2133091200 Appl Tooling Spec Datasheet by Molex

Yerminal Order No. Wire Size Insulation Diameter Strip Length Loose Piece * Reel AWG mm2 mm In. mm In. up NDUCTO I \ "T" CRIMP \ \ \ \ \ 'rw15'r
Hand Crimp Tool for Milli-Grid and MicroBlade Crimp Terminals
Doc No: 2133091200 Release Date: 11-26-19 UNCONTROLLED COPY Page 1 of 8
Revision: A Revision Date: 11-26-19
INSULATION
CRIMP
SEE NOTE
BRUSH
STRIP
LENGTH
BELL MOUTH
CRIMP HEIGHT
BEND
DOWN
BEND UP
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
SCOPE
Products: Milli-Grid and MicroBlade Crimp Terminals, 24-30 AWG.
Terminal Series No.
Terminal Order No.
Wire Size
Insulation Diameter
Strip Length
Loose Piece
* Reel
AWG
mm²
mm
In.
mm
In.
50394
50394-8100
50394-8200
50394-8300
50394-8400
50394-8051
50394-8052
50394-8053
50394-8054
50394-8055
24-30
0.20-0.05
0.80-1.40
.031-055
1.30-1.80
.051-.071
50011
50011-8100
50011-8000
24-30
0.20-0.05
0.80-1.40
.031-055
1.60-2.10
.063-.083
* Customer to cut off terminal from reel: 0.15mm (.006”) 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.
TYPE 4D
Order Number
213309-1200
OVERLAP FORM GEOMETRV / ‘1; ANVIL I Conductor Crimp Insulation Crimp Hei ht Width(Ref.) Height met.) Width(Ref.) 'AWG mm1 mm In. mm In. mm In. mm In. N LD. 24 26 23-30 24 0.20 0.58-0.68.023-.027 1.03 .041 1.43 .056 1.40 .055 29.4 6.60 x 26 0.12 0.53-0.63.021-.025 1.04 .041 1.43 .056 1.32 .052 19.6 4.40 x 28 0.08 0.49-0.59.019-.023 1.02 .040 1.33 .052 1.31 .052 9.8 2.2 x 30 0.05 0.49-0.59 .019 023 1.02 .040 1.31 .052 1.30 .051 4.9 1.10 x 24 0.20 0.58-0.68.023-.027 1.03 .041 1.40 .055 1.40 .055 29.4 6.60 x 26 0.12 0.53-0.63.021-.025 1.04 .041 1.37 .054 1.32 .052 19.6 4.40 x 28 0.08 0.49-0.59 .019 023 1.02 .040 1.33 .052 1.31 .052 9.8 2.2 x 30 0.05 0.49-0.59.019-.023 1.02 .040 1.31 .052 1.30 .051 4.9 1.10 x Q AWG mm‘ mm In. mm In. 24 0.20 26 0.12 28 0.08 30 0.05 24 0.20 26 0.12 28 0.08 30 0.05
Hand Crimp Tool for Milli-Grid and MicroBlade Crimp Terminals
Doc No: 2133091200 Release Date: 11-26-19 UNCONTROLLED COPY Page 2 of 8
Revision: A Revision Date: 11-26-19
Insulation Crimp Note
Due to the terminal’s insulation grip design or
insulation diameter range, this tool uses 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. (Some tools
with multiple crimp pockets may not have the
overlap profile on all pockets.)
CONDITIONS
After crimping, the conductor profiles should measure the following:
Terminal
Series No.
Wire Size
Conductor Crimp
Insulation Crimp
Pull Force
Minimum
Profile
Height
Width (Ref.)
Height (Ref.)
Width (Ref.)
AWG
mm2
mm
In.
mm
In.
mm
In.
mm
In.
N
Lb.
24
26
28-30
50394
24
0.20
0.58-0.68
.023-.027
1.03
.041
1.43
.056
1.40
.055
29.4
6.60
X
26
0.12
0.53-0.63
.021-.025
1.04
.041
1.43
.056
1.32
.052
19.6
4.40
X
28
0.08
0.49-0.59
.019-.023
1.02
.040
1.33
.052
1.31
.052
9.8
2.2
X
30
0.05
0.49-0.59
.019-.023
1.02
.040
1.31
.052
1.30
.051
4.9
1.10
X
50011
24
0.20
0.58-0.68
.023-.027
1.03
.041
1.40
.055
1.40
.055
29.4
6.60
X
26
0.12
0.53-0.63
.021-.025
1.04
.041
1.37
.054
1.32
.052
19.6
4.40
X
28
0.08
0.49-0.59
.019-.023
1.02
.040
1.33
.052
1.31
.052
9.8
2.2
X
30
0.05
0.49-0.59
.019-.023
1.02
.040
1.31
.052
1.30
.051
4.9
1.10
X
Terminal
Series No.
Wire Size
Bell Mouth
Conductor Brush
AWG
mm2
mm
In.
mm
In.
50394
24
0.20
0.05-0.30
.002-.012
0.00-0.70
.000-.028
26
0.12
28
0.08
30
0.05
50011
24
0.20
0.05-0.30
.002-.012
0.00-0.70
.000-.028
26
0.12
28
0.08
30
0.05
Tool Qualification Notes
1. Pull force should be measured with no influence from the insulation crimp.
2. The above specifications are guidelines to an optimum crimp.
OVERLAP
INSULATION
CRIMP
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
WIRE
Hand Crimp Tool for Milli-Grid and MicroBlade Crimp Terminals
Doc No: 2133091200 Release Date: 11-26-19 UNCONTROLLED COPY Page 3 of 8
Revision: A Revision Date: 11-26-19
Bell Mouth Adjustment Notes
The 213309-1200 hand crimp tool features an adjustable locator that allows the operator to
increase or decrease the bell mouth and brush length specifications.
Note: The tool was set up in manufacturing and used to produce the included crimp samples,
but it may be necessary to adjust the tool because of variations in terminal production.
Use a 1.5mm hex wrench to adjust to bell mouth size and brush length.
The adjustment screw is accessible through the hole
in the side of the terminal locator on the back of the
hand crimp tool. See Figure 1.
To increase bell mouth and brush length, turn the
screw clockwise.
To decrease bell mouth and brush length, turn the
screw counterclockwise.
When making an adjustment, turn the adjustment screw half a rotation or less, and then re-check
your bell mouth and brush length.
If you feel or hear a click during the rotation, you have reached the limits of the adjustment.
Once the bell mouth and brush length are properly adjusted, follow the tool operation instructions
listed below.
INCREASE
DECREASE
Figure 1
TERMINAL
LOCATOR
ADJUSTMENT
HOLE
SPRINKE OPEN K? H \> ,/ , TERMINAL
Hand Crimp Tool for Milli-Grid and MicroBlade Crimp Terminals
Doc No: 2133091200 Release Date: 11-26-19 UNCONTROLLED COPY Page 4 of 8
Revision: A Revision Date: 11-26-19
RELEASE
LOCATOR BUTTON
TERMINAL
Figure 4
LOCATOR
PUSHED THROUGH
TOOLING
TERMINAL
LOCATOR
BUTTON
PUSHED IN
LOCATOR
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 2.
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 3.
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 tooling. See Figure 4.
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 5.
6. Insert the properly stripped wire through the terminal and
against the wire stop. See Figure 6.
7. Crimp the terminal by squeezing the tool handles until the
ratchet mechanism cycle has been completed. Release the
handles to open the jaws.
PARTIALLY
CLOSE HANDLE
TOOLING
PARTIALLY
CLOSED
Figure 5
FIRST RATCHET
POSITION
OPEN
POSITION
SQUEEZE
HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Figure 2
LOCATOR
IN DOWN
POSTION
PUSH ON
THE
LOCATOR
BUTTON
Figure 3
TERMINAL WIRE
Hand Crimp Tool for Milli-Grid and MicroBlade Crimp Terminals
Doc No: 2133091200 Release Date: 11-26-19 UNCONTROLLED COPY Page 5 of 8
Revision: A Revision Date: 11-26-19
PRE-STRIPPED
WIRE
TERMINAL
Figure 6
TERMINAL
WIRE
AGAINST THE
WIRE STOP
WIRE
WIRE STOP IS
PART OF
THE LOCATOR
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 7.
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 crimp hand tool.
2. Squeeze gently on the lower area
shown in Figure 8A 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 8A.
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
8B.
6. Holding onto the lower part of the
locator with your thumb and index
finger, insert the locators 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.
SQUEEZE
HERE
SQUEEZE
HERE
LOCATOR
Figure 8A
TOP HOOKS
TOP SLOTS OF
HAND TOOL
LOWER TABS
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
Figure 8B
TERMINAL
Figure 7
WIRE
WIRE
STOP
H t} a) Figure 10 :—~ at Ma 4/
Hand Crimp Tool for Milli-Grid and MicroBlade Crimp Terminals
Doc No: 2133091200 Release Date: 11-26-19 UNCONTROLLED COPY Page 6 of 8
Revision: A Revision Date: 11-26-19
Right- or Left-Handed Operation
This hand tool has an added feature that 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.
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 9 and 10.
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 11.
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 12.
Figure 9
PUSH ON
HANDLE
JAWS OPEN
PULL OPEN
TOOLING
TOOLING
M3 BHCS
MATCH
UP MARKS
FRONT
BACK
Figure 10
LUBRICATION POINTS
(BOTH SIDES) LIGHT
OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figure 11
RATCHET RELEASE
LEVER
Figure 12
CAUTIONS:
Hand Crimp Tool for Milli-Grid and MicroBlade Crimp Terminals
Doc No: 2133091200 Release Date: 11-26-19 UNCONTROLLED COPY Page 7 of 8
Revision: A Revision Date: 11-26-19
How to Adjust Tool Preload (See Figure 13)
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 13. 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 the How to Adjust Preload section.
When the hand tool is no longer capable of achieving minimum pull force, it should be taken
out of service and replaced.
Figure 13
SQUEEZE THE
LINK IN THE
HANDLE
HOLD THE HAND
TOOL IN
POSITION
SETTING WHEEL
RATCHET
RELEASE LEVER
Item Number Order Number Description Quantity 1 213309-1275 Locator Assembly 1 2 638100104 Spring, Return 1
Hand Crimp Tool for Milli-Grid and MicroBlade Crimp Terminals
Doc No: 2133091200 Release Date: 11-26-19 UNCONTROLLED COPY Page 8 of 8
Revision: A Revision Date: 11-26-19
RATCHET
RELEASE LEVER
2
Figure 14
1
3
PARTS LIST
Item Number
Order Number
Description
Quantity
REF
213309-1200
Hand Crimp Tool
Figure 14
1
213309-1275
Locator Assembly
1
2
63810-0104
Spring, Return
1
3
63810-0105
Spring, Ratchet
1
Application Tooling Support
Phone: (402) 458-TOOL (8665)
E-Mail: applicationtooling@molex.com
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.