molex 63811-5100 User manual

Hand Crimp Tool for Mini-Fit Jr.™ Crimp Terminals
Doc No: ATS- 638115100 Release Date: 04-03-06 UNCONTROLLED COPY Page 1 of 7
Revision: C Revision Date: 03-27-08
TYPE 2C
HAND CRIMP TOOL
SPECIFICATION SHEET
Order No. 63811-5100
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.™ Male, and Female Crimp Terminals, 22-28 AWG.
Terminal Order No. Wire Size
 Insulation
Diameter
Maximum
Strip Length
Terminal
Series No.
Loose Piece  Reel AWG
mm² mm In. mm In.
39-00-0047 39-00-0172 39-00-0046 39-00-0171
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
5556
39-00-0166 39-00-0165
22-28 0.35-0.08 1.80 .071 2.79-3.30 .110-.130
39-00-0049 39-00-0129 39-00-0048 39-00-0128
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
5558
39-00-0123 39-00-0122
22-28 0.35-0.08 1.80 .071 2.79-3.30 .110-.130
39-00-2212 39-00-2412 39-00-2211 39-00-2411
44485 39-00-2312
39-00-2311 22-28 0.35-0.08
1.80 .071 2.79-3.30 .110-.130
 Customer to cut off terminal from reel: 0.20mm (.008”) maximum Cut-off Tab.
 See Conditions on page 2

Hand Crimp Tool for Mini-Fit Jr.™ Crimp Terminals
Doc No: ATS- 638115100 Release Date: 04-03-06 UNCONTROLLED COPY Page 2 of 7
Revision: C Revision Date: 03-27-08
INSULATION
CRIMP
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.
CONDITIONS:
After crimping, the conductor profiles should measure the following (see notes on page 5).
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. A B
22 0.35 0.76-0.86 .030-.034 1.44 .057 1.72 .068 1.61 .063 40.0 9.00 X
24 0.20 0.69-0.79 .027-.031 1.44 .057 1.72 .068 1.61 .063 31.1 7.00 X
26 0.12 0.64-0.74 .025-.029 1.44 .057 1.43 .056 1.57 .062 22.2 5.00 X
5556
28 0.08 0.61-0.71 .024-.028 1.44 .057 1.43 .056 1.57 .062 13.3 3.00 X
22 0.35 0.76-0.86 .030-.034 1.44 .057 1.72 .068 1.61 .063 40.0 9.00 X
24 0.20 0.69-0.79 .027-.031 1.44 .057 1.72 .068 1.61 .063 31.1 7.00 X
26 0.12 0.64-0.74 .025-.029 1.44 .057 1.43 .056 1.57 .062 22.2 5.00 X
5558
28 0.08 0.61-0.71 .024-.028 1.44 .057 1.43 .056 1.57 .062 13.3 3.00 X
22 0.35 0.76-0.86 .030-.034 1.44 .057 1.72 .068 1.61 .063 40.0 9.00 X
24 0.20 0.69-0.79 .027-.031 1.44 .057 1.72 .068 1.61 .063 31.1 7.00 X
26 0.12 0.64-0.74 .025-.029 1.44 .057 1.43 .056 1.57 .062 22.2 5.00 X
44485
28 0.08 0.61-0.71 .024-.028 1.44 .057 1.43 .056 1.57 .062 13.3 3.00 X
 To Achieve IPC-A-620 Class 2 Crimps, the following over-all wire insulation diameter ranges are recommended:
1. Profile A: 1.12-1.80mm (.044-.071 inch)
2. Profile B: 0.90-1.30mm (.035-.051 inch)

Hand Crimp Tool for Mini-Fit Jr.™ Crimp Terminals
Doc No: ATS- 638115100 Release Date: 04-03-06 UNCONTROLLED COPY Page 3 of 7
Revision: C Revision Date: 03-27-08
TERMINAL
PUSH HERE TO
OPEN WIRE STOP
SWING OPEN
LOCATOR
LOCATOR
TERMINAL IN PLACE
Figure 2
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.
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.
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 or B 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.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
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.
Figure 1
LOCATOR
JAWS OPEN

Hand Crimp Tool for Mini-Fit Jr.™ Crimp Terminals
Doc No: ATS- 638115100 Release Date: 04-03-06 UNCONTROLLED COPY Page 4 of 7
Revision: C Revision Date: 03-27-08
LOCATOR
IN PLACE
WIRE STOP
TERMINAL
WIRE
WIRE STOP
WIRE
AGAINST STOP
Figure 3
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 desired locator by putting over the
brass pivot shaft and snapping it into place.
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 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 6,
every 5,000 crimps or 3 months, will significantly
enhance the tool life.
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figure 5
SWING
LOCATOR
OPEN
PRESS DOWN
ON BRASS
PIVOT SHAFT
LIFT UP
LOCATOR
JAWS
OPEN
Figure 4

Hand Crimp Tool for Mini-Fit Jr.™ Crimp Terminals
Doc No: ATS- 638115100 Release Date: 04-03-06 UNCONTROLLED COPY Page 5 of 7
Revision: C Revision Date: 03-27-08
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 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:
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.
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.
RATCHET
RELEASE LEVER
Figure 6
HANDLE
GRIP
REMOVED
ECCENTRIC AXLE
HANDLE
GRIP
LOCKING
SCREW
WRENCH SET
(SOLD
SEPERATELY)
PRELOAD
CHECK POINT
25.4MM
SETTING WHEEL

Hand Crimp Tool for Mini-Fit Jr.™ Crimp Terminals
Doc No: ATS- 638115100 Release Date: 04-03-06 UNCONTROLLED COPY Page 6 of 7
Revision: C Revision Date: 03-27-08
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.

Hand Crimp Tool for Mini-Fit Jr.™ Crimp Terminals
Doc No: ATS- 638115100 Release Date: 04-03-06 UNCONTROLLED COPY Page 7 of 7
Revision: C Revision Date: 03-27-08
PARTS LIST
Item Number Order Number Description Quantity
REF 63811-5100 Hand Crimp Tool Figure 7
1 63810-0101 Wrench Set (Not included) 0
2 63810-0102 Locator Base Assembly 1
3 63810-0103 Repair Kit (Not included) 0
4 63811-5175 Locator 1
Americas Headquarters
Lisle, Illinois 60532 U.S.A.
1-800-78MOLEX
[email protected]
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Yamato, Kanagawa, Japan
81-462-65-2324
[email protected]
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Jurong, Singapore
65-6-268-6868
[email protected]
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49-89-413092-0
[email protected]
Corporate Headquarters
2222 Wellington Ct.
Lisle, IL 60532 U.S.A.
630-969-4550
Fax: [phone]
Visit our Web site at http://www.molex.com
RATCHET
RELEASE LEVER
2
Figure 7
M4 X 5LG
BHCS
3
4
1
3