Hand Crimp Tool for Mini-Fit Jr. Male and Female Crimp Terminals
Order No. 200218-2200
Application Tooling Specification
Type 4D
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, as indicated on page 2
This tool is RoHS compliant; however, RoHS compliance is not required
SCOPE
Products: Mini-Fit Jr. Male and Female Crimp Terminals, 16 AWG.
Terminal
Series No.
Terminal Order No.
Loose Piece
Reel
Wire Size Insulation Diameter
AWG
mm
In.
Strip Length
mm
In.
39-00-0078 39-00-0174 39-00-0077 39-00-0173
39-00-0080 39-00-0180 39-00-0079 39-00-0179
39-00-0090 39-00-0186 39-00-0089 39-00-0185
39-00-0094 39-00-0199 39-00-0093 39-00-0198
5556
39-00-0113 39-00-0205 39-00-0112 39-00-0204
39-00-0119 39-00-0212 39-00-0118 39-00-0211
39-00-0142 39-00-0218 39-00-0141 39-00-0217
39-00-0158 39-00-0448 39-00-0157 39-00-0447
39-00-0168
39-00-0167
39-00-0082 39-00-0131 39-00-0081 39-00-0130
39-00-0084 39-00-0148 39-00-0083 39-00-0147
5558
16
1.80-3.10 .071-.122
3.00-3.50 .118-.138
39-00-0096 39-00-0224 39-00-0095 39-00-0223
39-00-0100 39-00-0450 39-00-0099 39-00-0449
39-00-0125
39-00-0124
44476
44476-3112
44476-3111
44478
44476-3112 44476-3212 44476-3111 44476-3211
44485
44476-3212 44476-3412 44476-3211 44476-3411
44476-3312
44476-3311
45750
44476-3112 44476-3212 44476-3111 44476-3211
46012
44476-3142 44476-3242 44476-3141 44476-3241
46018
44476-3542
44476-3541
Customer to cut off terminal from reel: 0.20mm (.008”) maximum cut-off tab.
+See conditions on page 3.
Doc. No: ATS-2002182200 Release Date: 11-30-17
Revision: A
Revision Date: 11-30-17
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Page 1 of 8
Hand Crimp Tool for Mini-Fit Jr. Male and Female Crimp Terminals
DEFINITION OF TERMS
BEND UP
BRUSH
BELL MOUTH
CONDUCTOR
CRIMP
INSULATION
CRIMP
▲SEE NOTE
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.
CONDITIONS
After crimping, the conductor profiles should measure the following:
Conductor Crimp
Insulation Crimp
Pull Force
Profile
Locator
Minimum
Height (Ref.)
Width (Ref.) Height (Ref.) Width (Ref.)
Color
mm
In.
mm
In.
mm
In.
mm
In.
N
Lb.
A B C
2.85
.112
2.50
.098
X
5556
16
1.14-1.24 .045-.049 1.95
.077
2.85
.112
2.75
.108 68.5 15.40
Red
X
3.35
.132
3.25
.128
X
2.85
.112
2.50
.098
X
5558
16
1.14-1.24 .045-.049 1.95
.077
2.85
.112
2.75
.108 68.5 15.40
Blue
X
3.35
.132
3.25
.128
X
2.80
.110
2.50
.098
X
44476
16
1.14-1.24 .045-.049 1.95
.077
2.80
.110
2.75
.108 68.5 15.40
Red
X
3.35
.132
3.25
.128
X
2.85
.112
2.50
.098
X
44478
16
1.14-1.24 .045-.049 1.95
.077
2.85
.112
2.75
.108 68.5 15.40
Blue
X
3.35
.132
3.25
.128
X
2.85
.112
2.50
.098
X
44485
16
1.14-1.24 .045-.049 1.95
.077
2.90
.114
2.75
.108 68.5 15.40
Red
X
3.35
.132
3.25
.128
X
2.85
.112
2.50
.098
X
45750
16
1.14-1.24 .045-.049 1.95
.077
2.80
.110
2.75
.108 68.5 15.40
Red
X
3.35
.132
3.25
.128
X
2.80
.110
2.50
.098
X
46012
16
1.14-1.24 .045-.049 1.95
.077
2.85
.112
2.75
.108 68.5 15.40
Blue
X
3.35
.132
3.25
.128
X
2.80
.110
2.50
.098
X
46018
16
1.14-1.24 .045-.049 1.95
.077
2.85
.112
2.75
.108 68.5 15.40 Yellow
X
3.35
.132
3.25
.128
X
To achieve IPC-A-620 Class 2 crimps, the following overall wire insulation diameter ranges are recommended:
Terminal Wire
Size
Series
No.
AWG
● Profile A: 2.20-2.60mm (.087-.102 in.) or UL1007
● Profile B: 2.85-3.15mm (.112-.124 in.) or UL1015
● Profile C: 1.75-2.45mm (.069-.097 in.) or UL1061
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-2002182200 Release Date: 11-30-17
Revision: A
Revision Date: 11-30-17
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Page 2 of 8
Hand Crimp Tool for Mini-Fit Jr. Male and Female Crimp Terminals
▲Insulation Crimp Note
OVERLAP FORM GEOMETRY
PUNCH
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 (A620compliant). 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).
OVERLAP
INSULATION
CRIMP
Note
WIRE
ANVIL
A crimp height chart is provided with this document as a reference only. Due to the wide range of
wires, strands, insulation diameters and durometers available, actual crimp height measurements may
very slightly. An occasional destructive pull force test should be performed to check hand tool crimp.
Pull force value must exceed the minimum pull force specifications listed.
SETUP
Locator Replacement
Refer to the above chart to determine the correct locator based on your specific crimping
application. Match the terminal series number to the appropriate locator color.
Note: You must install the correct locator prior to operating this hand tool.
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 1A 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 1A.
4. To install 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 1B.
6. Holding onto the lower part of the
locator with your thumb and index
finger, insert the locator’s top hooks (2)
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.
Doc. No: ATS-2002182200 Release Date: 11-30-17
Revision: A
Revision Date: 11-30-17
LOCATOR
SQUEEZE
HERE
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
SQUEEZE
HERE
Figure 1A
TOP SLOTS OF
HANDTOOL
TOP HOOKS
Figure 1B
LOWER TABS
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Hand Crimp Tool for Mini-Fit Jr. Male and Female Crimp Terminals
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.
LOCATOR
IN DOWN
POSTION
HANDLE WILL
SPRING OPEN
SQUEEZE
HANDLES
TOGETHER
Figure 3
Figure 2
LOCATOR
PUSHED THROUGH
TOOLING
LOCATOR
PUSH ON THE
LOCATOR BUTTON
RELEASE
LOCATOR
BUTTON
LOCATOR
BUTTON
PUSHED IN
TERMINAL
Figure 4
TERMINAL
Crimping Terminals
TOOLING
PARTIALLY
CLOSED
1. Select the desired terminal listed in the preceding charts.
PARTIALLY
2. Make sure the center of the locator is in the down position.
CLOSE HANDLE
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
OPEN
proper nest opening in the locator based on the wire gauge or
POSITION
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.
FIRST RATCHET
See Figure 5.
POSITION
6. Insert the properly stripped wire through the terminal and
Figure 5
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.
Doc. No: ATS-2002182200 Release Date: 11-30-17
Revision: A
Revision Date: 11-30-17
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Hand Crimp Tool for Mini-Fit Jr. Male and Female Crimp Terminals
WIRE STOP IS PART
OF THE LOCATOR
WIRE AGAINST THE
WIRE STOP
TERMINAL
PRE-STRIPPED
WIRE
Figure 6
WIRE
TERMINAL
Note: The tamper-proof ratchet action will not release the tool until it has been fully closed.
WIRE
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.
WIRE
STOP
TERMINAL
Figure 7
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:
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 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.
JAWS OPEN
PULL OPEN
TOOLING
TOOLING
M3 BHCS
Figure 8
PUSH ON
HANDLE
MATCH
UP MARKS
Figure 9
FRONT
Doc. No: ATS-2002182200 Release Date: 11-30-17
Revision: A
Revision Date: 11-30-17
BACK
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Hand Crimp Tool for Mini-Fit Jr. Male and Female Crimp Terminals
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.
LUBRICATION
POINTS
(BOTH SIDES) LIGHT
OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figure 10
RATCHET RELEASE
LEVER
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.
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 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 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.
SQUEEZE
THE LINK IN
RATCHET
RELEASE LEVER THE HANDLE
HOLD THE HAND
TOOL IN POSITION
Figure 12
SETTING
WHEEL
Doc. No: ATS-2002182200 Release Date: 11-30-17
Revision: A
Revision Date: 11-30-17
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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, 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 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.
Doc. No: ATS-2002182200 Release Date: 11-30-17
Revision: A
Revision Date: 11-30-17
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Hand Crimp Tool for Mini-Fit Jr. Male and Female Crimp Terminals
PARTS LIST
Item Number Order Number
REF
1A
1B
1C
2
3
200218-2200
200218-2275
200218-2276
200218-2277
63810-0104
63810-0105
Description
Quantity
Hand Crimp Tool
Locator Assembly (Red)
Locator Assembly (Blue)
Locator Assembly (Yellow)
Spring, Return
Spring, Ratchet
Figure 13
1
1
1
1
1
2
1C
1B
1A
RATCHET
RELEASE LEVER
3
Figure 13
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.
Doc. No: ATS-2002182200 Release Date: 11-30-17
Revision: A
Revision Date: 11-30-17
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