Molex 64001-8800 User manual

Tool Kit for AviKrimpFully Insulated and-Insulated Quick Disconnect Flags

Doc No: ATS-6400188HM Release Date: 04-08-15 UNCONTROLLED COPY Page 1 of 9

Revision: B Revision Date: 06-17-15

Application Tooling

Specification Sheet

Tool Kit

Order No. 64001-8870

Hand Crimp Tool

Order No. 64001-8800

FEATURES

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

Tool kits are easily installed into the Hand Crimp Tool or the 63816-0300 Power Crimp Head which is installed

into the 63816-0200 (110 V) or the 63816-0250 (220 V) Battery Powered Tool.

Many different Tool kits can be used with a single Battery Powered Tool.

SCOPE

Products: AviKrimpFully Insulated and-Insulated Quick Disconnect Flags 10-12 AWG.

Testing

Mechanical

The tensile test or pull test is a means of evaluating the mechanical properties of the crimped connections. The

following chart shows the UL specifications for various wire sizes. The tensile strength is shown in pounds and

indicates the minimum acceptable force to break or separate the terminal from the conductor.

Wire Size (AWG)

*UL - 310

*UL –310 –Quick Disconnects

CONDITIONS:

The following is a partial list of the product part numbers and their specifications that this tool is designed to

crimp. We will be adding to this list and an up to date copy is available on www.molex.com.

Wire Size: 10 –12 AWG 5.00 –3.30 mm²

Terminal No.

Terminal Eng. No. (REF)

Wire Strip Length

Insulation Diameter Maximum

In.

19006-0019

C-5211

.344

8.73

.245

6.22

19007-0040

C-2211

.344

8.73

.260

6.60

19007-0082

C-2211V

.344

8.73

.260

6.60

TYPE 4C

Tool Kit for AviKrimpFully Insulated and-Insulated Quick Disconnect Flags

Doc No: ATS-6400188HM Release Date: 04-08-15 UNCONTROLLED COPY Page 2 of 9

Revision: B Revision Date: 06-17-15

MAXIMUM

INSULATION

DIAMETER

STRIP LENGTH

CONDUCTOR

CRIMP

CUT-OFF TAB

WIRE

SWING

LOCATOR

OPEN

PRESS DOWN

ON THE BRASS

PIVOT SHAFT

LIFT UP ON

THE LOCATOR

Figure 2

ANVILS

POWER

CRIMP

HEAD

Figure 1

PUNCHES

M4 X 10 LONG

BHCS

M4 X 18 LONG

BHCS

DEFINITION OF TERMS

CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects as damage can

occur to the tool or die.

INSTALLATION

To install the Tool Kit into the Power Crimp Head follow the steps below:

Anvils and Punches Installation

1. Insert the Anvils into the bottom slots of the nest. Install the M4 x 10 long BHCS and tighten in place.

2. Insert the Punches into the top slots of the nest. Install the M4 x 18 long BHCS and tighten in place. See

Figure 1.

Locator Installation and Removal

Follow the steps below to install or replace the locator. See Figure 2.

To install the locator

1. Position the locator with the hole over the brass pivot shaft and snap it into place.

Tool Kit for AviKrimpFully Insulated and-Insulated Quick Disconnect Flags

Doc No: ATS-6400188HM Release Date: 04-08-15 UNCONTROLLED COPY Page 3 of 9

Revision: B Revision Date: 06-17-15

To remove 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.

OPERATION

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.

Loading and Crimping Terminals

Terminals may be loaded when locator is swung open, however when swinging the locator into crimping position,

the spring loaded locator may need to be pushed down to clear the tooling. Swing the terminal locator against the

crimp tool and turn lock up to lock the locator. Terminals may also be loaded easily while locator is up against the

crimp tool and locked. See Figure 3 and 4.

1. Insert the terminal with the barrel into the nest

and the square edge of the flag facing out. Make

sure the back of the flag terminal is against the

locator. When the locator is against the crimp

tool and locked, the terminal is now in proper

position for crimping.

2. Partially close the tool to hold the terminal in

place.

3. Insert the properly stripped wire into the terminal

barrel. See Figure 5. The wire ends should butt

against the inside of the connector. See Figure

6. Cycle the tool.

Note: The tamper proof ratchet action will not release the tool until it has been fully closed.

Figure 3

LATCH LOCKED

LATCH UNLOCKED

LOCATOR OPENED

Figure 4

TERMINAL

CONDUCTOR ANVIL

FLAT EDGE OF

TERMINAL

WIRE

INSULATION

PUNCH

INSULATION

ANVIL

Figure 6

CONDUCTOR

PUNCH

TERMINAL

BARREL

LOCATOR

Figure 5

TERMINAL

WIRE

Tool Kit for AviKrimpFully Insulated and-Insulated Quick Disconnect Flags

Doc No: ATS-6400188HM Release Date: 04-08-15 UNCONTROLLED COPY Page 4 of 9

Revision: B Revision Date: 06-17-15

4. Remove the crimped terminal. Inspect for proper crimp location,

and check for insulation damage.

5. Visually inspect the crimped terminal for proper insulation crimp

closure.

6. If the insulation part of the crimp needs to be adjusted, first loosen

the M4 screw on the upper tool jaw. Then insert a 2.5mm hex

wrench (supplied) into the set screw at the top of the upper die.

See Figure 7. A clockwise (CW) rotation decreases insulation

crimp while a counter-clockwise (CCW) rotation increases

insulation crimp. After adjusting, retighten the M4 screw.

Note: The tamper proof ratchet action will not release the tool until it

has been fully closed.

For the Battery Power Tool:

1. Cycle the Battery Power Tool to crimp the terminal to the wire.

2. 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.

3. Visually inspect the crimped terminal for

proper crimp location.

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 in the tool head are protected with a thin coat of high

quality machine oil. Do not oil excessively. This 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. The use of a

light oil, such as 30 weight automotive oil, every 5,000 crimps or monthly, will significantly enhance the tool life

and ensure a stable calibration. See Figure 8A or 8B for lubrication points.

4. Store the tool in a clean and dry area when not in use.

Miscrimps or Jams for Hand Crimp Tools Only (See Figure 12)

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 rotating the small slotted screw marked with an arrow. See Figure 12.

WIRE

LUBRICATION

POINTS

(BOTH SIDES)

LIGHT OIL

(EVERY MONTH

5,000 CRIMPS)

Figure 8A

Figure 8B

Figure 7

2.5mm HEX

WRENCH

LOOSEN

M4 SCREW

SET SCREW

Tool Kit for AviKrimpFully Insulated and-Insulated Quick Disconnect Flags

Doc No: ATS-6400188HM Release Date: 04-08-15 UNCONTROLLED COPY Page 5 of 9

Revision: B Revision Date: 06-17-15

Tool Calibration

A Certificate of Calibration (see last page) was supplied with the tool. To

recalibrate this tool, pin gauge measurements should be taken in each

conductor nest and compared to this chart. The tool should be

lubricated prior to recalibration to ensure consistent measurements.

Handle preload is factory set to 25-45 LBS. See How to Adjust Tool

Preload, see Figure 5 to recalibrate.

Nest Color Code

Wire Range

“X” Dimension Conductor Crimp

Crimp Inspection

Marking

Mean

No Go

AWG

mm²

In.

Yellow

10 - 12

5.00-3.30

.115

2.92

.112

2.84

.118

3.00

Warranty

This tool kit is for electrical terminal crimping purposes only. This tool kit 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 kit free of charge. This repair or exchange

will not be applicable to altered, misused, or damaged tools.

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.

3. Wear eye protection at all times.

4. Use only the Molex terminals specified for crimping with this tool.

CAUTION: Repetitive use of this tool should be avoided.

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.

When the hand tool is no longer capable of achieving minimum pull force, it should be taken out of service and

replaced.

This tool is very difficult to disassemble and reassemble. Customer repair is not recommended.

PIN GAUGE IN

CONDUCTOR CRIMP

“ Confining ” Crimp

Tool Kit for AviKrimpFully Insulated and-Insulated Quick Disconnect Flags

Doc No: ATS-6400188HM Release Date: 04-08-15 UNCONTROLLED COPY Page 6 of 9

Revision: B Revision Date: 06-17-15

The chart below shows all applications for this Tool Kit.

Tool Kit

Order No.

Tool

Order no.

Tool

Description

Power Head

Order No.

Adapter

Description

Figure

No.

64001-8870

63810-1050

Hand Crimp Frame (Short)

N/A

63810-1000

Hand Crimp Frame (Long)

N/A

63816-0200

Battery Power Tool (110 V)

63816-0300

Power Crimp Head

63816-0250

Battery Power Tool (220 V)

63816-0300

Power Crimp Head

Applications for the Tool Kit

Hand Crimp Tool

Battery Powered Tool

Figure 10

Figure 11

WARNING: NEVER operate service, install tool kits, or adjust the Power Crimp Head without proper

instruction and without first reading and understanding the instructions in the proper Manual or

Specification Sheet. See Chart above for the correct Manual or Specification Sheet.

WARNING: NEVER install tooling or service this tool while it is into any power source. Make sure the

power is turned off.

CAUTION: Keep fingers away from the crimping area when operating this tool. It may cause severe injury.

CAUTION: Wear safety glasses when operating or serving this tool.

POWER

CRIMP

HEAD

LOCKING PINS

BATTERY

POWERED

TOOL

TOOLING KIT

HAND CRIMP

FRAME LONG

AND SHORT

TOOLING KIT

Tool Kit for AviKrimpFully Insulated and-Insulated Quick Disconnect Flags

Doc No: ATS-6400188HM Release Date: 04-08-15 UNCONTROLLED COPY Page 7 of 9

Revision: B Revision Date: 06-17-15

RATCHET

RELEASE SCREW

Figure 12

M4 X 8mm

LONG BHCS

M4 X 18mm

LONG BHCS

M4 X 10mm

LONG BHCS

WITH TOOL KIT

LOCATOR ONLY

HAND TOOL PARTS LIST

Item Number

Order Number

Description

Quantity

63810-1000

Hand Crimp Frame (Long)

64001-8870

Tool Kit with Locator

63811-4773

Locator Base

64001-8875

Locator

REF

Tool Kit for AviKrimpFully Insulated and-Insulated Quick Disconnect Flags

Doc No: ATS-6400188HM Release Date: 04-08-15 UNCONTROLLED COPY Page 8 of 9

Revision: B Revision Date: 06-17-15

Figure 11

M4 by 8 Long

BHCS

M4 by 18 Long

BHCS

M4 by 10 Long

BHCS

POWER HEAD PARTS LIST

Item

Order No

Engineering No.

Description

Quantity

63816-0300

Power Crimp Head

64001-8870

64003-1570

Tool Kit

Tool Kit for AviKrimpFully Insulated and-Insulated Quick Disconnect Flags

Doc No: ATS-6400188HM Release Date: 04-08-15 UNCONTROLLED COPY Page 9 of 9

Revision: B Revision Date: 06-17-15

Hand Crimp Tool

AviKrimp

Certificate of Calibration

Order No. 64001-8800

Tool Order Number __________________

Tool Revision ___________________

Serial Number ___________________

Date of Manufacture__________________

Handle Load Range at 1 inch from the Tips =______________

Actual =_____________

Pin Gauge of Conductor Nest/Nests or Slug height if the nest is the “F” Crimp style.

Range, Conductor Nest = ____________-- Actual = ______________

Technician ______________

Date of Calibration ______________

Calibration should be done every 5,000 cycles or 3 months.

Tools should be lubricated during this operation.

Visit our Web site at http://www.molex.com

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