0640018100

Hand Crimp Tool Hand Crimp Tool Insulkrimp  Male Q.D. Application Tooling Specification Sheet Order No. 64001-8100 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 Insulation crimp adjustment allows a precise insulation crimp to meet or exceed the requirements of UL, CSA and Military Class II SCOPE Products: Insulkrimp Male Quick Disconnect, 10 - 12 AWG. Wire Size (AWG) 10 12 *UL - 310 80 70 *UL – 310 – Quick Disconnects 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. 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 – 3.30mm² Wire Strip Length Insulation Diameter Maximum Terminal No. Terminal Eng No. (REF) In. mm In. mm 19023-0008 CMCT-2X .375 9.53 .250 6.35 OPERATION Open the tool by first closing the jaws sufficiently for the ratchet mechanism to release. Crimping Terminals 1. Push up on the locator blade and position the terminal with the barrel facing up into the nest with the front edge of the barrel against the locator. See Figure 1. Release the locator blade to hold the terminal in position. 2. Partially close the tool to hold the terminal in place. See Figure 2. 3. Insert the properly stripped wire into the terminal barrel. See Figure 2 and 3. The wires end should butt against the wire stop position of the locator. Doc No: ATS-640018100 Revision: A Release Date: 03-21-13 Revision Date: 03-21-13 JAWS OPEN FRONT EDGE OF BARREL Figure 1 TERMINAL LOCATOR UNCONTROLLED COPY PUSH UP Page 1 of 5 Hand Crimp Tool 4. Cycle the tool. INSULATION PUNCH CONDUCTOR PUNCH TERMINAL BARREL LOCATOR TERMINAL WIRE TERMINAL WIRE Figure 2 CONDUCTOR ANVIL Figure 3 INSULATION ANVIL Note: The tamper proof ratchet action will not release the tool until it has been fully closed. 5. Lift the locator blade or wire stop and remove the crimped terminal. Inspect for proper crimp location, and check for insulation closure. The locator is adjustable, up and down, to keep the terminals straight after crimping. 6. If the insulation part of the crimp needs to be adjusted, first loosen the M4 screw on the bottom tool jaw, then insert a 3/32 hex wrench (supplied) into the bottom of the lower die. See Figure 4. A clockwise rotation decreases insulation crimp while a counter-clockwise rotation increases insulation crimp. After adjusting retighten the M4 screw. 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. LOOSEN M4 SCREW Maintenance It is recommended that each operator of the tool be made aware of, and responsible for, the following maintenance steps. Figure 4 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. 3/32” HEX 3. Make certain all pins; pivot points and bearing WRENCH surfaces are protected with a thin coat of high LUBRICATION POINTS quality machine oil. Do not oil excessively. This (BOTH SIDES) tool was engineered for durability, but like any fine LIGHT OIL (EVERY 3 MONTHS OR 5,000 CRIMPS) piece of equipment it needs cleaning and lubrication for a maximum service life of troublefree 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. 4. When the 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-640018100 Revision: A Release Date: 03-21-13 Revision Date: 03-21-13 UNCONTROLLED COPY Page 2 of 5 Hand Crimp Tool PRELOAD TEST POINT 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 the Tool Preload (See Fig. 5) Over the life of the tool, it may be necessary to adjust the tool handle preload force. Listed below are the steps required to adjust the crimping force of the hand tool to obtain proper crimp conditions: 1. 2. 3. 4. 5. 6. RATCHET RELEASE LEVER PUSH UP 1.00 PRELOAD PRELOAD ADJUSTMENT TEST POINT LOCKING SCREW 1.00 Figure 5 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 the 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 the 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 the tool preload, see Figure 5 to recalibrate. Nest Color Code Yellow Wire Range AWG 10 - 12 mm² 3.30 - 5.00 “X” Dimension Conductor Crimp Mean Go No Go .100 .097 .103 X “ Confining ” Crimp Crimp Inspection Marking oo 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-640018100 Revision: A Release Date: 03-21-13 Revision Date: 03-21-13 UNCONTROLLED COPY Page 3 of 5 Hand Crimp Tool PARTS LIST Item Order No 64001-8100 64000-0076 63810-0000 64001-1275 64001-8170 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 64001-8102 Conductor Punch 1 6 64001-8101 Conductor Anvil 1 7 64001-8104 Insulation Punch 1 8 64001-8103 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 Pt. Set Screw 1** ** Available from an Industrial supply company such as MSC (1-800-645-7270). 2 M4 WING NUT M4 FLAT WASHER RATCHET RELEASE LEVER 3 SCREW AND PLASTIC COVER FOR HANDTOOL PRELOAD ADJUSTMENT M4 X 12LG PAN HEADSCREW 5 M4 X 25LG PAN HEAD SCREW 6 (2) 9 10 FOR SPRING ACCESS SWING OPEN COVER Figure 6 7 8 1 REPAIR KIT. ALL PARTS REQUIRED FOR REPAIR. (ONLY MAIN SPRING SHOWN) 4 Doc No: ATS-640018100 Revision: A Release Date: 03-21-13 Revision Date: 03-21-13 UNCONTROLLED COPY Page 4 of 5 Hand Crimp Tool Hand Crimp Tool Insulkrimp  Certificate of Calibration Order No. 64001-8100 Tool Order Number 64001-8100 Tool Revision ___________________ Serial Number ___________________ Date of Manufacture__________________ Handle Preload Range: At 1 inch from the Tips = 25 – 45 lbs. Actual =_____________ Pin Gauge of Conductor Crimp Nest: Conductor Nest Range = .097” - .103” (2.46mm – 2.62mm) 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 Doc No: ATS-640018100 Revision: A Release Date: 03-21-13 Revision Date: 03-21-13 UNCONTROLLED COPY Page 5 of 5