Hand Crimp Tool for Mini-Fit Sr. ™ Grounding Crimp Terminals Hand Crimp Tool Specification Sheet Order No. 63811-3800 FEATURES % % % % TYPE 4A A full cycle ratcheting hand tool ensures complete crimps Ergonomically designed soft handles Precisely designed crimping profiles with simple contact positioning Easy handling due to outstanding force ratio SCOPE Products: 10.00mm (.393") Pitch Mini-Fit Sr. ™ Male and Female Grounding Crimp Terminals, 14-16 AWG. Terminal Series No. Terminal Order No. Wire Size ●Reel Loose AWG mm² Insulation Diameter Maximum mm In. Strip Length mm 42815-0040 42815-0048 3.33 .131 4.25-4.75 42815-0041 42815-0049 14-16 2.00-1.30 42815-0042 42817-0040 42817-0140 42817-0041 42817-0141 3.33 .131 4.25-4.75 42817-0042 42817-0142 14-16 2.00-1.30 42817-0048 42817-0149 42817-0049 ●Customer to cut off terminal from reel: 0.50mm (.020”) maximum Cut-off Tab. 42815 42817 In. .167-.187 .167-.187 DEFINITION OF TERMS WIRE INSULATION 3.75mm ± 0.20 3.75mm ± 0.20 CONTACT GAP 1.00mm ± .20 BEND UP SEAM BELL MOUTH CONTACT GAP 0.00mm - 0.05mm TWISTING ROLLING BEND DOWN The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the scope. Doc No: ATS-638113800 Revision: C Release Date: 02-19-03 Revision Date: 04-24-08 UNCONTROLLED COPY Page 1 of 4 Hand Crimp Tool for Mini-Fit Sr. ™ Grounding Crimp Terminals CONDITIONS: After crimping, the crimp profiles should measure the following (see notes on page 3). Terminal Series No. 42815 42817 Wire Size AWG 14 16 14 16 mm2 2.00 1.30 2.00 1.30 Conductor Crimp Height (REF) Width (Ref) mm In. mm In. 1.89-1.99 .074-.078 3.20 .126 1.82-1.92 .072-.075 3.20 .126 1.89-1.99 .074-.078 3.20 .126 1.82-1.92 .072-.075 3.20 .126 Insulation Crimp Width (Ref) mm In. 4.50 .177 4.50 .177 4.50 .177 4.50 .177 OPERATION Pull Force Minimum N 222.4 133.4 222.4 133.4 Profile Lb. A 50.00 X 30.00 50.00 X 30.00 B X X PRE-STRIPPED WIRE 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. Place the terminal into the correct die profile (A or B) until the terminal stopped by the locator. 2. Partially close the tool until the terminal is held in place. See Figure 1. 3. Place a pre-striped wire into the terminal and align the wire with the conductor and insulation grips visually. See Figure 2. 4. Close the tool until the ratchet releases. 5. Carefully remove the crimped terminal. TERMINAL Figure 1 CONDUCTOR GRIPS LOCATOR INSULATION GRIPS Note: The tamper proof ratchet action will not release the tool until it has been fully closed. Maintenance It is recommended that each operator of the tool be made aware of, and responsible for, the following maintenance steps: WIRE TERMINAL Figure 2 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 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. Doc No: ATS-638113800 Revision: C Release Date: 02-19-03 Revision Date: 04-24-08 UNCONTROLLED COPY Page 2 of 4 Hand Crimp Tool for Mini-Fit Sr. ™ Grounding Crimp Terminals 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 lifting the ratchet release lever. See Figure 3. 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: Repetitive use of this tool should be avoided. 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. Notes: 1. This tool should only be used for the terminals and wire gauges specified on this sheet. 2. This tool is not adjustable for crimp height, however crimp force is adjustable (See instructions above). Variations in tools, terminals, wire stranding and insulation types may affect crimp height. 3. This tool is intended for standard conductor sizes. It may not give a good insulation crimp support for all insulation sizes. 4. Molex does not repair hand tools (see warranty above) The replacement parts listed are the only parts available for repair. If the handles or crimp tooling is damaged or worn, a new tool must be purchased. 5. Pull force should be used as the final criteria for an acceptable crimp. Pull force is measured with no influence from the insulation crimp. The insulation should be stripped long (1/2 in.) so the insulation grips on the terminal do not grip the wire insulation or the conductor. Refer to Molex Quality Crimping Handbook 63800-0029 for additional information on crimping and crimp testing. 6. Molex does not certify crimp hand tools. CAUTION: Molex crimp specifications are valid only when used with Molex terminals and tooling. Doc No: ATS-638113800 Revision: C Release Date: 02-19-03 Revision Date: 04-24-08 UNCONTROLLED COPY Page 3 of 4 Hand Crimp Tool for Mini-Fit Sr. ™ Grounding Crimp Terminals PARTS LIST Item Order Number Description Quantity 1 63600-0520 Crimping Spring 2 2 63811-3875 Locator 1 3 63600-0525 Handle Spring 1 M4 X 12mm LONG BHCS RATCHET RELEASE LEVER 2 BEL 3 LOCATOR 1 HANDLE SPRING CRIMPING SPRING (2) Figure 3 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 Doc No: ATS-638113800 Revision: C Release Date: 02-19-03 Revision Date: 04-24-08 UNCONTROLLED COPY Page 4 of 4