.60-1.85

.063-.073

0.90-1.85

.035-.073

2.54-2.92

.100-.115

43031

●(3)

43031-0021

43031-0022

43031-0023

45807

45807-0003

—

45807-0005

203951

203951-0001

—

►Insulation Diameter Notes

(1) Insulation OD range for optimum (IPC/WHMA-A-620 Class 2) insulation crimps

(2) Insulation OD range for the terminal product design

●Terminal Locator Note

(3) Separate terminal locator is needed for 43031 series (see page 2). If locator is missing it can be ordered (see page 7)

DEFINITION OF TERMS

Order Number

63828-0200

Type 4D

Hand Crimp Tool for Micro-Fit 3.0 Crimp Terminals

Doc. No: ATS-638280200 Release Date: 03-15-16 UNCONTROLLED COPY Page 2 of 7

Revision: C Revision Date: 06-18-19

CONDITIONS

After crimping to the wire, the crimped terminal should measure as follows:

Terminal

Order No.

Wire Size

Conductor Crimp

Height

Conductor Crimp

Width (Ref)

Pull Force

Minimum

Tool Profile

Locator

AWG

mm2

In.

Lb.

0.75mm2

Order No.

Color

43030-0038

—

1.00-1.10

.039-.043

1.65

.065

63828-0275

Red

—

0.75

0.85-0.95

.033-.037

43031-0021

—

1.00-1.10

.039-.043

63828-0276

Yellow

—

0.75

0.85-0.95

.033-.037

43031-0022

—

1.00-1.10

.039-.043

—

0.75

0.85-0.95

.033-.037

43031-0023

—

1.00-1.10

.039-.043

—

0.75

0.85-0.95

.033-.037

45807-0003

45807-0005

—

1.00-1.10

.039-.043

1.65

.065

63828-0275

Red

203951-0001

—

1.00-1.10

.039-.043

1.65

.065

63828-0275

Red

Terminal

Series No.

Wire Size

Insulation Crimp

Height (Ref)

Insulation Crimp

Width (Ref)

AWG

mm2

In.

43030

43031

45807

203951

0.75

1.90

.075

2.00

.078

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 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 crimp hand tools.

Hand Crimp Tool for Micro-Fit 3.0 Crimp Terminals

Doc. No: ATS-638280200 Release Date: 03-15-16 UNCONTROLLED COPY Page 3 of 7

Revision: C Revision Date: 06-18-19

RELEASE

LOCATOR BUTTON

TERMINAL

Figure 3

LOCATOR PUSHED

THROUGH TOOLING

TERMINAL

LOCATOR

BUTTON

PUSHED IN

LOCATOR

Figure 5

TERMINAL

WIRE AGAINST THE

WIRE STOP

WIRE

WIRE STOP IS PART OF

THE LOCATOR

PRE-STRIPPED

WIRE

TERMINAL

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 1.

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 2.

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 tool.

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 locator. 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.

LOCATOR

IN DOWN

POSTION

PUSH ON THE

LOCATOR BUTTON

Figure 2

SQUEEZE

HANDLES

TOGETHER

HANDLE WILL

SPRING OPEN

Figure 1

PARTIALLY

CLOSE HANDLE

TOOLING

PARTIALLY CLOSED

Figure 4

FIRST RATCHET

POSITION

OPEN

POSITION

Hand Crimp Tool for Micro-Fit 3.0 Crimp Terminals

Doc. No: ATS-638280200 Release Date: 03-15-16 UNCONTROLLED COPY Page 4 of 7

Revision: C Revision Date: 06-18-19

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.

Locator Installation

Depending on the terminal to be crimped, the locator may need to be changed. Follow the steps

below to remove and install 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 red insert 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 has an added feature in that it can

be converted from a right-handed 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.

Figure 8

PUSH ON

HANDLE

JAWS OPEN

PULL OPEN

TOOLING

M3 BHCS

MAKE SURE

CENTER OF

LOCATOR IS IN

THE DOWN

POSITION

Figure 7B

SQUEEZE

HERE

SQUEEZE

HERE

LOCATOR

Figure 7A

TOP HOOKS

TOP SLOTS OF

HAND TOOL

LOWER TABS

TERMINAL

Figure 6

WIRE

STOP

Hand Crimp Tool for Micro-Fit 3.0 Crimp Terminals

Doc. No: ATS-638280200 Release Date: 03-15-16 UNCONTROLLED COPY Page 5 of 7

Revision: C Revision Date: 06-18-19

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.

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 hand tool, particularly from 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.

MATCH

UP MARKS

FRONT

BACK

Figure 9

LUBRICATION POINTS

(BOTH SIDES) LIGHT

OIL

(EVERY 3 MONTHS OR

5,000 CRIMPS)

Figure 10

RATCHET RELEASE

LEVER

Figure 11

Hand Crimp Tool for Micro-Fit 3.0 Crimp Terminals

Doc. No: ATS-638280200 Release Date: 03-15-16 UNCONTROLLED COPY Page 6 of 7

Revision: C Revision Date: 06-18-19

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.

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.

Figure 12

SQUEEZE

THE LINK IN

THE HANDLE

HOLD THE HAND

TOOL IN POSITION

SETTING

WHEEL

RATCHET

RELEASE LEVER

Hand Crimp Tool for Micro-Fit 3.0 Crimp Terminals

Doc. No: ATS-638280200 Release Date: 03-15-16 UNCONTROLLED COPY Page 7 of 7

Revision: C Revision Date: 06-18-19

Figure 13

PARTS LIST

Item Number

Order Number

Description

Quantity

REF

63828-0200

Hand Crimp Tool

Figure 13

63828-0275

Locator Assembly (Red)

63828-0276

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.

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