0638190901 Appl Tooling Spec Datasheet by Molex

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x b o m Order No. 635 19-0901
Hand Crimp Tool For Mini-Fit Jr. Male and Female Crimp Terminals
Doc. No: 638190901 Release Date: 04-24-18 UNCONTROLLED COPY Page 1 of 9
Revision: A Revision Date: 04-24-18
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 wire stop 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
This tool is IPC/WHMA-A-620 Class 2 compliant, as indicated on page 3
Many different tool kits can be used with a single Battery Powered Crimp Tool
This tool is RoHS compliant; however, RoHS compliance is not required
SCOPE
Products: Mini-Fit Jr. Male and Female Crimp Terminals, 18-24 AWG.
Terminal
Series No.
Terminal Order No.
Wire Size
Insulation Diameter
Maximum +
Strip Length
Loose Piece
Reel
AWG
In.
mm
In.
5556
39-00-0039
39-00-0182
39-00-0038
39-00-0181
18-24
.122
3.00-3.30
.118-.130
39-00-0056
39-00-0195
39-00-0055
39-00-0194
39-00-0060
39-00-0201
39-00-0059
39-00-0200
39-00-0074
39-00-0208
39-00-0073
39-00-0207
39-00-0109
39-00-0214
39-00-0108
39-00-0213
39-00-0115
39-00-0406
39-00-0114
39-00-0405
39-00-0154
39-00-0408
39-00-0153
39-00-0407
39-00-0164
39-00-0429
39-00-0163
39-00-0428
39-00-0170
39-00-0441
39-00-0169
39-00-0440
39-00-0176
40-13-0852
39-00-0175
40-13-0851
5558
39-00-0041
39-00-0127
39-00-0040
39-00-0126
18-24
.122
3.00-3.30
.118-.130
39-00-0054
39-00-0220
39-00-0053
39-00-0219
39-00-0062
39-00-0431
39-00-0061
39-00-0430
39-00-0076
40-13-0854
39-00-0075
40-13-0853
39-00-0121
39-00-0120
30490
30490-1012
30490-2012
30490-1002
30490-9802
18-24
.122
3.00-3.30
.118-.130
30490-2002
30490-9902
44476
44476-1112
44476-1212
44476-1111
18-20
.122
3.00-3.30
.118-.130
44478
44478-1112
44478-1111
44478-1211
18-20
.122
3.00-3.30
.118-.130
Type 4D
Order No. 63819-0901
er .20 .30 Z 1 Z 1 .50 .30 Z 1 .50 .30 Z 1 .50 .30 Z 1 .50 .30 Z 1 Z 1 .50 .30 STRIP LENGYH BELL MOUTH NDUCYO CRIMP
Hand Crimp Tool For Mini-Fit Jr. Male and Female Crimp Terminals
Doc. No: 638190901 Release Date: 04-24-18 UNCONTROLLED COPY Page 2 of 9
Revision: A Revision Date: 04-24-18
INSULATION
CRIMP
SEE NOTE
BRUSH
STRIP
LENGTH
BELL MOUTH
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLL
CONDUCTOR
CRIMP
TWIST
Terminal
Series No.
Terminal Order No.
Wire Size
Insulation Diameter
Maximum +
Strip Length
Loose Piece
Reel
AWG
In.
mm
In.
44485
44485-1212
44485-1412
44485-1211
44485-1411
18-24
.122
3.00-3.30
.118-.130
44485-1312
44485-1311
45750
45750-1112
45750-1212
45750-1111
45750-1211
18-20
.122
3.00-3.30
.118-.130
46012
46012-1142
46012-1242
46012-1141
46012-1241
18-20
.122
3.00-3.30
.118-.130
46018
46018-1542
46018-1541
18-20
.122
3.00-3.30
.118-.130
46083
46083-1112
46083-1212
46083-1111
46083-1211
18-20
.122
3.00-3.30
.118-.130
46083-1122
46083-1222
46083-1121
46083-1221
46098
46098-1542
46098-1541
18-20
.122
3.00-3.30
.118-.130
Customer to cut off terminals from reel: 0.2mm (.008”) maximum cut-off tab.
+ See conditions on page 3.
DEFINITION OF TERMS
The above terminal drawing is a generic terminal representation. It is not an image of a terminal
listed in the scope.
Height(Ref.) Width(Ref.) Height (Ref.) Width(Ref.) AWG mm mm In. mm In. mm In. mm In. N Lb. 18 20-24 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 90 .031-.035 1.63 .064 2.24 .088 2.61 .103 39.1 8.00 x 24 0.20 .030-.034 1.63 .064 2.21 .087 2.60 .102 29.3 6.60 x 18 0.80 .039-.043 1.69 .067 2.38 .094 2.68 .106 88.0 19.80 x 20 0.50 .033-.037 1.64 .065 2.24 .088 2.65 .104 58.7 13.20 x 22 0.35 .031-.035 1.63 .064 2.24 .088 2.61 .103 39.1 8.00 x 24 0.20 .030-.034 1.63 .064 2.21 .087 2.60 .102 29.3 6.60 x 18 0.80 .039-.043 1.69 .067 2.38 .094 2.68 .106 88.0 19.80 x 20 0.50 .033-.037 1.64 .065 2.24 .088 2.65 .104 58.7 13.20 x 22 0.35 .031-.035 1.63 .064 2.24 .088 2.61 .103 39.1 8.00 x 24 0.20 .030-.034 1.63 .064 2.21 .087 2.60 .102 29.3 6.60 x 18 0.80 .039-.043 1.69 .067 2.38 .094 2.68 .106 68.5 15.40 x 20 0.50 .033-.037 1.64 .065 2.24 .088 2.65 .104 58.7 13.20 x 18 0.80 1.00- .039-.043 1.69 .067 2.38 .094 2.68 .106 68.5 15.40 x 20 0.50 .033-.037 1.64 .065 2.24 .088 2.65 .104 58.7 13.20 x 18 0.80 .039-.043 1.69 .067 2.38 .094 2.68 .106 68.5 15.40 x 20 0.50 .033-.037 1.64 .065 2.24 .088 2.65 .104 58.7 13.20 x 22 0.35 .031-.035 1.63 .064 2.24 .088 2.61 .103 39.1 8.00 x 24 0.20 .030-.034 1.63 .064 2.21 .087 2.60 .102 29.3 6.60 x 20 0.50 .033-.037 1.64 .065 2.24 .088 2.65 .104 58.7 13.20 x 18 0.80 .039-.043 1.69 .067 2.38 .094 2.68 .106 68.5 15.40 x 20 0.50 .033-.037 1.64 .065 2.24 .088 2.65 .104 58.7 13.20 x 18 0.80 .039-.043 1.69 .067 2.38 .094 2.68 .106 68.5 15.40 x 20 0.50 .033-.037 1.64 .065 2.24 .088 2.65 .104 58.7 13.20 x 18 0.80 .039-.043 1.69 .067 2.38 .094 2.68 .106 68.5 15.40 x 20 0.50 .033-.037 1.64 .065 2.24 .088 2.65 .104 58.7 13.20 x 18 0.80 1.00- .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 . 20-24 AWG Profile: 1.70-2.30mm (.067-.091")
Hand Crimp Tool For Mini-Fit Jr. Male and Female Crimp Terminals
Doc. No: 638190901 Release Date: 04-24-18 UNCONTROLLED COPY Page 3 of 9
Revision: A Revision Date: 04-24-18
CONDITIONS
After crimping, the conductor profiles should measure the following:
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.
18
20-24
5556
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
5558
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
30490
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
44476
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
44478
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
44485
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
45750
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
46012
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
46018
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
46083
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
46098
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/WHMA-A-620 Class 2 crimps, the following overall wire insulation diameter ranges are recommended:
18 AWG Profile: 1.70-2.30mm (.067-.091”)
20-24 AWG Profile: 1.70-2.30mm (.067-.091)
Tool Qualification Notes
1. (Ref) means that the dimension provided is approximate because of the wide range of
wires, conductor stranding, insulation diameter and insulation hardness.
2. An occasional pull force test should be performed. It must exceed the minimum pull force
specification.
3. Pull force should be measured with no influence from the insulation crimp. To ensure this,
strip the wire long enough so the terminal insulation grips do not contact the wire
insulation.
PUNCH / \ 7 7\ w w \ TERMINAL Figure 3 ANDLE wll-L RING OPEN TERMINAL
Hand Crimp Tool For Mini-Fit Jr. Male and Female Crimp Terminals
Doc. No: 638190901 Release Date: 04-24-18 UNCONTROLLED COPY Page 4 of 9
Revision: A Revision Date: 04-24-18
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).
Note
A crimp height chart is provided with this document as a reference only. Because of 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 because 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 1.
OVERLAP
INSULATION
CRIMP
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
WIRE
LOCATOR
IN DOWN
POSTION
PUSH ON THE
LOCATOR BUTTON
Figure 2
SQUEEZE HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Figure 1
TERMINAL
Figure 3
LOCATOR
PUSHED THROUGH
TOOLING
TERMINAL
RELEASE
LOCATOR
BUTTON
LOCATOR
BUTTON
PUSHED IN
TERMINAL
LOCATOR
00 Q TERMINAL ‘\ U ® \ \ \ ¢ 1 U Figure 5 6/ \ j) x K L/ \_\_ \ \ RE 'i'ERMINAL
Hand Crimp Tool For Mini-Fit Jr. Male and Female Crimp Terminals
Doc. No: 638190901 Release Date: 04-24-18 UNCONTROLLED COPY Page 5 of 9
Revision: A Revision Date: 04-24-18
Figure 5
TERMINAL
WIRE
WIRE STOP IS PART
OF THE LOCATOR
PRE-STRIPPED
WIRE
TERMINAL
WIRE AGAINST
THE WIRE STOP
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.
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,
and 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. Gently squeeze 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
\‘ LOCAYOR TOOLING Maancs 0) fl, \ ‘ V ~ fl \
Hand Crimp Tool For Mini-Fit Jr. Male and Female Crimp Terminals
Doc. No: 638190901 Release Date: 04-24-18 UNCONTROLLED COPY Page 6 of 9
Revision: A Revision Date: 04-24-18
3. Lift and pull the locator 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’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.
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.
Figure 8
PUSH ON HANDLE
JAWS OPEN
PULL OPEN
TOOLING
TOOLING
M3 BHCS
MATCH
UP MARKS
FRONT
BACK
Figure 9
SQUEEZE
HERE
LOCATOR
Figure 7A
SQUEEZE
HERE
TOP HOOKS
TOP SLOTS OF
HAND TOOL
LOWER TABS
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
Figure 7B
Hand Crimp Tool For Mini-Fit Jr. Male and Female Crimp Terminals
Doc. No: 638190901 Release Date: 04-24-18 UNCONTROLLED COPY Page 7 of 9
Revision: A Revision Date: 04-24-18
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.
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 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 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.
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figure 10
RATCHET RELEASE
LEVER
Figure 11
Figure 12
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
SETTING
WHEEL
RATCHET
RELEASE LEVER
CAUTIONS:
Hand Crimp Tool For Mini-Fit Jr. Male and Female Crimp Terminals
Doc. No: 638190901 Release Date: 04-24-18 UNCONTROLLED COPY Page 8 of 9
Revision: A Revision Date: 04-24-18
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.
Item Number Order Number Description Quantity 1 6351970975 Locator Assembly 1 2 638100104 Spring, Return 1 Figure 13
Hand Crimp Tool For Mini-Fit Jr. Male and Female Crimp Terminals
Doc. No: 638190901 Release Date: 04-24-18 UNCONTROLLED COPY Page 9 of 9
Revision: A Revision Date: 04-24-18
2
Figure 13
1
3
PARTS LIST
Item Number
Order Number
Description
Quantity
REF
63819-0901
Hand Crimp Tool
Figure 13
1
63819-0975
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
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trademarks listed herein belong to their respective owners.

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