Hand Crimp Tom for Minx-FMTM Jr. and Mxm-Fn HCS‘M Crimp Termina‘s /'\® molex V Products
Hand Crimp Tool for Mini-Fit Jr. and Mini-Fit HCS Crimp Terminals
Doc No: ATS-640160200 Release Date: 02-27-09 UNCONTROLLED COPY Page 1 of 5
Revision: B Revision Date: 02-27-09
ServiceGrade™ Hand Crimp Tool
Specification Sheet
Order No. 64016-0200
FEATURES
A full cycle ratcheting hand tool ensures complete crimps
Ergonomic soft grip handles for comfortable crimping
For crimps conforming to WHMA-IPCA620 Class 2, use hand crimp tools
63819-0900, and/or 63819-1000.
SCOPE
Products: Mini-Fit™ Jr. and Mini-Fit HCS™, Male and Female Crimp Terminals 16 - 28 AWG.
Terminal Wire Size Insulation Diameter
Maximum Strip Length
Series No.
Terminal Order No.
AWG mm² mm In. mm In.
39-00-0078 39-00-0158 39-00-0218
39-00-0080 39-00-0168 39-00-0448
39-00-0090 39-00-0180
39-00-0094 39-00-0186
39-00-0142
39-00-0212
16 1.3
39-00-0039 39-00-0164
39-00-0429
39-00-0056 39-00-0182 39-00-0441
39-00-0060 39-00-0195 40-13-0852
39-00-0074 39-00-0208
39-00-0154
39-00-0214
18–20
0.80-0.50
3.10 .122 3.00-3.50
.118-.138
39-00-0047 39-00-0156
39-00-0066 39-00-0166
39-00-0086 39-00-0184
39-00-0092 39-00-0210
5556
39-00-0140
39-00-0435
22-28 0.35-0.08
1.80 .071 2.79-3.30
.110-.130
39-00-0082 39-00-0125
39-00-0084 39-00-0131
39-00-0096 39-00-0224
16 1.3
39-00-0041 39-00-0076 39-00-0220
39-00-0054 39-00-0121 39-00-0431
39-00-0062 39-00-0127 40-13-0854
18–20
0.80-0.50
3.10 .122 3.00-3.50
.118-.138
39-00-0049 39-00-0098 39-00-0216
39-00-0068 39-00-0123 39-00-0222
5558
39-00-0088 39-00-0129 39-00-0433
22 - 28 0.35-0.08
1.80 .071 2.79-3.30
.110-.130
30490 30490-1012
30490-2012
18-20 0.80-0.50
3.10 .122 3.00-3.50
.118-.138
44476-3112
16 1.3
44476 44476-1112
44476-1212
18-20 0.80-0.50
3.10 .122 3.00-3.50
.118-.138
44478-3112
16 1.3
44478 44478-1112
18-20 0.80-0.50
3.10 .122 3.00-3.50
.118-.138
44485-3212
44485-3312
44485-3412
16 1.3
44485 44485-1212
44485-1312
44485-1412
18-20 0.80-0.20
3.10 .122 3.00-3.50
.118-.138
45750-3112
45750-3212
16 1.3
45750 45750-1111
45750-1211
18-20 0.80-0.50
3.10 .122 3.00-3.50
.118-.138
46012-3142
46012-3242
16 1.3
46012 46012-1142
46012-1242
18-20 0.80-0.50
3.10 .122 3.00-3.50
.118-.138
Hand Crim Tom for Minx-FMTM Jr. and Mxm-Fn HCS‘M Crim Termina‘s
Hand Crimp Tool for Mini-Fit Jr. and Mini-Fit HCS Crimp Terminals
Doc No: ATS-640160200 Release Date: 02-27-09 UNCONTROLLED COPY Page 2 of 5
Revision: B Revision Date: 02-27-09
Terminal Wire Size Insulation Diameter
Maximum Strip Length
Series No.
Terminal Order No.
AWG mm² mm In. mm In.
46018-3542
16 1.3
46018 46018-1541
18-20 0.80-0.50
3.10 .122 3.00-3.50
.118-.138
46083-3112
46083-3122
46083-3212
46083-1111
46083-3222
16 1.3
46083-1211
46083
46083-1121
46083-1221
18-20 0.80-0.50
3.10 .122 3.00-3.50
.118-.138
46098-3542
16 1.3
46098 46098-1541
18-20 0.80-0.50
3.10 .122 3.00-3.50
.118-.138
For the 22 and 24AWG terminals in this series use hand crimp tool 63819-0900
Crimping Information:
Crimp the terminal and appropriate gauge wire in the specified profile. Crimp profile “A” is for small-insulation
terminals (do not crimp 22 or 24 AWG from an 18-24 AWG terminal in this profile).
Wire Size Pull Force Min. ▼ Tool Crimp Profile
Terminal Series No
AWG
mm2
N Lb. A B C
16 1.30 68.5
15.40 X
18 0.80 88.0
19.80 X
20 0.50 58.7
13.20 X
22 0.35 39.1
8.80 X
24 0.20 29.3
6.60 X
26 0.12 22.2
5.0 X
5556, 5558
28 0.08 13.3
3.0 X
18 0.80 88.0
19.80 X
30490 20 0.50 58.7
13.20 X
16 1.30 68.5
15.40 X
18 0.80 88.0
19.80 X
44476, 44478,45750
20 0.50 58.7
13.20 X
16 1.30 68.5
15.40 X
18 0.80 88.0
19.80 X
44485
20 0.50 58.7
13.20 X
16 1.30 68.5
15.40 X
18 0.80 68.5
15.40 X
46012, 46018, 46083,46098
20 0.50 58.7
13.20 X
▼ Pull force test samples should not have the wire insulation crimped.
Hand Crimp Tom for Minx-FMTM Jr. and Mxm-Fn HCS‘M Crimp Termina‘s DER DER
Hand Crimp Tool for Mini-Fit Jr. and Mini-Fit HCS Crimp Terminals
Doc No: ATS-640160200 Release Date: 02-27-09 UNCONTROLLED COPY Page 3 of 5
Revision: B Revision Date: 02-27-09
SHELF OF
HAND TOOL
CENTER TERMINAL OVER
CRIMP PROFILE
TERMINAL HOLDER
WIRE
CENTER CONDUCTOR
GRIP OVER THE
CONDUCTOR ANVIL
SHELF OF
HAND TOOL
Figure 2
TERMINAL CENTERED
IN TOOL HOLDER
PRESS DOWN
LEVER TO OPEN
CONDUCTOR
GRIP
Figure 1
TERMINAL HOLDER
CLOSED ON TERMINAL
INSULATION GRIP
TERMINAL HOLDER
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.
Remove the terminal holder from the tool and set it aside.
Open the hand tool by squeezing the handles together; at the end of the closing stroke the anti-backup ratchet will
release. Release the handles and the hand tool will open.
Crimping Terminals
1. Select the desired terminal listed in the preceding charts.
2. Open the terminal holder by pressing down the lever and place the terminal in the holder.
Note: The above illustration is a general representation. Some of the terminals may look different and be held in a
different area of the terminal.
3. Release the lever to hold the terminal in place. See Figure 1.
Hand Crimp Tom for Minx-FMTM Jr. and Mxm-Fn HCS‘M Crimp Termina‘s
Hand Crimp Tool for Mini-Fit Jr. and Mini-Fit HCS Crimp Terminals
Doc No: ATS-640160200 Release Date: 02-27-09 UNCONTROLLED COPY Page 4 of 5
Revision: B Revision Date: 02-27-09
4. Carefully place the terminal holder on the shelf of the hand tool and center the terminal as shown over the
appropriate tool crimp profile. See Figure 2.
Note: Some terminals may have a large insulation grip; extra care should be taken when loading these
terminals into the tool to avoid terminal damage.
5. Place a pre-stripped wire into the terminal (see Scope chart for
recommended strip lengths). Position the wire so the conductor lies
in the conductor grip.
6. While holding the wire in place, slowly close the handles of the tool.
If excessive resistance is felt, there may be a jam. If this occurs,
stop closing the tool and release the anti-backup ratchet by lifting up
the lever near the top of the moving handle. See figure 3.
7. Continue to close the tool handles until the anti-backup ratchet
releases. Allow the handles to open.
8. Remove the crimped terminal and terminal holder from the tool.
9. Press down the lever on the terminal holder and remove the crimped
terminal.
10. Inspect the crimp for loose wire strands, missing crimp, or other
damage. Any minor terminal bending may be straightened by hand.
Note:
An occasional, destructive, pull force test with the terminal and wire
crimped should be performed to check hand tool crimp. The pull force value must exceed the terminal’s minimum
pull force specifications listed on page 3. If values do not exceed the minimum pull force when all instructions are
followed then a new tool is required.
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. Light oil (such
as SAE30W oil) applied at the oil points, shown in Figure 4, every 5,000 crimps or 3 months, is recommended.
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.
Fig
ure
4
Fig
ure
3
RATCHET
RELEASE
LEVER
LIFT UP
LEVER
Hand Crimp Tom for Minx-FMTM Jr. and Mxm-Fn HCS‘M Crimp Termina‘s CAUTIONS:
Hand Crimp Tool for Mini-Fit Jr. and Mini-Fit HCS Crimp Terminals
Doc No: ATS-640160200 Release Date: 02-27-09 UNCONTROLLED COPY Page 5 of 5
Revision: B Revision Date: 02-27-09
Miscrimps or Jams
If the tool ever becomes jammed in a partially closed position, DO NOT force the handles open or closed. The tool
will open by lifting the ratchet release lever. See Figure 3.
Tool Handle Preload
Tool handle preload cannot be adjusted.
This hand tool is set to a preload that will fully close the tool jaws without excessive force from the operator. Over
the life of the tool the tool linkage can wear and handle preload force may decrease. It is the operator’s
responsibility to periodically perform a tensile pull test on the crimped wire. If the pull test value falls below
specification, the tool should be replaced.
Warranty
This tool is for electrical terminal crimping purposes only. All tools are warranted to be free of manufacturing
defects for a period of 30 days. Should such a defect occur, the tool will be exchanged free of charge. This
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. NEVER perform crimps on active
electrical circuits.
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 ServiceGrade™ hand tools but rather supplies the following guidelines for
customers to maintain their 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.
% When the hand tool is no longer capable of achieving minimum pull force, it should be replaced.
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49-89-413092-0
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