Molex 207129 Series Manual de usuario

Tool Kit for High Temperature Female Quick Disconnects

Doc No: ATS-64 315HM Release Date: 1- 8-14 UNCONTROLLED COPY Page 1 of 9

Revision: A Revision Date: 1- 8-14

Application Tooling

Specification Sheet

Crimp Tool Kit Hand Crimp Tool

Order No 64003-1500

FEATURES

% A full cycle ratcheting hand tool ensures complete crimps

% Ergonomically designed soft handles

% Precisely designed crimping profiles with simple contact positioning

% Easy handling due to outstanding force ratio

 Tool kits are easily installed into the Hand Crimp Tool or the 63816- 3 Power Crimp Head which is installed

into the 63816- 2 (11 V) or the 63816- 25 (22 V) Battery Powered Tool.

 Many different Tool kits can be used with a single Battery Powered Tool.

SCOPE

Products: Krimptite High Temperature Female Non-Insulated Steel Quick Disconnects, 1 -12 AWG.

Testing

Mechanical

The tensile test or pull test is a means of evaluating the mechanical properties of the crimped connections. The

following chart shows 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)

*UL

310

*UL – 31 – Quick Disconnects

CONDITIONS:

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: 1

–

2 AWG

5 00

–

3 30

mm²

Terminal No Terminal

Eng No (REF)

re Strip Length

Insulation Diameter Maximum

2 3 379

.25

6.35

N/A

2 3 468

.25

6.35

N/A

TYPE 4C

Tool Kit for High Temperature Female Quick Disconnects

Doc No: ATS-64 315HM Release Date: 1- 8-14 UNCONTROLLED COPY Page 2 of 9

Revision: A Revision Date: 1- 8-14

SWING

LOCATOR

OPEN

PRESS DOWN

ON THE BRASS

PIVOT SHAFT

LIFT UP ON

THE LOCATOR

Figure

ANVILS

POWER

CRIMP

HEAD

Figure

PUNCHES

M4 X 10 LONG

BHCS

M4 X 18 LONG

BHCS

TAB SIZE

CUT

OFF

TAB

MWID OR MAX

INSULATION

DIAMETER

STRIP

LENGTH

MALE QD

TAPE OR

MOLDED REF

BRUSH

TAB

SIZE

Un-insulated Female

Quick Disconnect

TERMINAL STRIP

DEFINITION OF TERMS

CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects as damage

can occur to the tool or die.

INSTALLATION

To install the Tool Kit into the Power Crimp Head follow the steps below:

Anvils and Punches Installation

1. Insert the Anvils into the bottom slots of the nest. Install the M4 x 1 long BHCS and tighten in place.

2. Insert the Punches into the top slots of the nest. Install the M4 x 18 long BHCS and tighten in place. See

Figure 1.

Tool Kit for High Temperature Female Quick Disconnects

Doc No: ATS-64 315HM Release Date: 1- 8-14 UNCONTROLLED COPY Page 3 of 9

Revision: A Revision Date: 1- 8-14

Locator Installation and Removal

Follow the steps below to install or replace the locator. See

Figure 2.

To install the locator

1. Position the locator with the hole over the brass pivot

shaft and snap it into place.

To remove the locator

1. Open the crimp hand tool.

2. Swing the existing locator open and away from the hand tool.

3. Firmly press down on the brass pivot shaft with your thumb, while pulling the locator up. Slip the locator off the

top of the brass pivot shaft.

OPERATION

Open the tool by squeezing the handles together, at the end of the closing stroke, the ratchet mechanism will

release the handles, and the hand tool will spring open.

Crimping Terminals

1. Select the desired terminal listed in the preceding chart.

2. Turn the Locator Lock Latch down to unlock.

See Figure 3.

3. Swing the terminal locator away from the crimp tool. The

terminal must then be loaded into the locator by pressing

down on the wire stop as shown in Figure 4.

4. Return the locator to its original position.

5. Turn the Locator Lock Latch up to lock. Make sure that

the terminal is visually centered over the punch.

6. Insert the proper wire into the terminal.

7. Gently touch the wire stop with the end of the wire. See

Figure 5 and 6.

Figure 3

LATCH LOCKED

LATCH UNLOCKED

LOCATOR

OPENED

Figure 4

TERMINAL

PUSH HERE TO

OPEN WIRE STOP

JAWS

PARTIALLY

CLOSED

Figure 5

WIRE IN TERMINAL

WIRE AGAINST

WIRE STOP

LOCATOR

CONDUCTOR

ANVIL

TERMINAL

WIRE

CONDUCTOR

PUNCH

WIRE AGAINST

STOP

Figure 6

Tool Kit for High Temperature Female Quick Disconnects

Doc No: ATS-64 315HM Release Date: 1- 8-14 UNCONTROLLED COPY Page 4 of 9

Revision: A Revision Date: 1- 8-14

8. Compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.

Release the handles to open the jaws.

9. Remove the crimped terminal from the terminal locator by pressing down on the wire stop and gently pulling on

the wire. The terminal locator can be in either position.

1 . Visually inspect the crimped terminal for proper crimp location.

Note: The tamper proof ratchet action will not release the tool until it has been fully closed.

For the Battery Power Tool:

1. Cycle the Battery Power Tool to crimp the

terminal to the wire.

2. Remove the crimped terminal from the

terminal locator by pressing down on the

wire stop and gently pulling on the wire.

The terminal locator can be in either

position.

3. Visually inspect the crimped terminal for

proper crimp location.

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.

2. Do not use any abrasive materials that could damage the tool.

3. Make certain all pins; pivot points and bearing surfaces in the tool head are protected with a thin coat of high

quality machine oil. Do not oil excessively. 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. The use of a

light oil, such as 3 weight automotive oil, every 5, crimps or monthly, will significantly enhance the tool life

and ensure a stable calibration. See Figure 6A or 6B for lubrication points.

4. Store the tool in a clean and dry area when not in use.

Miscrimps or Jams for Hand Crimp Tools Only (See Figure 10)

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 rotating the small slotted screw marked with an arrow. See Figure 1 .

Tool Calibration (See Figure 7)

A Certificate of Calibration (See Last Page) was supplied with the tool. To check this Tool, a soft metal slug or

solder should be crimped in the conductor nest and the “X” Dimension measured in the conductor nest and

compared to the chart. The tool should be lubricated prior to recalibration to ensure consistent measurements.

Handle preload is factory set to 25-45 lbs.

LUBRICATION

POINTS

(BOTH SIDES)

LIGHT OIL

(EVERY MONTH

5,000 CRIMPS)

Figure

Tool Kit for High Temperature Female Quick Disconnects

Doc No: ATS-64 315HM Release Date: 1- 8-14 UNCONTROLLED COPY Page 5 of 9

Revision: A Revision Date: 1- 8-14

Figure 7

“ X

”

NOT POSSIBLE TO PIN GAUGE, MEASURE A

CRIMPED UNINSULATED TERMINAL OR SLUG*

*SOLDER, LEAD OR

SIMILAR SOFT METAL

Wire Range

“X” Dimension Conductor Crimp

Mean

No Go

AWG

mm²

–

3.3

. 83

2.12

. 79

2. 1

. 89

2.26

Warranty

This tool kit is for electrical terminal crimping purposes only. This tool kit 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 3

days. Should such a defect occur, we will repair or exchange the tool kit free of charge. This repair or exchange

will not be applicable to altered, misused, or damaged tools.

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.

3. Wear eye protection at all times.

4. Use only the Molex terminals specified for crimping with this tool.

CAUTION: Repetitive use of this tool should be avoided.

Certification

Molex does not certify or re-certify commercial grade hand tools but rather supplies the following guidelines for

customers to re-certify 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. ”) 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 taken out of service and

replaced.

% This tool is very difficult to disassemble and reassemble. Customer repair is not recommended.

Tool Kit for High Temperature Female Quick Disconnects

Doc No: ATS-64 315HM Release Date: 1- 8-14 UNCONTROLLED COPY Page 6 of 9

Revision: A Revision Date: 1- 8-14

The chart below shows all applications for this Tool Kit.

Tool Kit

Order No

Tool

Order no

Tool

Description

Power

Head

Order No

Adapter

Description

Figure

64 3-157

6381

1 5

Hand Crimp Frame (Short)

N/A

6381

Hand Crimp Frame (Long)

N/A

63816

Battery Pow

Tool (11 V)

63816

Power Crimp Head

63816

Battery Power

Tool (22 V)

63816

Power Crimp Head

Applications for the Tool Kit

Hand Crimp Tool

Battery Powered Tool

Figure

igure

WARNING: NEVER operate service, install tool kits, or adjust the Power Crimp Head without proper

instruction and without first reading and understanding the instructions in the proper Manual or

Specification Sheet. See Chart above for the correct Manual or Specification Sheet.

WARNING: NEVER install tooling or service this tool while it is into any power source. Make sure the

power is turned off.

CAUTION: Keep fingers away from the crimping area when operating this tool. It may cause severe injury.

CAUTION: Wear safety glasses when operating or serving this tool.

POWER

CRIMP

HEAD

LOCKING PINS

BATTERY

POWERED

TOOL

TOOLING KIT

HAND CRIMP

FRAME LONG

AND SHORT

TOOLING KIT

Tool Kit for High Temperature Female Quick Disconnects

Doc No: ATS-64 315HM Release Date: 1- 8-14 UNCONTROLLED COPY Page 7 of 9

Revision: A Revision Date: 1- 8-14

RATCHET

RELEASE SCREW

igure 10

M4 X 8mm

LONG BHCS

M4 X 18mm

LONG BHCS

M4 X 10mm

LONG BHCS

WITH TOOL KIT

LOCATOR ONLY

HAND TOOL PARTS LIST

Item Number

Order Number

Description

Quantity

6381

Hand Crimp Frame (Long)

64 3

157

Tool Kit with

Locator

63811

Locator Base

1575

Locator

REF

Figure 10

Tool Kit for High Temperature Female Quick Disconnects

Doc No: ATS-64 315HM Release Date: 1- 8-14 UNCONTROLLED COPY Page 8 of 9

Revision: A Revision Date: 1- 8-14

Figure 11

Long

BHCS

Long

BHCS

Long

BHCS

POWER HEAD PARTS LIST

Item

Order No

Engineering No

Description

Quantity

63816- 3 63816- 3 Power Crimp Head 1

64 3-157 64 3-157 Tool Kit 1

Tool Kit for High Temperature Female Quick Disconnects

Doc No: ATS-64 315HM Release Date: 1- 8-14 UNCONTROLLED COPY Page 9 of 9

Revision: A Revision Date: 1- 8-14

Hand Crimp Tool

Krimptite 





Certificate of Calibration

Order No 64003-1500

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/Nests or Slug height if the nest is the “F” Crimp style.

Range, Conductor Nest = ____________-- Actual = ______________

Technician ______________

Date of Calibration ______________

Calibration should be done every 5, cycles or 3 months.

Tools should be lubricated during this operation.

Visit our Web site at http://www.molex.com

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