molex 63819-0900 User manual

Hand Crimp Tool ForMini-Fit™ Jr. Male and Female Crimp Terminals
Doc No: ATS-638190900 Release Date:01-24-08 UNCONTROLLED COPY Page 1 of9
Revision: A Revision Date:01-24-08
HAND CRIMP TOOL
Specification Sheet
Order No. 63819-0900
FEATURES
 A full cycle ratcheting hand tool ensures completecrimps
 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 toolis IPC/WHMAA-620 Class 2 compliantas indicated
 This toolis RoHScompliant,however RoHS compliantis notrequired
SCOPE
Products: Mini-Fit™ Jr. Male and Female Crimp Terminals,16 - 24 AWG.
Terminal Order No. Wire Size InsulationDiameter
Maximum Strip LengthTerminal
SeriesNo. Loose Piece
Æ 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

Hand Crimp Tool ForMini-Fit™Jr. Male and Female Crimp Terminals
Doc No: ATS-638190900 Release Date:01-24-08 UNCONTROLLED COPY Page 2 of9
Revision: A Revision Date:01-24-08
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
BELL MOUTH
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
Terminal Order No. Wire Size InsulationDiameter
Maximum Strip Length
Terminal
SeriesNo. Loose Piece
Æ Reel AWG mm²mm 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
Æ 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. Itis not an image of a terminal listed in the scope.

Hand Crimp Tool ForMini-Fit™Jr. Male and Female Crimp Terminals
Doc No: ATS-638190900 Release Date:01-24-08 UNCONTROLLED COPY Page 3 of9
Revision: A Revision Date:01-24-08
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
SeriesNo. 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)

Hand Crimp Tool ForMini-Fit™Jr. Male and Female Crimp Terminals
Doc No: ATS-638190900 Release Date:01-24-08 UNCONTROLLED COPY Page 4 of9
Revision: A Revision Date:01-24-08
RELEASE
LOCATOR
BUTTON
TERMINAL Figure 3
LOCATOR
PUSHED THRU
TOOLING
TERMINAL
LOCATOR
BUTTON
PUSHED IN
LOCATOR
OPERATION
CAUTION: Installonly 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. Atthe end ofthe closing stroke, the
ratchet mechanism will release the handles and
the hand tool will spring open. See Figure 1.
Crimping Terminals
1. Selectthe desired terminallisted in the
preceding charts.
2. Make sure the center ofthe 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 terminaltype
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 ratchetposition engages. See
Figure 4.
6. Insert the properly stripped wire through the terminaland against the
wire stop. See Figure 5.
7. Crimp the terminal by squeezing the tool handles until the ratchet
mechanismcycle has been completed. Release the handles to open
the jaws.
PARTIALLY
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

Hand Crimp Tool ForMini-Fit™Jr. Male and Female Crimp Terminals
Doc No: ATS-638190900 Release Date:01-24-08 UNCONTROLLED COPY Page 5 of9
Revision: A Revision Date:01-24-08
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 ithas been fully closed.
8. Remove the crimped terminal fromthe terminal
locator by pulling on the wire.
9. Visually inspect the crimped terminal for proper
crimp location.
10. On some large O.D. wires,itmay notbe 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 manualas Reference Only. Due to the wide range ofwires, strands,
insulation diameters,and durometers available,actual crimp heightmeasurements may very slightly. An
occasional, destructive, pull force testshould be performed to check hand tool crimp. Pull ForcevalueMustexceed
the Minimumpull 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

Hand Crimp Tool ForMini-Fit™Jr. Male and Female Crimp Terminals
Doc No: ATS-638190900 Release Date:01-24-08 UNCONTROLLED COPY Page 6 of9
Revision: A Revision Date:01-24-08
Figure 8
PUSH ON
HANDLE
JAWS OPEN
PULL OPEN
TOOLING
TOOLING
M3 BHCS
MATCH
UP MARKS
FRONT BACK
Figure 9
Locator Replacement
See the parts liston the last page of this documentfor
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 thehand
tool.
3. Liftand pull away from the hand tool. The top
locator hooks should slip outof the top slots easily.
See Figure 7A.
4. To reinstallthe 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 ofthe locator with your thumb and index finger, insertthe locators top hooks (2)
into the hand tooltop 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. Itis 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 BHCSwhich 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
frontand 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. Reinstallthe locator by following the Instructions in the locator replacementsection.
Maintenance
Itis 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 thatcould damage the tool.

Hand Crimp Tool ForMini-Fit™Jr. Male and Female Crimp Terminals
Doc No: ATS-638190900 Release Date:01-24-08 UNCONTROLLED COPY Page 7 of9
Revision: A Revision Date:01-24-08
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
oilexcessively. The tool was
engineered for durability but like
any other equipmentitneeds
cleaning and lubrication for a
maximumservice life oftrouble
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 fromthe 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 thecrimpingdies,
and store the tool in a clean, dry area.
Miscrimps or Jams
Should this toolever 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 presetto 25-45
LBS. preload. It may be necessary over
the life ofthe 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 ofyour hand as shown in Figure 12. Using the index finger squeeze the link
towards the top ofthe hand tool frame. This will release the preload adjustmentwheel.
2. Rotate the setting wheel counter-clockwise (CCW) to increase handle force. The numbers will display higher.
To decrease handle force rotate the setting wheelclockwise (CW).
3. Release the link to lock the setting wheelin 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

Hand Crimp Tool ForMini-Fit™Jr. Male and Female Crimp Terminals
Doc No: ATS-638190900 Release Date:01-24-08 UNCONTROLLED COPY Page 8 of9
Revision: A Revision Date:01-24-08
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 ofmanufacturing 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 toolis 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 NOTintended for
production use. Repetitive use ofthis tool should be avoided.
2. Insulated rubber handles are not protection against electricalshock.
3. Wear eye protection atalltimes.
4. Use only the Molex terminals specified for crimping with this tool.
Certification
Molex does notcertify or re-certify hand tools but rather supplies the following guidelines forcustomers 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.
% Ifthe tool does not meet minimum pull force values, handle preload should be increased and the pulltest
rerun, (See How to AdjustPreload).
% When the hand tool is no longer capable ofachieving minimum pull force,it should be taken out ofservice and
replaced.

Hand Crimp Tool ForMini-Fit™Jr. Male and Female Crimp Terminals
Doc No: ATS-638190900 Release Date:01-24-08 UNCONTROLLED COPY Page 9 of9
Revision: A Revision Date:01-24-08
RATCHET
RELEASE LEVER
2
Figure 13
1
3
PARTS LIST
Item Number Order Number Description Quantity
REF 63819-0900 Hand Crimp Tool Figure13
1 63819-0975 LocatorAssembly 1
2 63810-0104 Spring,Return 1
3 63810-0105 Spring,Ratchet 1
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[e-mail]
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CorporateHeadquarters
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Lisle, IL 60532 U.S.A.
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Fax: [phone]
Visit our Web site at http://www.molex.com