Hand Crimp Tool for Avikrimp™ /Insulkrimp ™ Terminals and Slices
ServiceGrade™
™
Hand Crimp Tool
Application Tooling
Specification Sheet
Order No. 64016-0036
FEATURES
A full cycle ratcheting hand tool ensures complete crimps
Ergonomic soft grip handles for comfortable crimping
For crimps conforming to industry standards such as UL, USCAR21, and WHMA-IPCA620 Class 2,
please use the 64001-0100 Premium Grade™ hand tool for the Molex terminal
SCOPE
Products: Avikrimp™ /Insulkrimp ™ Terminals and Splices 10 - 22 AWG, (Rings, Spades, Hooks, Block Spades
and Flanged Spades). Also terminates ends of step down butt splice 10-12 to 14 - 16 AWG and 14 - 16 to 18 -
22 AWG.
Crimping Information:
Crimp the terminal and appropriate gauge wire in the specified profile.
Tool Crimp Profile
Markings
Description
2
AWG mm
N
Lb.
Red Blue Yellow
10 5.00 356.0
80.0
X
12 3.30 311.5
70.0
X
Terminals
14 2.00 222.6
50.0
X
(Rings, spades, hooks,
16 1.30 133.5
30.0
X
block spades, or
18 0.80
89.0
20.0
X
flanged spades)
20 0.50
57.9
13.0
X
22 0.35
35.6
8.0
X
10 5.00
178
40.00
X
12 3.30 155.7
35.00
X
14 2.00 111.2
25.00
X
Splices
16 1.30
66.8
15.00
X
(Butt splices or
parallel splices)
18 0.80
44.5
10.00
X
20 0.50
44.5
10.00
X
22 0.35
35.6
8.0
X
▼
Pull force test samples should not have the wire insulation crimped.
Wire Size
Pull Force Min.
▼
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 above. If values
do not exceed the minimum pull force when all instructions are followed then a new tool is required.
Doc No: ATS-640160036
Revision: A
Release Date: 06-25-12
Revision Date: 06-25-12
UNCONTROLLED COPY
Page 1 of 4
Hand Crimp Tool for Avikrimp™ /Insulkrimp ™ Terminals and Slices
DEFINITION OF TERMS
The illustrations in this document are a general representation. Some of
the terminals may look different and be held in a different area of the
terminal.
MWID OR MAX
INSULATION DIAMETER
BARREL
OPERATION
CAUTION:
Install only Molex terminals listed above with this tool.
Do not crimp hardened objects as damage can occur to the tool.
WARNING:
Make sure that the wire is
DISCONNECTED
from any
power supply
Make sure work area is clean and dry and wear approved eye
protection.
BRUSH
STRIP
LENGTH
STUD SIZE
(REF)
INSULATION
FERRULE
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. See the Molex website (http://www.molex.com).
2. Holding the terminal at the contact end, place the terminal in the appropriate nest. See Figure 1.
3. Slowly close the handles of the tool until the terminal is held in place. If the handles are closed too far the
terminal will begin to crimp.
4. Place a pre-stripped wire into the terminal. See terminal product specification on the Molex website. Push the
wire into the terminal barrel until it stops. See Figure 2.
5. While holding the wire in place, slowly close the handles of the tool. If a jam occurs, stop closing the tool and
release the anti-backup ratchet located on the top of the tool. Pushing it forward will release the jaws. See
Figure 5.
HAND TOOL
OPEN
WIRE
TERMINAL
Figure 2
WIRE
TERMINAL
Figure 1
CONDUCTOR PUNCH
INSULATION PUNCH
6. Continue to close the tool handles until the anti-backup ratchet releases. Allow the handles to open.
7. Remove the crimped terminal from the tool.
8. Inspect the crimp for loose wire strands, missing crimp, or other damage. Any minor terminal bending may be
straightened by hand.
Doc No: ATS-640160036
Revision: A
Release Date: 06-25-12
Revision Date: 06-25-12
UNCONTROLLED COPY
Page 2 of 4
Hand Crimp Tool for Avikrimp™ /Insulkrimp ™ Terminals and Slices
Crimping Butt Splices
1. Position the splice into the nest.
2. Partially close the tool to hold the splice in place.
3. Insert the properly stripped wire into the splice. The wires end
should butt against the tab in the terminal. See Figure 3.
4. Continue to close the tool handles until the anti-backup ratchet
releases. Allow the handles to open.
5. Remove the crimped splice. Inspect for proper crimp location.
6. Rotate the butt splice terminal 180°, so that the opposite end of
splice is in the nest.
7. Repeat steps 1 thru 4.
BUTT SPLICE
TERMINAL
WIRE TAB
Figure 3
WIRE
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
Figure 4
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.
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 5.
RATCHET RELEASE
LEVER
Tool Handle Preload
Tool handle preload should
NOT
require adjustment upon receipt of tool.
Figure 5
This hand tool is set from the factory 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 and preload can
be adjusted. It is the operator’s responsibility to periodically perform a tensile pull test on the crimped wire. If the
pull test value falls below the specification, the preload should be adjusted. If after adjustment, the crimp does not
meet the pull test value, then the tool should be replaced.
Doc No: ATS-640160036
Revision: A
Release Date: 06-25-12
Revision Date: 06-25-12
UNCONTROLLED COPY
Page 3 of 4
Hand Crimp Tool for Avikrimp™ /Insulkrimp ™ Terminals and Slices
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 repaired or 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.
ServiceGrade™ crimp hand tools are low cost tools used in field repair for a limited number of terminations. If a
high quality tool is required or a higher volume of terminations required, please purchase the corresponding
PremiumGrade™ crimp hand tool. A ServiceGrade™ crimp tool may or may not have a terminal locator and in
some case may need the locator removed to operate properly.
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.
Visit our Web site at http://www.molex.com
Doc No: ATS-640160036
Revision: A
Release Date: 06-25-12
Revision Date: 06-25-12
UNCONTROLLED COPY
Page 4 of 4
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