Hand Crimp Tool for InsulKrimp™ Piggyback QD
Hand Crimp Tool Operating Instruction
And Specifications Sheet
Order No. 64001-6200
Engineering No. 19800-1200
FEATURES
A full cycle ratcheting hand tool ensures complete crimps
Long handles for comfortable crimping with reduced crimping force
A precision user-friendly terminal locator wire stop holds terminals in the proper crimping position for each of
the three nests
Insulation crimp adjustment allows a precise insulation crimp. To meet or exceed the requirements of UL,
CSA and Military Class II
3-nested tool eliminates the need for additional tools
SCOPE
Products: InsulKrimp™ Piggyback Quick Disconnect 10 - 22 AWG.
Testing
Mechanical
The tensile test, or pull test, is a means of evaluating the mechanical properties of the crimped connections.
The following charts show the UL specifications for various wire sizes. The tensile strength is shown in
pounds. It indicates the minimum acceptable force to break or separate the terminal from the conductor.
Wire Size (AWG)
22
20
18
16
14
12
10
*UL - 310
8
13
20
30
50
70
80
*UL – 310 – Quick Disconnects
The following is a partial list of the product part numbers and their specifications that this tool is designed to run.
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 – 3.30mm²
Terminal Eng No. Terminal No. Wire Strip Length
Terminal No.
(REF)
Mylar Tape
In
mm
19011-0007
C-2303
19011-0008
.380
9.53
19011-0039
19011-0039
19011-0040
.380
9.53
19013-0033
C-2319
19013-0034
.380
9.53
Insulation Diameter
Maximum
In.
mm
.260
6.48
.225
5.71
.280
7.11
Doc No: ATS-640016200
Revision: B
Release Date: 09-19-06
Revision Date: 05-12-08
UNCONTROLLED COPY
Page 1 of 6
Hand Crimp Tool for InsulKrimp™ Piggyback QD
Wire Size: 14 – 16 AWG 2.00 – 1.30mm²
Terminal Eng No. Terminal No. Wire Strip Length
Terminal No.
(REF)
Mylar Tape
In.
mm
19011-0004
BB-2302
19011-0006
.310
7.94
19011-0037
19011-0037
19011-0038
.310
7.94
Wire Size: 18 – 22 AWG 0.80 – 0.35mm²
Terminal Eng No. Terminal No. Wire Strip Length
Terminal No.
(REF)
Mylar Tape
In.
mm
19011-0001
AA-2301
19011-0003
.310
7.94
19011-0035
19011-0035
19011-0036
.310
7.94
Insulation Diameter
Maximum
In.
mm
.140
3.56
.110
2.79
Insulation Diameter
Maximum
In.
mm
.150
3.68
.140
3.56
OPERATION
Open the tool by first closing the jaws sufficiently for the ratchet
mechanism to release.
Crimping Terminals
JAWS
OPEN
TERMINAL
1. Push the terminal onto the Tab Locator all the way to the
stop in the proper color-coded nest. The male tab of the
Figure 1
terminal should be up. See Figure 1.
2. The height of the locator may need to be adjusted when
changing from one terminal size to another. To do this,
TAB LOCATOR
MALE TAB
loosen the locator lock nut, (See Figure 3), and adjust height
FACING UP LOCATOR
so the tab aligns with the female locator tab. Tighten the
lock nut.
3. Partially close the tool to hold the terminal in place. See Figure 2.
4. Insert the properly stripped wire into the terminal barrel. See Figure 2 and 3. The wires end should butt
against the wire stop stamped into each terminal. Cycle the tool.
CONDUCTOR PUNCH
TERMINAL TAB
TAB LOCATOR
WIRE
INSULATION
PUNCH
LOCATOR
TERMINAL
WIRE
Figure 2
WIRE STOP BUILT
CONDUCTOR
INTO TERMINAL
ANVIL
Figure 3
TERMINAL
BARREL
INSULATION
ANVIL
Doc No: ATS-640016200
Revision: B
Release Date: 09-19-06
Revision Date: 05-12-08
UNCONTROLLED COPY
Page 2 of 6
Hand Crimp Tool for InsulKrimp™ Piggyback QD
Note:
The tamper proof ratchet action will not release the tool until it has been fully closed.
5. Remove the crimp and inspect for proper crimp location, and check for insulation closure. Molex offers a
Crimp Inspection Handbook for closed barrel industrial product. See our website or contact your sales
engineer.
Note:
Whenever crimping without the locator, make sure the seam of the terminal is oriented up or down in the
tool if using unbrazed product, as this will provide higher pull force values.
Maintenance
It is recommended that each operator of
the tool be made aware of, and responsible
for, the following maintenance steps.
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
1.
Remove dust, moisture and other
LOOSEN
contaminants with a clean brush, or
M4 SCREW
soft, lint-free cloth.
2.
Do not use any abrasive materials that
3/32” HEX
could damage the tool.
WRENCH
3.
Make certain all pins; pivot points and
bearing surfaces are protected with a
Figure 4
thin coat of high quality machine oil.
Do not oil excessively.
4.
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. A light oil, such as 30 weight automotive oil used at the oil
points shown in Figure 4, every 5,000 crimps or 3 months will significantly enhance the tool life and ensure a
stable calibration.
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 5.
PRELOAD
TEST POINT
1.00
How to Adjust Tool Preload
(See Figure 5)
RATCHET
RELEASE LEVER
PUSH UP
PRELOAD
TEST POINT
PRELOAD
ADJUSTMENT
LOCKING SCREW
1.00
Figure 5
Over the life of the tool, it may be necessary 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:
Doc No: ATS-640016200
Revision: B
Release Date: 09-19-06
Revision Date: 05-12-08
UNCONTROLLED COPY
Page 3 of 6
Hand Crimp Tool for InsulKrimp™ Piggyback QD
1.
2.
3.
4.
5.
6.
Remove the screw and plastic cover washer. Note the setting wheel position.
Lift the setting wheel off the axle. Turn the eccentric axle with a screwdriver.
Turning the eccentric axle counter-clockwise will increase handle force.
Replace the setting wheel to the axle, aligning the nearest notch in the setting wheel to the dowel pin.
Replace the plastic cover washer and screw.
Check the crimp specifications after tool crimp force is adjusted.
PIN GAUGE IN
CONDUCTOR CRIMP
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.
X
“ Confining ” Crimp
Nest Color Code
Red
Blue
Yellow
Wire Range
AWG
18 - 22
14 - 16
10 - 12
mm²
0.35 - 0.80
1.30 - 2.00
3.30 - 5.00
“X” Dimension
Conductor Crimp
Mean Go No Go
.080 .076
.084
.098 .094
.102
.140 .136
.146
Crimp Inspection
Marking
N/A
N/A
N/A
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.
Hand held crimping tools are intended for low volume, prototyping, or repair requirements only.
CAUTION:
Molex crimp specifications are valid only when used with Molex terminals, applicators and
tooling.
Doc No: ATS-640016200
Revision: B
Release Date: 09-19-06
Revision Date: 05-12-08
UNCONTROLLED COPY
Page 4 of 6
Hand Crimp Tool for InsulKrimp™ Piggyback QD
PARTS LIST
Description
Quantity
Hand Crimp Tool
(Figure 6)
1
Repair Kit (Springs, Pins and E-Rings)
1
2
Handle
1
3
Locator Assembly
1
4
Tooling Kit
1
Tooling Kit Only
5
64001-6201
Conductor Punch
1
6
64001-6202
Conductor Anvil
1
7
64001-6204
Insulation Punch
1
8
64001-6203
Insulation Anvil
1
9
N/A
4mm Diameter by 5.0mm Long Roll Pins
2**
10
N/A
#10-32 by 5/16” Long Cup Point Set Screw
1**
** Available from an industrial supply company such as MSC (1-800-645-7270).
Item
Order No
64001-6200
64000-0076
63810-0000
64001-6275
64001-6270
2
M4 LOCKNUT WITH
HEX NYLON INSERT
M4 FLAT WASHER
RATCHET
RELEASE LEVER
3
SCREW AND PLASTIC
COVER FOR HANDTOOL
PRELOAD ADJUSTMENT
5
M4 X 12 LONG
PAN HEADSCREW
6
(2)
9
10
7
8
1
FOR SPRING
ACCESS SWING
OPEN COVER
M4 X 30 LONG
PAN HEAD SCREW
REPAIR KIT. ALL PARTS REQUIRED FOR
REPAIR. (ONLY MAIN SPRING SHOWN)
Figure 6
4
Doc No: ATS-640016200
Revision: B
Release Date: 09-19-06
Revision Date: 05-12-08
UNCONTROLLED COPY
Page 5 of 6
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