0640016300

64001-6300 Hand Crimp Tool Hand Crimp Tool Operating Instruction And Specifications Sheet Order No. 64001-6300 Engineering No. 19813-1000 FEATURES Œ Œ Œ Œ 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 3-nested tool eliminates the need for additional tools SCOPE Products: InsulKrimp™ Piggyback Quick Disconnect Terminals, 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 and 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: 14 – 16 AWG 2.00 – 1.30mm² Terminal No. Wire Strip Length Insulation Diameter Maximum Terminal No. Terminal Eng No. (REF) Mylar Tape In. mm In. mm 19013-0005 BB-2318 19013-0006 .313 7.94 .165 4.19 19013-0007 BB-2318X 19013-0008 .313 7.94 .165 4.19 19013-0029 19013-0029 19013-0030 .313 7.94 .165 4.19 19013-0031 19013-0031 19013-0032 .313 7.94 .165 4.19 Doc No. ATS-640016300 Revision: B Release Date: 03-09-06 Revision Date: 05-24-07 UNCONTROLLED COPY Page 1 of 6 64001-6300 Hand Crimp Tool Wire Size: 18 – 22 AWG 0.80 – 0.35mm² Terminal No. Wire Strip Length Insulation Diameter Maximum Terminal No. Terminal Eng No. (REF) Mylar Tape In. mm In. mm 19013-0001 AA-2317 19013-0002 .313 7.94 .140 3.56 19013-0003 AA-2317X 19013-0004 .313 7.94 .140 3.56 19013-0025 19013-0025 19013-0026 .313 7.94 .140 3.56 19013-0027 19013-0027 19013-0028 .313 7.94 .140 3.56 OPERATION Open the tool by first closing the jaws sufficiently for the ratchet mechanism to release. Crimping Terminals JAWS OPEN 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 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, loosen the locator lock nut, (See Figure 3), and adjust height 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. TERMINAL MALE TAB FACING UP TAB LOCATOR LOCATOR Figure 1 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. Molex offers a Crimp Inspection Handbook for closed barrel industrial product. See our website or contact your sales engineer. CONDUCTOR PUNCH PUNCH INSERT TERMINAL TAB WIRE TAB LOCATOR TERMINAL BARREL LOCATOR TERMINAL WIRE Figure 2 Doc No. ATS-640016300 Revision: B Release Date: 03-09-06 Revision Date: 05-24-07 WIRE STOP BUILT CONDUCTOR INTO TERMINAL ANVIL UNCONTROLLED COPY ANVIL INSERT Figure 3 Page 2 of 6 64001-6300 Hand Crimp Tool 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: 1. Remove dust, moisture and other contaminants with a clean brush, or soft, lint-free cloth. LUBRICATION POINTS 2. Do not use any abrasive materials that could damage the (BOTH SIDES) LIGHT OIL tool. (EVERY 3 MONTHS 3. Make certain all pins; pivot points and bearing surfaces are OR 5,000 CRIMPS) protected with a thin coat of high quality machine oil. Do not oil excessively. This hand 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. Figure 4 4. 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. How to Adjust Tool Preload (See 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 PRELOAD obtain proper crimp conditions: 1.00 TEST POINT 1. Remove the screw and plastic cover washer. Note the setting wheel position. 2. Lift the setting wheel off the axle. Turn the eccentric axle with a screwdriver. 3. Turning the eccentric axle counter-clockwise will increase handle force. 4. Replace the setting wheel to the axle, aligning the nearest notch in the setting wheel to the dowel pin. 5. Replace the plastic cover washer and screw. 6. Check the crimp specifications after tool crimp force is adjusted. Doc No. ATS-640016300 Revision: B Release Date: 03-09-06 Revision Date: 05-24-07 PRELOAD TEST POINT RATCHET RELEASE LEVER PUSH UP PRELOAD ADJUSTMENT LOCKING SCREW UNCONTROLLED COPY 1.00 Figure 5 Page 3 of 6 64001-6300 Hand Crimp Tool 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. 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 .072 .068 .076 .090 .086 .094 .134 .130 .138 X “ Confining ” Crimp 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-640016300 Revision: B Release Date: 03-09-06 Revision Date: 05-24-07 UNCONTROLLED COPY Page 4 of 6 64001-6300 Hand Crimp Tool PARTS LIST Item 1 2 3 4 Order No 64001-6300 64000-0076 63810-0000 64001-6275 64001-6370 5 6 7 8 9 64001-6301 64001-6302 64001-0312 64001-0311 N/A Description Hand Crimp Tool Repair Kit (Springs, Pins and E-Rings) Handle Locator Assembly Tooling Kit Tooling Kit Only Conductor Punch Conductor Anvil Insert, Punch Insert, Anvil 4mm Diameter by 5.0mm LongRoll Pins Quantity Figure 6 1 1 1 1 1 1 1 1 2** ** The following purchased parts are available from an Industrial supply company such as MSC (1-800-645-7270). 2 M4 LOCKNUT W/ HEX NYLON INSERT M4 FLAT WASHER RATCHET RELEASE LEVER 3 SCREW AND PLASTIC COVER FOR HANDTOOL PRELOAD ADJUSTMENT 5 M4 X 12LG PAN HEADSCREW 6 9 7 FOR SPRING ACCESS SWING OPEN COVER (2) 8 M4 X 30LG PAN HEAD SCREW 1 4 REPAIR KIT. ALL PARTS REQUIRED FOR REPAIR. (ONLY MAIN SPRING SHOWN) Figure 6 Doc No. ATS-640016300 Revision: B Release Date: 03-09-06 Revision Date: 05-24-07 UNCONTROLLED COPY Page 5 of 6 64001-6300 Hand Crimp Tool Certificate of Calibration Tool Order Number __________________ Tool Eng. 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 # 1 = ____________-- Actual = ______________ Range Conductor Nest # 2 = ____________-- Actual = ______________ Range Conductor Nest # 3 = ____________-- Actual = ______________ Technician ______________ Date of Calibration ______________ Calibration should be done every 5,000 cycles or 3 months. Tools should be lubricated during this operation. 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 Visit our Web site at http://www.molex.com Doc No. ATS-640016300 Revision: B Release Date: 03-09-06 Revision Date: 05-24-07 UNCONTROLLED COPY Page 6 of 6