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

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]

Far East North Headquarters

Yamato, Kanagawa, Japan

81-462-65-2324

[email protected]

Far East South Headquarters

Jurong, Singapore

65-6-268-6868

[email protected]

European Headquarters

Munich, Germany

49-89-413092-0

[email protected]

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

RATCHET

RELEASE LEVER

Figure 7

M4 X 5LG

BHCS

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