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
mm
In.
mm
In.
mm
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
mm
In.
mm
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.
Degree Max.
505572
4
2
3
6
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
mm
In.
mm
In.
mm
In.
mm
In.
N
Lb.
A
B
C
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
X
—
0.30
0.78-0.83
.031-.033
1.25
.049
1.70-1.76
.067-.070
1.50
.059
39.2
8.81
X
—
0.30
0.78-0.83
.031-.033
1.25
.049
1.82-1.90
.072-.075
1.58
.062
39.2
8.81
X
♦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)
—
—
7
63816-0050
Hand Crimp Frame (Long)
—
—
7
63816-0270
Battery Power Tool (110 V)
63816-0600
Battery Power Crimp Adapter
8
63816-0280
Battery Power Tool (220 V)
63816-0600
Battery Power Crimp Adapter
8
63816-1500
Electric Crimp Machine
63816-0600
Battery Power Crimp Adapter
9
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
1
63816-0000
Hand Crimp Frame (Short)
1
2
200218-4575
Locator
1
3
63816-0001
Locking Pin
2
4
63600-0525
Handle Spring
1
5
63600-0520
Crimping Spring
2
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.
4
1
HANDLE
SPRING
CRIMPING
SPRING (2)
3
5
M4 X 8mm
LONG BHCS
LOCATOR
2
Figure 10
RATCHET
RELEASE LEVER