Hand Crimp Tool For Mini-Fit™ Jr. Crimp Terminals
Doc No: ATS-638191000 Release Date: 12-07-07 UNCONTROLLED COPY Page 1 of 8
Revision: D Revision Date: 09-16-14
HAND CRIMP
TOOL
Application Tooling
Specification Sheet
Order No. 63819-1000
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, 22-28 AWG.
Terminal
Series No.
Terminal Order No.
Wire Size
Insulation Diameter
Strip Length
Reel
AWG
mm²
mm
In.
mm
In.
5556
39-00-0047
39-00-0172
39-00-0046
39-00-0171
22-28
0.35-0-08
0.90-1.80
.035-.071
2.79-3.30
.110-.130
39-00-0066
39-00-0178
39-00-0065
39-00-0177
39-00-0086
39-00-0184
39-00-0085
39-00-0183
39-00-0092
39-00-0197
39-00-0091
39-00-0196
39-00-0111
39-00-0203
39-00-0110
39-00-0202
39-00-0117
39-00-0210
39-00-0116
39-00-0209
39-00-0140
39-00-0216
39-00-0139
39-00-0215
39-00-0156
39-00-0435
39-00-0155
39-00-0434
39-00-0166
39-00-0165
5558
39-00-0049
39-00-0129
39-00-0048
39-00-0128
22-28
0.35-0-08
0.90-1.80
035-.071
2.79-3.30
.110-.130
39-00-0068
39-00-0146
39-00-0067
39-00-0145
39-00-0088
39-00-0222
39-00-0087
39-00-0221
39-00-0098
39-00-0433
39-00-0097
39-00-0432
39-00-0123
39-00-0122
44485
44485-2211
44485-2411
44485-2212
44485-2412
44485-2311
44485-2312
22-28
0.35-0-08
0.90-1.80
035-.071
2.79-3.30
.110-.130
45750
45750-2211
22-28
0.35-0-08
0.90-1.80
035-.071
2.79-3.30
.110-.130
46018
46018-2542
46018-2541
22-28
0.35-0-08
0.90-1.80
035-.071
2.79-3.30
.110-.130
Customer to cut off terminal from reel: 0.2mm (.008”) maximum Cut-off Tab.
TYPE 4D
Hand Crimp Tool For Mini-Fit™ Jr. Crimp Terminals
Doc No: ATS-638191000 Release Date: 12-07-07 UNCONTROLLED COPY Page 2 of 8
Revision: D Revision Date: 09-16-14
INSULATION
CRIMP
▲SEE NOTE
BRUSH
STRIP
LENGTH
BELL MOUTH
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
DEFINITION OF TERMS
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the
scope.
▲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).
CONDITIONS:
After crimping, the conductor profiles should measure the following. See Notes below.
Terminal
Series No.
Wire Size
Conductor Crimp
Insulation Crimp
Pull Force
Minimum
Profile
Height (Ref.)
Width (Ref.)
Height (Ref.)
Width (Ref.)
AWG
mm2
mm
In.
mm
In.
mm
In.
mm
In.
N
Lb.
22-24
26-28
5556
22
0.35
0.69-0.79
.027-.031
1.29
.051
1.62
.064
1.60
.063
39.0
8.78
X
24
0.20
0.67-0.77
.026-.030
1.29
.051
1.62
.064
1.58
.062
29.0
6.52
X
26
0.12
0.64-0.74
.025-.029
1.27
.050
1.46
.057
1.54
.061
19.0
4.27
X
28
0.08
0.62-0.72
.024-.028
1.27
.050
1.46
.057
1.52
.060
9.8
2.20
X
5558
22
0.35
0.69-0.79
.027-.031
1.29
.051
1.62
.064
1.60
.063
39.0
8.78
X
24
0.20
0.67-0.77
.026-.030
1.29
.051
1.62
.064
1.58
.062
29.0
6.52
X
26
0.12
0.64-0.74
.025-.029
1.27
.050
1.46
.057
1.54
.061
19.0
4.27
X
28
0.08
0.62-0.72
.024-.028
1.27
.050
1.46
.057
1.52
.060
9.8
2.20
X
44485
22
0.35
0.69-0.79
.027-.031
1.29
.051
1.62
.064
1.60
.063
39.0
8.78
X
24
0.20
0.67-0.77
.026-.030
1.29
.051
1.62
.064
1.58
.062
29.0
6.52
X
26
0.12
0.64-0.74
.025-.029
1.27
.050
1.46
.057
1.54
.061
19.0
4.27
X
28
0.08
0.62-0.72
.024-.028
1.27
.050
1.46
.057
1.52
.060
9.8
2.20
X
45750
22
0.35
0.69-0.79
.027-.031
1.29
.051
1.62
.064
1.60
.063
39.0
8.78
X
24
0.20
0.67-0.77
.026-.030
1.29
.051
1.62
.064
1.58
.062
29.0
6.52
X
46018
22
0.35
0.69-0.79
.027-.031
1.29
.051
1.62
.064
1.60
.063
39.0
8.78
X
24
0.20
0.67-0.77
.026-.030
1.29
.051
1.62
.064
1.58
.062
29.0
6.52
X
OVERLAP
INSULATION
CRIMP
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
WIRE
Hand Crimp Tool For Mini-Fit™ Jr. Crimp Terminals
Doc No: ATS-638191000 Release Date: 12-07-07 UNCONTROLLED COPY Page 3 of 8
Revision: D Revision Date: 09-16-14
RELEASE
LOCATOR BUTTON
TERMINAL
Figure 3
LOCATOR
PUSHED THRU
TOOLING
TERMINAL
LOCATOR
BUTTON
PUSHED IN
LOCATOR
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.
Note:
A crimp height chart is provided with this
document as 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.
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.
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 tooling. 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 wire stop. See Figure 5.
LOCATOR
IN DOWN
POSTION
PUSH ON THE
LOCATOR BUTTON
Figure 2
SQUEEZE
HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Figure 1
Hand Crimp Tool For Mini-Fit™ Jr. Crimp Terminals
Doc No: ATS-638191000 Release Date: 12-07-07 UNCONTROLLED COPY Page 4 of 8
Revision: D Revision Date: 09-16-14
Figure 5
TERMINAL
WIRE AGAINST THE
WIRE STOP
WIRE
WIRE STOP IS PART
OF THE LOCATOR
PRE-STRIPPED
WIRE
TERMINAL
7. Crimp the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.
Release the handles to open the jaws.
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 then close the tool. See Figure 6.
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 7A with your thumb and index finger. The lower tabs of the
locator should disengage from the hand tool.
PARTIALLY
CLOSE HANDLE
TOOLING
PARTIALLY
CLOSED
Figure 4
FIRST RATCHET
POSITION
OPEN
POSITION
TERMINAL
Figure 6
WIRE
WIRE STOP
Hand Crimp Tool For Mini-Fit™ Jr. Crimp Terminals
Doc No: ATS-638191000 Release Date: 12-07-07 UNCONTROLLED COPY Page 5 of 8
Revision: D Revision Date: 09-16-14
Figure 8
PUSH ON
HANDLE
JAWS OPEN
PULL OPEN
TOOLING
TOOLING
M3 BHCS
MATCH
UP MARKS
FRONT
BACK
Figure 9
3.
4. Lift and pull away from the hand tool. The top locator hooks should slip out of the top slots easily. See Figure
7A.
5. To reinstall the new locator, make sure the
hand tool is in the open position.
6. Press the red insert down as far as it will
go as shown in Figure 7B.
7. 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.
8. 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:
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 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.
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
Figure 7B
SQUEEZE
HERE
SQUEEZE
HERE
LOCATOR
Figure 7A
TOP HOOKS
TOP SLOTS OF
HANDTOOL
LOWER TABS
Hand Crimp Tool For Mini-Fit™ Jr. Crimp Terminals
Doc No: ATS-638191000 Release Date: 12-07-07 UNCONTROLLED COPY Page 6 of 8
Revision: D Revision Date: 09-16-14
Figure 12
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
SETTING
WHEEL
RATCHET
RELEASE LEVER
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.
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 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.
How to Adjust Tool Preload (See
Figure 12)
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:
1. Hold the hand tool in the palm of your
hand as shown in Figure 10. 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).
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figure 10
RATCHET RELEASE
LEVER
Figure 11
Hand Crimp Tool For Mini-Fit™ Jr. Crimp Terminals
Doc No: ATS-638191000 Release Date: 12-07-07 UNCONTROLLED COPY Page 7 of 8
Revision: D Revision Date: 09-16-14
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, 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. 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.
Hand Crimp Tool For Mini-Fit™ Jr. Crimp Terminals
Doc No: ATS-638191000 Release Date: 12-07-07 UNCONTROLLED COPY Page 8 of 8
Revision: D Revision Date: 09-16-14
RATCHET
RELEASE LEVER
2
Figure 13
1
3
PARTS LIST
Item Number
Order Number
Description
Quantity
REF
63819-1000
Hand Crimp Tool
Figure 13
1
63819-1075
Locator Assembly
1
2
63810-0104
Spring, Return
1
3
63810-0105
Spring, Ratchet
1
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