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
mm
In.
mm
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
mm
In.
mm
In.
76823
172063
213309-1475
Red
16
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
mm
In.
mm
In.
mm
In.
N
Lb.
A
B
76823
172063
105417
105418
UL1007
16 AWG
2.30-2.85
.090-.112
3.45
.136
2.90
.114
200.0
45.0
X
UL1015
16 AWG
3.00-3.45
.118-.136
3.55
.140
3.60
.142
200.0
45.0
X
Crimp attribute specifications are as follows:
Terminal
Series No.
Wire Size
Bell Mouth
Brush
Bend Up
Bend Down
Twist
Roll
AWG
mm
In.
mm
In.
76823
172063
105417
105418
16
0.20-0.80
.008-.032
0.10-0.80
.004-.032
3
3
4
8
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
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
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
1A
213309-1475
Locator Assembly (Red)
1
1B
213309-1476
Locator Assembly (Yellow)
1
2
63810-0104
Spring, Return
1
3
63810-0105
Spring, Ratchet
1
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.
2
1A
Figure 13
3
1B

Mouser Electronics
Authorized Distributor
Click to View Pricing, Inventory, Delivery & Lifecycle Information:
Molex:
213309-1476 213309-1400 213309-1475