0640031600

64003-1600 Hand Crimp Tool Hand Crimp Tool Krimptite  Application Tooling Quick Disconnects Specification Sheet Order No. 64003-1600 FEATURES A full cycle ratcheting hand tool ensures complete crimps Long handles for comfortable crimping with reduced crimping force SCOPE Products: Krimptite ™ Un-insulated Female Flag Quick Disconnect Terminals, 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 charts show the 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 12 70 10 80 *UL – 310 – Flag Quick Disconnects. Doc No. ATS-640031600 Release Date: 03-29-13 Revision: A Revision Date: 03-29-13 UNCONTROLLED COPY Page 1 of 10 64003-1600 Hand Crimp Tool 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 Wire Strip Length Insulation Diameter Maximum Terminal No. 19008-0063 Eng. No. (REF) In. mm In. mm C-1012 .313 7.94 N/A N/A OPERATION JAWS OPEN Open the tool by first closing the jaws sufficiently for the ratchet mechanism to release. LOCATOR Crimping Terminals Figure 1 BARREL OF FLAG TERMINAL 1. Insert the flag terminal into the nest with the barrel down and centered in the nest. The flag terminal should be against the locator. 2. Partially close the tool to hold the terminal in place. Doc No. ATS-640031600 Release Date: 03-29-13 Revision: A Revision Date: 03-29-13 UNCONTROLLED COPY Page 2 of 10 64003-1600 Hand Crimp Tool 3. Insert the properly stripped wire into the terminal barrel. See Figure 2. 4. Now close the handle completely and release. The jaws will open when the tool has fully closed. CONDUCTOR PUNCH WIRE CONDUCTOR ANVIL NO INSULATION GRIP BARREL TERMINAL Figure 2 WIRE Figure 3 Note: The tamper proof ratchet action will not release the tool until it has been fully closed. LUBRICATION POINTS (BOTH SIDES) LIGHT OIL (EVERY 3 MONTHS OR 5,000 CRIMPS) 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. Doc No. ATS-640031600 Release Date: 03-29-13 Revision: A Revision Date: 03-29-13 Figure 4 UNCONTROLLED COPY Page 3 of 10 64003-1600 Hand Crimp Tool 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. 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. 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 lifting 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 obtain proper crimp conditions: 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. Doc No. ATS-640031600 Release Date: 03-29-13 Revision: A Revision Date: 03-29-13 UNCONTROLLED COPY Page 4 of 10 64003-1600 Hand Crimp Tool PRELOAD TEST POINT 3. Turning the eccentric axle counter-clockwise (CCW) will increase handle force. 1.00 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. RATCHET RELEASE LEVER PUSH UP 6. Check the crimp specifications after tool handle preload force is adjusted. PRELOAD PRELOAD ADJUSTMENT TEST POINT LOCKING SCREW Figure 5 1.00 Tool Calibration A Certificate of Calibration (see last page) was supplied with the tool. To recalibrate this Tool, measurements should be taken from each conductor nest and compared to this chart. The tool should be lubricated before 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. PIN GAUGE IN CONDUCTOR CRIMP X “Indenter Crimp” Nest Color Code Yellow Wire Range AWG mm² 10 - 12 5.00 – 3.30 Doc No. ATS-640031600 Release Date: 03-29-13 Revision: A Revision Date: 03-29-13 “X” Dimension Conductor Crimp Mean Go No Go .086 .083 .088 UNCONTROLLED COPY Page 5 of 10 64003-1600 Hand Crimp Tool Warranty CAUTION: Molex crimp specifications are valid only when used with Molex terminals and tooling. 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 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. Hand held crimping tools are intended for low volume, prototyping, or repair requirements only. CAUTION: Repetitive use of this tool should be avoided. Doc No. ATS-640031600 Release Date: 03-29-13 Revision: A Revision Date: 03-29-13 UNCONTROLLED COPY Page 6 of 10 64003-1600 Hand Crimp Tool PARTS LIST Item Order No Description Quantity 64003-1600 Hand Crimp Tool Figure 6 1 64000-0076 Repair Kit (Springs, Pins and E-Rings) 1 2 63810-0000 Handle 1 3 64003-1670 Tooling Kit 1 4 64003-1675 Locator Assembly 1 Tooling Kit Only 5 64003-1601 Conductor Punch (indenter) 1 6 64003-1602 Conductor Anvil 1 2 4 M4 LOCKNUT RATCHET RELEASE LEVER SCREW AND PLASTIC COVER FOR HANDTOOL PRELOAD ADJUSTMENT 5 M4 X 12LG PAN HEADSCREW M4 X 30LG PAN HEADSCREW 6 Doc No. ATS-640031600 3 Release Date: 03-29-13 Revision: A Revision Date: 03-29-13 Figure 6 FOR SPRING ACCESS SWING OPENUNCONTROLLED COVER 1 COPY REPAIR KIT. ALL PARTS REQUIRED FOR REPAIR. (ONLY MAIN SPRING SHOWN) Page 7 of 10 64003-1600 Hand Crimp Tool Hand Crimp Tool Krimptite  Quick Disconnects Application Tooling Doc No. ATS-640031600 Release Date: 03-29-13 Revision: A Revision Date: 03-29-13 UNCONTROLLED COPY Page 8 of 10 64003-1600 Hand Crimp Tool Specification Sheet Order No. 64003-1600 Certificate of Calibration 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: Conductor Nest Range = ____________-- Actual = ______________ Doc No. ATS-640031600 Release Date: 03-29-13 Revision: A Revision Date: 03-29-13 UNCONTROLLED COPY Page 9 of 10 64003-1600 Hand Crimp Tool 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-640031600 Release Date: 03-29-13 Revision: A Revision Date: 03-29-13 UNCONTROLLED COPY Page 10 of 10