molex 207129 Series User manual

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
12
7
1
8
*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
0
–
1
2 AWG
5 00
–
3 30
mm²
Terminal No Terminal
Eng No (REF)
Wi
re Strip Length
Insulation Diameter Maximum
In
mm
In
mm
19
2 3 379
19
2 3 379
.25
6.35
N/A
N/A
19
2 3 468
19
2 3 468
.25
6.35
N/A
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
2
ANVILS
POWER
CRIMP
HEAD
Figure
1
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
OR
5,000 CRIMPS)
Figure
6
A
Figure
6
B

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
Go
No Go
AWG
mm²
In
mm
In
mm
In
mm
1
-
12
5.
–
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
No
64 3-157
6381
-
1 5
Hand Crimp Frame (Short)
N/A
N/A
8
6381
-
1
Hand Crimp Frame (Long)
N/A
N/A
8
63816
-
2
Battery Pow
er
Tool (11 V)
63816
-
3
Power Crimp Head
9
63816
-
25
Battery Power
Tool (22 V)
63816
-
3
Power Crimp Head
9
Applications for the Tool Kit
Hand Crimp Tool
Battery Powered Tool
Figure
8
F
igure
9
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
F
igure 10
M4 X 8mm
LONG BHCS
2
1
3
M4 X 18mm
LONG BHCS
M4 X 10mm
LONG BHCS
2
4
WITH TOOL KIT
LOCATOR ONLY
HAND TOOL PARTS LIST
Item Number
Order Number
Description
Quantity
1
6381
-
1
Hand Crimp Frame (Long)
1
2
64 3
-
157
Tool Kit with
Locator
1
3
63811
-
47
73
Locator Base
1
4
64
3
-
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
1
2
2
M
4
by
8
Long
BHCS
M
4
by
18
Long
BHCS
M
4
by
10
Long
BHCS
1
POWER HEAD PARTS LIST
Item
Order No
Engineering No
Description
Quantity
1
63816- 3 63816- 3 Power Crimp Head 1
2
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