Hand Crimp Tool For Mini-Fit™ Jr. Male and Female Crimp Terminals
HAND CRIMP
TOOL
Application Tooling
Specification Sheet
TYPE 4D
Order No. 63819-0900
FEATURES
A full cycle ratcheting hand tool ensures complete crimps
Ergonomic soft grip handles for comfortable crimping
A precision user-friendly terminal locator wire stop holds terminals in the proper crimping position
Right and Left handed applications
Dies and Locator from this tool can be used in the Battery Powered Tool Order No.63816-0200 (110 V) or
63816-0250 (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
This tool is RoHS compliant, however RoHS compliant is not required
SCOPE
Products: Mini-Fit™ Jr. Male and Female Crimp Terminals, 16 - 24 AWG.
Terminal
Series No.
5556
5558
Terminal Order No.
Loose Piece
39-00-0078 39-00-0174
39-00-0080 39-00-0180
39-00-0090 39-00-0186
39-00-0094 39-00-0199
39-00-0113 39-00-0205
39-00-0119 39-00-0212
39-00-0142 39-00-0218
39-00-0158 39-00-0448
39-00-0168
39-00-0039 39-00-0182
39-00-0056 39-00-0195
39-00-0060 39-00-0201
39-00-0074 39-00-0208
39-00-0109 39-00-0214
39-00-0115 39-00-0406
39-00-0154 39-00-0408
39-00-0164 39-00-0429
39-00-0170 39-00-0441
39-00-0176 40-13-0852
39-00-0082 39-00-0131
39-00-0084 39-00-0148
39-00-0096 39-00-0224
39-00-0100 39-00-0450
39-00-0125
Doc No: ATS-638190900
Revision: H
Wire Size
Reel
AWG
mm²
39-00-0077 39-00-0173
39-00-0079 39-00-0179
39-00-0089 39-00-0185
39-00-0093 39-00-0198
39-00-0112 39-00-0204
16
1.30
39-00-0118 39-00-0211
39-00-0141 39-00-0217
39-00-0157 39-00-0447
39-00-0167
39-00-0038 39-00-0181
39-00-0055 39-00-0194
39-00-0059 39-00-0200
39-00-0073 39-00-0207
39-00-0108 39-00-0213
18-24 0.80-0.20
39-00-0114 39-00-0405
39-00-0153 39-00-0407
39-00-0163 39-00-0428
39-00-0169 39-00-0440
39-00-0175 40-13-0851
39-00-0081 39-00-0130
39-00-0083 39-00-0147
39-00-0095 39-00-0223
16
1.30
39-00-0099 39-00-0449
39-00-0124
Release Date: 01-24-08
Revision Date: 08-28-15
Insulation Diameter
Maximum
mm
In.
Strip Length
mm
In.
3.10
.122
3.00-3.30 .118-.130
3.10
.122
3.00-3.30 .118-.130
3.10
.122
3.00-3.30 .118-.130
UNCONTROLLED COPY
Page 1 of 9
Hand Crimp Tool For Mini-Fit™ Jr. Male and Female Crimp Terminals
Terminal
Series No.
5558
30490
44476
44478
44485
45750
46012
46018
46083
46098
Terminal Order No.
Wire Size
Loose Piece
39-00-0041 39-00-0127
39-00-0054 39-00-0220
39-00-0062 39-00-0431
39-00-0076 40-13-0854
39-00-0121
30490-1012 30490-2012
44476-3112
44476-1112
44478-3112
44478-1112
44485-3212
44485-3312
44485-1212
44485-1312
45750-3112
45750-1112
46012-3142
46012-1142
46018-3542
46018-1542
46083-3112
46083-3122
46083-1112
46083-1122
46098-3542
46098-1542
Insulation Diameter
Maximum
mm
In.
Reel
AWG
mm²
39-00-0040 39-00-0126
39-00-0053 39-00-0219
39-00-0061 39-00-0430 18-24 0.80-0.20
3.10
.122
39-00-0075 40-13-0853
39-00-0120
30490-1002 30490-9802
18-24 0.80-0.20
3.10
.122
30490-2002 30490-9902
44476-3111
16
1.30
3.10
.122
44476-1212 44476-1111
18-20 0.80-0.50
44478-3212 44478-3111 44478-3211 16
1.30
3.10
.122
44478-1111 44478-1211 18-20 0.80-0.50
44485-3412 44485-3211 44485-3411
16
1.30
44485-3311
3.10
.122
44485-1412 44485-1211 44485-1411
18-24 0.80-0.20
44485-1311
45750-3212 45750-3111 45750-3211 16
1.30
3.10
.122
45750-1212 45750-1111 45750-1211 18-20 0.80-0.50
46012-3242 46012-3141 46012-3241 16
1.30
3.10
.122
46012-1242 46012-1141 46012-1241 18-20 0.80-0.50
46018-3541
16
1.30
3.10
.122
46018-1541
18-20 0.80-0.50
46083-3212 46083-3111 46083-3211
16
1.30
46083-3222 46083-3121 46083-3221
3.10
.122
46083-1212 46083-1111 46083-1211
18-20 0.80-0.50
46083-1222 46083-1121 46083-1221
46098-3541
16
1.30
3.10
.122
46098-1541
18-20 0.80-0.50
Customer to cut off terminal from reel: 0.2mm (.008”) maximum Cut-off Tab.
+ See conditions on page 3
Strip Length
mm
In.
3.00-3.30 .118-.130
3.00-3.30 .118-.130
3.00-3.30 .118-.130
3.00-3.30 .118-.130
3.00-3.30 .118-.130
3.00-3.30 .118-.130
3.00-3.30 .118-.130
3.00-3.30 .118-.130
3.00-3.30 .118-.130
3.00-3.30 .118-.130
DEFINITION OF TERMS
BEND UP
BRUSH
BELL MOUTH
INSULATION
CRIMP
▲SEE NOTE
CONDUCTOR
CRIMP
ROLLING
TWISTING
STRIP
LENGTH
BEND
DOWN
CRIMP HEIGHT
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the
scope.
Doc No: ATS-638190900
Revision: H
Release Date: 01-24-08
Revision Date: 08-28-15
UNCONTROLLED COPY
Page 2 of 9
Hand Crimp Tool For Mini-Fit™ Jr. Male and Female Crimp Terminals
CONDITIONS:
After crimping, the conductor profiles should measure the following.
Conductor Crimp
Insulation Crimp
Pull Force
+ Profile
Height (Ref.)
Width (Ref.) Height (Ref.) Width (Ref.) Minimum
AWG mm2
mm
In.
mm
In.
mm
In.
mm
In.
N
Lb. 16 18 20-24
16 1.30 1.06-1.16 .042-.046 1.92 .076 2.82 .111 2.89 .114 68.5 15.40 X
18 0.80 1.00-1.10 .039-.043 1.69 .067 2.38 .094 2.68 .106 88.0 19.80
X
20 0.50 0.83-0.93 .033-.037 1.64 .065 2.24 .088 2.65 .104 58.7 13.20
X
22 0.35 0.80-0.90 .031-.035 1.63 .064 2.24 .088 2.61 .103 39.1 8.00
X
24 0.20 0.78-0.88 .030-.034 1.63 .064 2.21 .087 2.60 .102 29.3 6.60
X
16 1.30 1.06-1.16 .042-.046 1.92 .076 2.82 .111 2.89 .114 68.5 15.40 X
18 0.80 1.00-1.10 .039-.043 1.69 .067 2.38 .094 2.68 .106 88.0 19.80
X
20 0.50 0.83-0.93 .033-.037 1.64 .065 2.24 .088 2.65 .104 58.7 13.20
X
22 0.35 0.80-0.90 .031-.035 1.63 .064 2.24 .088 2.61 .103 39.1 8.00
X
24 0.20 0.78-0.88 .030-.034 1.63 .064 2.21 .087 2.60 .102 29.3 6.60
X
18 0.80 1.00-1.10 .039-.043 1.69 .067 2.38 .094 2.68 .106 88.0 19.80
X
20 0.50 0.83-0.93 .033-.037 1.64 .065 2.24 .088 2.65 .104 58.7 13.20
X
22 0.35 0.80-0.90 .031-.035 1.63 .064 2.24 .088 2.61 .103 39.1 8.00
X
24 0.20 0.78-0.88 .030-.034 1.63 .064 2.21 .087 2.60 .102 29.3 6.60
X
16 1.30 1.06-1.16 .042-.046 1.92 .076 2.82 .111 2.89 .114 68.5 15.40 X
18 0.80 1.00-1.10 .039-.043 1.69 .067 2.38 .094 2.68 .106 68.5 15.40
X
20 0.50 0.83-0.93 .033-.037 1.64 .065 2.24 .088 2.65 .104 58.7 13.20
X
16 1.30 1.06-1.16 .042-.046 1.92 .076 2.82 .111 2.89 .114 68.5 15.40 X
18 0.80 1.00-1.10 .039-.043 1.69 .067 2.38 .094 2.68 .106 68.5 15.40
X
20 0.50 0.83-0.93 .033-.037 1.64 .065 2.24 .088 2.65 .104 58.7 13.20
X
16 1.30 1.06-1.16 .042-.046 1.92 .076 2.82 .111 2.89 .114 68.5 15.40 X
18 0.80 1.00-1.10 .039-.043 1.69 .067 2.38 .094 2.68 .106 68.5 15.40
X
20 0.50 0.83-0.93 .033-.037 1.64 .065 2.24 .088 2.65 .104 58.7 13.20
X
22 0.35 0.80-0.90 .031-.035 1.63 .064 2.24 .088 2.61 .103 39.1 8.00
X
24 0.20 0.78-0.88 .030-.034 1.63 .064 2.21 .087 2.60 .102 29.3 6.60
X
16 1.30 1.06-1.16 .042-.046 1.92 .076 2.82 .111 2.89 .114 68.5 15.40 X
18 0.80 1.00-1.10 .039-.043 1.69 .067 2.38 .094 2.68 .106 68.5 15.40
X
20 0.50 0.83-0.93 .033-.037 1.64 .065 2.24 .088 2.65 .104 58.7 13.20
X
16 1.30 1.06-1.16 .042-.046 1.92 .076 2.82 .111 2.89 .114 68.5 15.40 X
18 0.80 1.00-1.10 .039-.043 1.69 .067 2.38 .094 2.68 .106 68.5 15.40
X
20 0.50 0.83-0.93 .033-.037 1.64 .065 2.24 .088 2.65 .104 58.7 13.20
X
16 1.30 1.06-1.16 .042-.046 1.92 .076 2.82 .111 2.89 .114 68.5 15.40 X
18 0.80 1.00-1.10 .039-.043 1.69 .067 2.38 .094 2.68 .106 68.5 15.40
X
20 0.50 0.83-0.93 .033-.037 1.64 .065 2.24 .088 2.65 .104 58.7 13.20
X
16 1.30 1.06-1.16 .042-.046 1.92 .076 2.82 .111 2.89 .114 68.5 15.40 X
18 0.80 1.00-1.10 .039-.043 1.69 .067 2.38 .094 2.68 .106 68.5 15.40
X
20 0.50 0.83-0.93 .033-.037 1.64 .065 2.24 .088 2.65 .104 58.7 13.20
X
16 1.30 1.06-1.16 .042-.046 1.92 .076 2.82 .111 2.89 .114 68.5 15.40 X
18 0.80 1.00-1.10 .039-.043 1.69 .067 2.38 .094 2.68 .106 68.5 15.40
X
20 0.50 0.83-0.93 .033-.037 1.64 .065 2.24 .088 2.65 .104 58.7 13.20
X
To Achieve IPC-A-620 Class 2 Crimps, the following over-all wire insulation diameter ranges are recommended:
16 AWG Profile: 2.30-2.90mm (.090-.114 inch)
18 AWG Profile: 1.70-2.30mm (.067-.091 inch)
20-24 AWG Profile: 1.70-2.30mm (.067-.091 inch)
Terminal
Series No.
5556
5558
30490
44476
44478
44485
45750
46012
46018
46083
46098
+
Wire Size
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.
Doc No: ATS-638190900
Revision: H
Release Date: 01-24-08
Revision Date: 08-28-15
UNCONTROLLED COPY
Page 3 of 9
Hand Crimp Tool For Mini-Fit™ Jr. Male and Female Crimp Terminals
▲Insulation Crimp Note:
Due to the terminal’s insulation grip design and/or
insulation diameter range, this tool uses “overlap”
form geometry in the insulation punch. This
produces an overlap insulation crimp (A620 –
compliant). While 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).
OVERLAP FORM GEOMETRY
PUNCH
OVERLAP
INSULATION
CRIMP
WIRE
ANVIL
Note:
A crimp height chart is provided with this documentl as Reference Only. Due to the wide range of wires, strands,
insulation diameters, and durometers available,
actual crimp height measurements may very
LOCATOR
IN DOWN
slightly. An occasional, destructive, pull force
HANDLE WILL
POSTION
test should be performed to check hand tool
SPRING OPEN
crimp. 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 and/or crimp dies.
SQUEEZE
HANDLES
TOGETHER
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.
LOCATOR
PUSHED THRU
TOOLING
Figure 2
PUSH ON THE
LOCATOR BUTTON
Figure 1
RELEASE
LOCATOR
BUTTON
LOCATOR
LOCATOR
BUTTON
PUSHED IN
TERMINAL
Doc No: ATS-638190900
Revision: H
Figure 3
Release Date: 01-24-08
Revision Date: 08-28-15
TERMINAL
UNCONTROLLED COPY
Page 4 of 9
Hand Crimp Tool For Mini-Fit™ Jr. Male and Female Crimp Terminals
TOOLING
Crimping Terminals
PARTIALLY
CLOSED
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
PARTIALLY
CLOSE HANDLE
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
OPEN
markings on the hand tooling. See Figure 3.
POSITION
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.
FIRST RATCHET
6. Insert the properly stripped wire through the terminal and against the
POSITION
Figure 4
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.
WIRE STOP IS PART
OF THE LOCATOR
WIRE AGAINST THE
WIRE STOP
TERMINAL
PRE-STRIPPED
WIRE
Figure 5
WIRE
TERMINAL
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
LOCATOR
WIRE
SQUEEZE
HERE
SQUEEZE
HERE
WIRE
STOP
Figure 7A
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
TOP SLOTS OF
HANDTOOL
TOP HOOKS
TERMINAL
Figure 6
8. Remove the crimped terminal from the terminal
locator by pulling on the wire.
9. Visually inspect the crimped terminal for proper
crimp location.
Figure 7B
LOWER TABS
Doc No: ATS-638190900
Revision: H
Release Date: 01-24-08
Revision Date: 08-28-15
UNCONTROLLED COPY
Page 5 of 9
Hand Crimp Tool For Mini-Fit™ Jr. Male and Female Crimp Terminals
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 then close the
tool. See Figure 6.
JAWS OPEN
TOOLING
PULL OPEN
TOOLING
M3 BHCS
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.
Figure 8
1. Open the crimp hand tool.
2. Squeeze gently on the lower area shown in Figure
PUSH ON
7A with your thumb and index finger. The lower
HANDLE
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 locators top hooks (2)
into the hand tool 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 Hand 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:
MATCH
1. The locator must be removed before reversing the
UP MARKS
tooling.
2. Remove the M3 BHCS which is holding the upper
tooling.
Figure 9
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
BACK
FRONT
tool frame. See Figure 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:
Doc No: ATS-638190900
Revision: H
Release Date: 01-24-08
Revision Date: 08-28-15
UNCONTROLLED COPY
Page 6 of 9
Hand Crimp Tool For Mini-Fit™ Jr. Male and Female Crimp Terminals
RATCHET RELEASE
1. Remove dust, moisture, and other
LEVER
contaminants with a clean brush,
or 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
LUBRICATION POINTS
Figure 11
excessively. The tool was
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
engineered for durability but like
5,000 CRIMPS)
any other equipment it needs
cleaning and lubrication for a
maximum service life of trouble
Figure 10
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 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 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.
RATCHET
RELEASE LEVER
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
How to Adjust Tool Preload
(See Figure 12)
Figure 12
This hand tool is factory preset to 25-45
SETTING
LBS. preload. It may be necessary over
WHEEL
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 the index finger squeeze the link
towards the top of the hand tool frame. This will release the preload adjustment wheel.
2. Rotate the setting wheel counter-clockwise (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.
Doc No: ATS-638190900
Revision: H
Release Date: 01-24-08
Revision Date: 08-28-15
UNCONTROLLED COPY
Page 7 of 9
Hand Crimp Tool For Mini-Fit™ Jr. Male and Female Crimp Terminals
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, we 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 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 web site 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.
Doc No: ATS-638190900
Revision: H
Release Date: 01-24-08
Revision Date: 08-28-15
UNCONTROLLED COPY
Page 8 of 9
Hand Crimp Tool For Mini-Fit™ Jr. Male and Female Crimp Terminals
PARTS LIST
Item Number
REF
1
2
3
Order Number
63819-0900
63819-0975
63810-0104
63810-0105
Description
Hand Crimp Tool
Locator Assembly
Spring, Return
Spring, Ratchet
Quantity
Figure 13
1
1
1
2
1
RATCHET
RELEASE LEVER
Figure 13
3
Visit our Web site at http://www.molex.com
Doc No: ATS-638190900
Revision: H
Release Date: 01-24-08
Revision Date: 08-28-15
UNCONTROLLED COPY
Page 9 of 9
