molex 63828-0200 User manual

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
mm
In.
mm
In.
mm
In.
43030
43030-0038
18
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
18
—
45807-0005
203951
203951-0001
18
—
►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
mm
In.
mm
In.
N
Lb.
18
0.75mm2
Order No.
Color
43030-0038
18
—
1.00-1.10
.039-.043
1.65
.065
89
20
X
63828-0275
Red
—
0.75
0.85-0.95
.033-.037
X
43031-0021
18
—
1.00-1.10
.039-.043
X
63828-0276
Yellow
—
0.75
0.85-0.95
.033-.037
X
43031-0022
18
—
1.00-1.10
.039-.043
X
—
0.75
0.85-0.95
.033-.037
X
43031-0023
18
—
1.00-1.10
.039-.043
X
—
0.75
0.85-0.95
.033-.037
X
45807-0003
45807-0005
18
—
1.00-1.10
.039-.043
1.65
.065
89
20
X
63828-0275
Red
203951-0001
18
—
1.00-1.10
.039-.043
1.65
.065
89
20
X
63828-0275
Red
Terminal
Series No.
Wire Size
Insulation Crimp
Height (Ref)
Insulation Crimp
Width (Ref)
AWG
mm2
mm
In.
mm
In.
43030
43031
45807
203951
18
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
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
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
2
Figure 13
1
3
PARTS LIST
Item Number
Order Number
Description
Quantity
REF
63828-0200
Hand Crimp Tool
Figure 13
1
63828-0275
Locator Assembly (Red)
1
1
63828-0276
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.