Hand Crimp Tool for Mini-Fit™ Crimp Terminals
HAND CRIMP TOOL
SPECIFICATION SHEET
Order No. 63811-5000
TYPE 2C
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
This tool is WHMA-IPCA620 Class 2 and RoHS compliant
SCOPE
Products: Mini-Fit Jr.™, Mini-Fit HCS™, and Mini-Fit Plus HCS™, Male, and Female Crimp Terminal 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 39-00-0201
39-00-0056 39-00-0208
39-00-0060 39-00-0214
39-00-0074 39-00-0406
39-00-0109 39-00-0429
39-00-0115 39-00-0441
39-00-0154 40-13-0852
39-00-0164
39-00-0170
39-00-0176
39-00-0182
39-00-0195
39-00-0082 39-00-0125
39-00-0084 39-00-0131
39-00-0096 39-00-0224
39-00-0100 39-00-0450
39-00-0041 39-00-0220
39-00-0054 39-00-0431
39-00-0062 40-13-0854
39-00-0076
39-00-0121
39-00-0127
39-00-0148
Doc No: ATS-638115000
Revision: F
Wire Size
ÆReel
39-00-0077
39-00-0079
39-00-0089
39-00-0093
39-00-0112
39-00-0118
39-00-0141
39-00-0157
39-00-0167
39-00-0038
39-00-0055
39-00-0059
39-00-0073
39-00-0108
39-00-0114
39-00-0153
39-00-0163
39-00-0169
39-00-0175
39-00-0181
39-00-0194
39-00-0081
39-00-0083
39-00-0095
39-00-0099
39-00-0040
39-00-0053
39-00-0061
39-00-0075
39-00-0120
39-00-0126
39-00-0147
39-00-0173
39-00-0179
39-00-0185
39-00-0198
39-00-0204
39-00-0211
39-00-0217
39-00-0447
AWG
mm²
16
1.30
39-00-0200
39-00-0207
39-00-0213
39-00-0405
39-00-0410
39-00-0419
18-24 0.80-0.20
39-00-0425
39-00-0428
39-00-0436
39-00-0440
40-13-0851
39-00-0124
39-00-0130
16
1.30
39-00-0223
39-00-0449
39-00-0219
39-00-0411
39-00-0420
39-00-0426 18-24 0.80-0.20
39-00-0430
39-00-0437
40-13-0853
Release Date: 04-03-06
Revision Date: 03-27-08
ÆInsulation
Diameter
Maximum
mm
In.
Strip Length
mm
In.
3.10
.122
3.00-3.50 .118-.138
3.10
.122
3.00-3.50 .118-.138
UNCONTROLLED COPY
Page 1 of 8
Hand Crimp Tool for Mini-Fit™ Crimp Terminals
Terminal
Series No.
30490
44476
44478
44485
45750
46012
46018
46083
46098
Terminal Order No.
Loose Piece
30490-1012
30490-2012
44476-3112 44476-3212
44476-1112 44476-1212
44478-3112 44478-3212
44478-3122 44478-3222
44478-9904 44478-9908
44478-1112 44478-1212
44478-1122 44478-1222
44478-9902 44478-9906
44485-3212 44485-3412
44485-3312
44485-1212 44485-1412
44485-1312
45750-3112 45750-3212
45750-1112 45750-1212
46012-3142 46012-3242
46012-1142 46012-1242
46018-3542
46018-1542
46083-3112 46083-3122
46083-3212 46083-3222
46083-1112 46083-1122
46083-1212 46083-2222
46098-3541
46098-1541
Wire Size
Æ
Reel
AWG
mm²
30490-1002 30490-9802
18-24 0.80-0.20
30490-2002 30490-9902
44476-3111 44476-3211 16
1.30
44476-1111 44476-1211 18-20 0.80-0.50
44478-3111 44478-3211
1.30
44478-3121 44478-3221 16
44478-9903 44478-9907
44478-1111 44478-1211
44478-1121 44478-1221 18-20 0.80-0.50
44478-9901 44478-9905
44485-3211 44485-3411
16
1.30
44485-3311
44485-1211 44485-1411
18-24 0.80-0.20
44485-1311
45750-3111 45750-3211 16
1.30
45750-1111 45750-1211 18-20 0.80-0.50
46012-3141 46012-3241 16
1.30
46012-1141 46012-1241 18-20 0.80-0.50
46018-3541
16
1.30
46018-1541
18-20 0.80-0.50
46083-3111 46083-3121
16
1.30
46083-3211 46083-3221
46083-1111 46083-1121
18-20 0.80-0.50
46083-1211 46083-2221
46098-3542
16
1.30
46098-1542
18-20 0.80-0.50
See Conditions on page 3.
Æ
ÆInsulation
Diameter
Maximum
mm
In.
mm
In.
3.10
.122
3.00-3.50 .118-.138
3.10
.122
3.00-3.50 .118-.138
3.10
.122
3.00-3.50 .118-.138
3.10
.122
3.00-3.50 .118-.138
3.10
.122
3.00-3.50 .118-.138
3.10
.122
3.00-3.50 .118-.138
3.10
.122
3.00-3.50 .118-.138
3.10
.122
3.00-3.50 .118-.138
3.10
.122
3.00-3.50 .118-.138
DEFINITION OF TERMS
BRUSH
Strip Length
BEND UP
BELL MOUTH
CONDUCTOR
CRIMP
INSULATION
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-638115000
Revision: F
Release Date: 04-03-06
Revision Date: 03-27-08
UNCONTROLLED COPY
Page 2 of 8
Hand Crimp Tool for Mini-Fit™ Crimp Terminals
CONDITIONS:
After crimping, the conductor profiles should measure the following (See note on page 4).
Æ Profile
Pull Force
Conductor Crimp
Insulation Crimp
Height (Ref.)
Width (Ref.) Height (Ref.) Width (Ref.) Minimum
mm
In.
mm In.
mm
In.
mm In.
N
Lb. A
AWG mm2
16 1.30 1.14-1.24 .045-.049 1.91 .075 2.95 .116 2.75 .108 68.5 15.40 X
18 0.80 0.97-1.07 .038-.042 1.61 .063 2.73 .107 2.55 .100 88.0 19.80
5556
20 0.50 0.79-0.89 .031-.035 1.61 .063 2.51 .099 2.35 .092 58.7 13.20
22 0.35 0.79-0.89 .031-.035 1.61 .063 2.51 .099 2.35 .092 39.1 8.80
24 0.20 0.79-0.89 .031-.035 1.61 .063 2.51 .099 2.33 .091 29.3 6.60
16 1.30 1.14-1.24 .045-.049 1.91 .075 2.95 .116 2.75 .108 68.5 15.40 X
18 0.80 0.97-1.07 .038-.042 1.61 .063 2.73 .107 2.55 .100 88.0 19.80
5558
20 0.50 0.79-0.89 .031-.035 1.61 .063 2.51 .099 2.35 .092 58.7 13.20
22 0.35 0.79-0.89 .031-.035 1.61 .063 2.51 .099 2.35 .092 39.1 8.80
24 0.20 0.79-0.89 .031-.035 1.61 .063 2.51 .099 2.33 .091 29.3 6.60
18 0.80 0.97-1.07 .038-.042 1.61 .063 2.73 .107 2.55 .100 88.0 19.80
20 0.50 0.79-0.89 .031-.035 1.61 .063 2.51 .099 2.35 .092 58.7 13.20
30490
22 0.35 0.79-0.89 .031-.035 1.61 .063 2.51 .099 2.35 .092 39.1 8.80
24 0.20 0.79-0.89 .031-.035 1.61 .063 2.51 .099 2.33 .091 29.3 6.60
16 1.30 1.14-1.24 .045-.049 1.91 .075 2.95 .116 2.75 .108 68.5 15.40 X
44476
18 0.80 0.97-1.07 .038-.042 1.61 .063 2.73 .107 2.55 .100 88.0 19.80
20 0.50 0.79-0.89 .031-.035 1.61 .063 2.51 .099 2.35 .092 58.7 13.20
16 1.30 1.14-1.24 .045-.049 1.91 .075 2.95 .116 2.75 .108 68.5 15.40 X
44478
18 0.80 0.97-1.07 .038-.042 1.61 .063 2.73 .107 2.55 .100 88.0 19.80
20 0.50 0.79-0.89 .031-.035 1.61 .063 2.51 .099 2.35 .092 58.7 13.20
16 1.30 1.14-1.24 .045-.049 1.91 .075 2.95 .116 2.75 .108 68.5 15.40 X
18 0.80 0.97-1.07 .038-.042 1.61 .063 2.73 .107 2.55 .100 88.0 19.80
44485
20 0.50 0.79-0.89 .031-.035 1.61 .063 2.51 .099 2.35 .092 58.7 13.20
22 0.35 0.79-0.89 .031-.035 1.61 .063 2.51 .099 2.35 .092 39.1 8.80
24 0.20 0.79-0.89 .031-.035 1.61 .063 2.51 .099 2.33 .091 29.3 6.60
16 1.30 1.14-1.24 .045-.049 1.91 .075 2.95 .116 2.75 .108 68.5 15.40 X
45750
18 0.80 0.97-1.07 .038-.042 1.61 .063 2.73 .107 2.55 .100 68.5 15.40
20 0.50 0.79-0.89 .031-.035 1.61 .063 2.51 .099 2.35 .092 58.7 13.20
16 1.30 1.14-1.24 .045-.049 1.91 .075 2.95 .116 2.75 .108 68.5 15.40 X
46012
18 0.80 0.97-1.07 .038-.042 1.61 .063 2.73 .107 2.55 .100 68.5 15.40
20 0.50 0.79-0.89 .031-.035 1.61 .063 2.51 .099 2.35 .092 58.7 13.20
16 1.30 1.14-1.24 .045-.049 1.91 .075 2.95 .116 2.75 .108 68.5 15.40 X
46018
18 0.80 0.97-1.07 .038-.042 1.61 .063 2.73 .107 2.55 .100 68.5 15.40
20 0.50 0.79-0.89 .031-.035 1.61 .063 2.51 .099 2.35 .092 58.7 13.20
16 1.30 1.14-1.24 .045-.049 1.91 .075 2.95 .116 2.75 .108 68.5 15.40 X
46083
18 0.80 0.97-1.07 .038-.042 1.61 .063 2.73 .107 2.55 .100 68.5 15.40
20 0.50 0.79-0.89 .031-.035 1.61 .063 2.51 .099 2.35 .092 58.7 13.20
16 1.30 1.14-1.24 .045-.049 1.91 .075 2.95 .116 2.75 .108 68.5 15.40 X
46098
18 0.80 0.97-1.07 .038-.042 1.61 .063 2.73 .107 2.55 .100 68.5 15.40
20 0.50 0.79-0.89 .031-.035 1.61 .063 2.51 .099 2.35 .092 58.7 13.20
To Achieve IPC-A-620 Class 2 Crimps, the following over-all wire insulation diameter ranges are recommended:
Profile A: 1.90-3.10mm (.075-.122 inch)
Profile B: 1.68-3.10mm (.066-.122 inch)
Profile C: 1.40-2.54mm (.055-.100 inch)
Terminal Series No.
Wire Size
Æ
Doc No: ATS-638115000
Revision: F
Release Date: 04-03-06
Revision Date: 03-27-08
UNCONTROLLED COPY
B C
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Page 3 of 8
Hand Crimp Tool for Mini-Fit™ Crimp Terminals
OPERATION
CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects as damage can
occur to the tool or die.
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.
JAWS OPEN
LOCATOR
Crimping Terminals
1. Select the desired terminal listed in the preceding charts.
2. Swing the terminal locator away from the crimp tool shown in Figure 2.
Some terminals with large insulation grips may interfere with the crimp
tooling when swinging the locator into position. The terminal must then be
loaded into the locator in the closed/crimp position.
Figure 1
TERMINAL
SWING OPEN
PUSH HERE TO
OPEN WIRE STOP
LOCATOR
LOCATOR
TERMINAL IN PLACE
Figure 2
WIRE STOP
3. When using the locator, press down on the wire stop on the locator
as shown in Figure 2. Insert the proper terminal into the proper nest
opening. Make sure when choosing the nest opening, it will
correspond with the A, B, or C profile on the hand tool.
4. Return the locator to its original position.
5. Insert the proper wire over the terminal. Some large O.D. wires may
need to be placed into the terminal before closing the tool. Gently
touch the wire stop with the end of the wire. See Figure 3.
6. Compress the terminal by squeezing the tool handles until the
ratchet mechanism cycle has been completed. Release handles to
open the jaws.
WIRE
LOCATOR
IN PLACE
TERMINAL
WIRE STOP
Note: The tamper proof ratchet action will not release the tool until it has
been fully closed.
Doc No: ATS-638115000
Revision: F
Release Date: 04-03-06
Revision Date: 03-27-08
WIRE AGAINST
STOP
UNCONTROLLED COPY
Figure 3
Page 4 of 8
Hand Crimp Tool for Mini-Fit™ Crimp Terminals
7. Remove the crimped terminal from the terminal locator by pressing down on the wire stop and gently pulling on
the wire. The terminal locator can be in either position.
8. Visually inspect the crimped terminal for proper crimp location.
Note:
A crimp height chart is provided with this manual as Reference Only. Due to the wide range of wires, strands,
insulation diameters, and durometers, actual crimp height measurements may very slightly. An occasional,
destructive, pull force test should be preformed to check hand tool crimp. Pull Force value Must exceed the
Minimum pull force specifications listed on page 2.
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. Swing the existing locator open and away from the
hand tool.
3. Firmly press down on the brass pivot shaft with your
thumb, while pulling the locator up. Slip the locator
off the top of the brass pivot shaft. See Figure 4.
4. Replace it with the new locator by putting over the
brass pivot shaft and snapping it into place.
LIFT UP LOCATOR
JAWS OPEN
PRESS DOWN ON
BRASS PIVOT SHAFT
SWING
LOCATOR
OPEN
Figure 4
Doc No: ATS-638115000
Revision: F
Release Date: 04-03-06
Revision Date: 03-27-08
UNCONTROLLED COPY
Page 5 of 8
Hand Crimp Tool for Mini-Fit™ 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 soft, lint free cloth.
2. Do not use any abrasive materials that could damage the
tool.
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
3. Make certain all pins; pivot points and bearing surfaces are
(EVERY 3 MONTHS OR
protected with a thin coat of high quality machine oil. Do not
5,000 CRIMPS)
oil excessively. The tool was engineered for durability but
like any fine piece of 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, shown in Figure 5, 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
Figure 5
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 the ratchet release lever. See Figure 6.
How to Adjust Tool Preload (See Figure 6)
This hand tool is factory preset to 25-45 LBS.
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:
PRELOAD
CHECK POINT
25.4MM
SETTING WHEEL
ECCENTRIC
AXLE
HANDLE
GRIP
REMOVED
WRENCH SET
(SOLD
SEPERATELY)
LOCKING
SCREW
HANDLE
GRIP
RATCHET
RELEASE LEVER
Figure 6
1. Remove or fold back the handle grip from the
handle to expose the eccentric axle and setting wheel.
2. Remove the locking screw with a 2mm hex wrench. The wrench set (63810-0101), is not supplied. It is sold
separately from the hand tool.
3. Turn the eccentric axle and setting wheel with the wrench or pliers Counter-clockwise (CCW) to increase handle
force.
4. Replace the locking screw, aligning the nearest notch in the setting wheel to locking screw.
5. Replace the handle grip.
6. Check the crimp specifications or conduct a pull test after tool handle preload force is adjusted.
Doc No: ATS-638115000
Revision: F
Release Date: 04-03-06
Revision Date: 03-27-08
UNCONTROLLED COPY
Page 6 of 8
Hand Crimp Tool for Mini-Fit™ 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 commercial grade 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, which has been stripped
12.7mm (1/2”) 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 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-638115000
Revision: F
Release Date: 04-03-06
Revision Date: 03-27-08
UNCONTROLLED COPY
Page 7 of 8
Hand Crimp Tool for Mini-Fit™ Crimp Terminals
PARTS LIST
Item Number
REF
1
2
3
4
Order Number
63811-5000
63810-0101
63810-0102
63810-0103
63811-5075
Description
Hand Crimp Tool
Wrench Set (Not included)
Locator Base Assembly
Repair Kit (Not included)
Locator
Quantity
Figure 7
0
1
0
1
1
3
4
M4 X 5LG
BHCS
RATCHET
RELEASE LEVER
2
3
Figure 7
Americas Headquarters
Lisle, Illinois 60532 U.S.A.
1-800-78MOLEX
amerinfo@molex.com
Far East North Headquarters
Yamato, Kanagawa, Japan
81-462-65-2324
feninfo@molex.com
Far East South Headquarters
Jurong, Singapore
65-6-268-6868
fesinfo@molex.com
European Headquarters
Munich, Germany
49-89-413092-0
eurinfo@molex.com
Corporate Headquarters
2222 Wellington Ct.
Lisle, IL 60532 U.S.A.
630-969-4550
Fax: 630-969-1352
Visit our Web site at http://www.molex.com
Doc No: ATS-638115000
Revision: F
Release Date: 04-03-06
Revision Date: 03-27-08
UNCONTROLLED COPY
Page 8 of 8
