Molex 4d User manual

Hand Crimp Tool For Mini-Fit™ Jr. Male and Female Crimp Terminals

Doc No: ATS-638190900 Release Date: 01-24-08 UNCONTROLLED COPY Page 1 of 9

Revision: B Revision Date: 02-26-09

HAND CRIMP TOOL

Specification Sheet

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

This tool is IPC/WHMA A-620 Class 2 compliant as indicated

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 Order No. Wire Size Insulation Diameter

Maximum Strip Length

Terminal

Series No. Loose Piece 



Reel AWG mm² mm In. 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

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

16 1.30 3.10 .122 3.00-3.50 .118-.138

39-00-0039 39-00-0182 39-00-0038 39-00-0181

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

5556

39-00-0176 40-13-0852 39-00-0175 40-13-0851

18-24 0.80-0.20 3.10 .122 3.00-3.50 .118-.138

39-00-0082 39-00-0131 39-00-0081 39-00-0130

39-00-0084 39-00-0148 39-00-0083 39-00-0147

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

16 1.30 3.10 .122 3.00-3.50 .118-.138

39-00-0041 39-00-0127 39-00-0040 39-00-0126

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

5558

39-00-0121 39-00-0120

18-24 0.80-0.20 3.10 .122 3.00-3.50 .118-.138

TYPE 4D

WWW.100Y.COM.TW WWW.100Y.COM.TW WWW.100Y.COM.TW

Hand Crimp Tool For Mini-Fit™ Jr. Male and Female Crimp Terminals

Doc No: ATS-638190900 Release Date: 01-24-08 UNCONTROLLED COPY Page 2 of 9

Revision: B Revision Date: 02-26-09

INSULATION

CRIMP

BRUSH

STRIP

LENGTH

BELL MOUTH

CRIMP HEIGHT

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP

TWISTING

Terminal Order No. Wire Size Insulation Diameter

Maximum Strip Length

Terminal

Series No. Loose Piece 



Reel AWG mm² mm In. mm In.

30490-1012 30490-2012 30490-1002 30490-9802

30490 30490-2002 30490-9902

18-24 0.80-0.20 3.10 .122 3.00-3.50 .118-.138

44476-3112 44476-3111 16 1.30

44476 44476-1112 44476-1212 44476-1111 18-20 0.80-0.50 3.10 .122 3.00-3.50 .118-.138

44478-3112 44478-3212 44478-3111 44478-3211 16 1.30

44478 44478-1112 44478-1111 44478-1211 18-20 0.80-0.50

3.10 .122 3.00-3.50 .118-.138

44485-3212 44485-3412 44485-3211 44485-3411

44485-3312 44485-3311 16 1.30

44485-1212 44485-1412 44485-1211 44485-1411

44485

44485-1312 44485-1311 18-24 0.80-0.20

3.10 .122 3.00-3.50 .118-.138

45750-3112 45750-3212 45750-3111 45750-3211 16 1.30

45750 45750-1112 45750-1212 45750-1111 45750-1211 18-20 0.80-0.50 3.10 .122 3.00-3.50 .118-.138

46012-3142 46012-3242 46012-3141 46012-3241 16 1.30

46012 46012-1142 46012-1242 46012-1141 46012-1241 18-20 0.80-0.50 3.10 .122 3.00-3.50 .118-.138

46018-3542 46018-3541 16 1.30

46018 46018-1542 46018-1541 18-20 0.80-0.50

3.10 .122 3.00-3.50 .118-.138

46083-3112 46083-3212 46083-3111 46083-3211

46083-3122 46083-3222 46083-3121 46083-3221 16 1.30

46083-1112 46083-1212 46083-1111 46083-1211

46083

46083-1122 46083-1222 46083-1121 46083-1221 18-20 0.80-0.50

3.10 .122 3.00-3.50 .118-.138

46098-3542 46098-3541 16 1.30

46098 46098-1542 46098-1541 18-20 0.80-0.50

3.10 .122 3.00-3.50 .118-.138

Customer to cut off terminal 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.

WWW.100Y.COM.TW WWW.100Y.COM.TW WWW.100Y.COM.TW

Hand Crimp Tool For Mini-Fit™ Jr. Male and Female Crimp Terminals

Doc No: ATS-638190900 Release Date: 01-24-08 UNCONTROLLED COPY Page 3 of 9

Revision: B Revision Date: 02-26-09

CONDITIONS:

After crimping, the conductor profiles should measure the following.

Conductor Crimp Insulation Crimp

Wire Size Height (Ref.) Width (Ref.) Height (Ref.) Width (Ref.)

Pull Force

Minimum +Profile

Terminal

Series No. AWG mm2mm 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

5556

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

5558

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

30490

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

44476

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

44478

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

44485

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

45750

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

46012

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

46018

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

46083

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

46098

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: 1.90-3.10mm (.075-.122 inch)

18 AWG Profile: 1.68-2.85mm (.066-.112 inch)

20-24 AWG Profile: 1.40-2.54mm (.055-.100 inch)

WWW.100Y.COM.TW WWW.100Y.COM.TW WWW.100Y.COM.TW

Hand Crimp Tool For Mini-Fit™ Jr. Male and Female Crimp Terminals

Doc No: ATS-638190900 Release Date: 01-24-08 UNCONTROLLED COPY Page 4 of 9

Revision: B Revision Date: 02-26-09

RELEASE

LOCATOR

BUTTON

TERMINAL Figure 3

LOCATOR

PUSHED THRU

TOOLING

TERMINAL

LOCATOR

BUTTON

PUSHED IN

LOCATOR

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. 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.

7. Crimp the terminal by squeezing the tool handles until the ratchet

mechanism cycle has been completed. Release the handles to open

the jaws.

PARTIALL

Y

CLOSE HANDLE

TOOLING

PARTIALLY

CLOSED

Figure 4

FIRST RATCHET

POSITION

OPEN

POSITION

SQUEEZE

HANDLES

TOGETHER

HANDLE WILL

SPRING OPEN

Figure 1

LOCATOR

IN DOWN

POSTION

PUSH ON THE

LOCATOR BUTTON

Figure 2

WWW.100Y.COM.TW WWW.100Y.COM.TW WWW.100Y.COM.TW

Hand Crimp Tool For Mini-Fit™ Jr. Male and Female Crimp Terminals

Doc No: ATS-638190900 Release Date: 01-24-08 UNCONTROLLED COPY Page 5 of 9

Revision: B Revision Date: 02-26-09

Figure 5 TERMINAL

WIRE AGAINST THE

WIRE STOP

WIRE

WIRE STOP IS PART

OF THE LOCATOR

PRE-STRIPPED

WIRE

TERMINAL

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.

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 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.

TERMINAL

Figure 6

WIRE

WIRE STOP

SQUEEZE

HERE

SQUEEZE

HERE

LOCATOR

Figure 7A

TOP HOOKS

TOP SLOTS OF

HANDTOOL

LOWER TABS

MAKE SURE

CENTER OF LOCATOR

IS IN THE

DOWN POSITION

Figure 7B

WWW.100Y.COM.TW WWW.100Y.COM.TW WWW.100Y.COM.TW

Hand Crimp Tool For Mini-Fit™ Jr. Male and Female Crimp Terminals

Doc No: ATS-638190900 Release Date: 01-24-08 UNCONTROLLED COPY Page 6 of 9

Revision: B Revision Date: 02-26-09

Figure 8

PUSH ON

HANDLE

JAWS OPEN

PULL OPEN

TOOLING TOOLING

M3 BHCS

MATCH

UP MARKS

FRONT BAC

K

Figure 9

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.

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:

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.

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.

WWW.100Y.COM.TW WWW.100Y.COM.TW WWW.100Y.COM.TW

Hand Crimp Tool For Mini-Fit™ Jr. Male and Female Crimp Terminals

Doc No: ATS-638190900 Release Date: 01-24-08 UNCONTROLLED COPY Page 7 of 9

Revision: B Revision Date: 02-26-09

Figure 12

SQUEEZE

THE LINK IN

THE HANDLE

HOLD THE HAND

TOOL IN POSITION

SETTING

WHEEL

RATCHET

RELEASE LEVER

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 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.

LUBRICATION POINTS

(BOTH SIDES) LIGHT OIL

(EVERY 3 MONTHS OR

5,000 CRIMPS)

Figure 10

RATCHET RELEASE

LEVER

Figure 11

WWW.100Y.COM.TW WWW.100Y.COM.TW WWW.100Y.COM.TW

Hand Crimp Tool For Mini-Fit™ Jr. Male and Female Crimp Terminals

Doc No: ATS-638190900 Release Date: 01-24-08 UNCONTROLLED COPY Page 8 of 9

Revision: B Revision Date: 02-26-09

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.

WWW.100Y.COM.TW WWW.100Y.COM.TW WWW.100Y.COM.TW

Hand Crimp Tool For Mini-Fit™ Jr. Male and Female Crimp Terminals

Doc No: ATS-638190900 Release Date: 01-24-08 UNCONTROLLED COPY Page 9 of 9

Revision: B Revision Date: 02-26-09

RATCHET

RELEASE LEVER

2

Figure 13

1

3

PARTS LIST

Item Number Order Number Description Quantity

REF 63819-0900 Hand Crimp Tool Figure 13

1 63819-0975 Locator Assembly 1

2 63810-0104 Spring, Return 1

3 63810-0105 Spring, Ratchet 1

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

WWW.100Y.COM.TW WWW.100Y.COM.TW WWW.100Y.COM.TW

molex 4D User manual

Popular Crimping Tools manuals by other brands