Molex ServiceGrade 64016-0038 User manual

Hand Crimp Tool for Krimptite / VersaKrimp Terminals

Doc No: ATS-6401600 8 Release Date: 06-27-12 UNCONTROLLED COPY Page 1 of 5

Revision: A Revision Date: 06-27-12

ServiceGrade





Hand Crimp Tool

Application Tooling

Specification S eet Order No. 64016-0038

FEATURES





 A full cycle ratcheting hand tool ensures complete crimps





 Ergonomic soft grip handles for comfortable crimping





 For crimps conforming to industry standards such as UL, USCAR21, and WHMA-IPCA620 Class 2,

please use the 6400 -0100 Premium Grade™ hand tool for the Molex terminal

SCOPE

Products: Krimptite / VersaKrimp Quick Disconnects, Rings, Spades, Hooks, Block, and Flanged Spades, Butt

and Parallel Splices, 10 - 22 AWG.

Crimping Information:

Crimp the terminal and appropriate gauge wire in the specified profile.

Description Wire Size Pull Force Min. ▼

Tool Crimp Profile

Markings

AWG

Lb.

Terminals

(Quick Disconnect,

rings, spades, hooks,

block spades, or

flanged spades)

5.00

56.0

80.0

. 0

11.5

70.0

2.00

222.6

50.0

1. 0

1 .5

0.0

0.80

89.0

20.0

0.50

57.9

1 .0

0. 5

5.6

8.0

Splices

(Butt splices or

parallel splices)

5.00

178.0

40.00

. 0

155.7

5.00

2.00

111.2

25.00

1. 0

66.8

15.00

0.80

44.5

10.00

0.50

44.5

10.00

0. 5

5.6

8.0

▼

Pull force test samples should not have the wire insulation crimped.

Note:

An occasional, destructive, pull force test with the terminal and wire crimped should be performed to check hand tool

crimp. The pull force value must exceed the terminal’s minimum pull force specifications listed above. If values do

not exceed the minimum pull force when all instructions are followed then a new tool is required.

Hand Crimp Tool for Krimptite / VersaKrimp Terminals

Doc No: ATS-6401600 8 Release Date: 06-27-12 UNCONTROLLED COPY Page 2 of 5

Revision: A Revision Date: 06-27-12

Figure 1

TERMINAL

WIRE

HAND TOOL

OPEN

TERMINAL

Figure 2

WIRE

CONDUCTOR PUNCH

TERMINAL

BARREL

CONDUCTOR

ANVIL

TAB SIZE

CUT

OFF

TAB

FEMALE QD

MWID OR MAX

INSULATION DIAMETER

STRIP

LENGTH

MALE QD

TAPE OR

MOLDED REF

WIRE STOP

BRUSH

TAB

SIZE

TERMINAL

STRIP

DEFINITION OF TERMS

The illustrations in this document are a general representation. Some of the terminals may look different and be

held in a different area of the terminal.

OPERATION

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

can occur to the tool.

WARNING: Make sure that the wire is DISCONNECTED from any power supply

Make sure work area is clean and dry and wear approved eye protection.

Open the hand tool by squeezing the handles together; at the end of the closing stroke the anti-backup ratchet will

release. Release the handles and the hand tool will open.

Crimping Terminals

1. Select the desired terminal. See the Molex website (http://www.molex.com).

2. Holding the terminal at the contact end, place the terminal in the appropriate nest. See Figure 1.

Hand Crimp Tool for Krimptite / VersaKrimp Terminals

Doc No: ATS-6401600 8 Release Date: 06-27-12 UNCONTROLLED COPY Page of 5

Revision: A Revision Date: 06-27-12

Figure 3

WIRE

CONDUCTOR ANVIL

BUTT SPLICE

VISUALLY

CENTER SPLICE

NDUCTOR

PUNCH

Figure 4

WIRE

CONDUCTOR ANVIL

PARALLEL SPLICE

2ND WIRE

VISUALLY

CENTER SPLICE

CONDUCTOR PUNCH

Note: some terminals may have a large insulation or conductor grip; the grip may need to be slightly closed

(by hand) so it will fit between the open jaws.

. Slowly close the handles of the tool until the terminal is held in place. If the handles are closed too far the

terminal will begin to crimp.

4. Place a pre-stripped wire into the terminal. See terminal product specification on the Molex website. Push the

wire into the terminal barrel until it stops. See Figure 2.

5. While holding the wire in place, slowly close the handles of the tool. If a jam occurs, stop closing the tool and

release the anti-backup ratchet located on the top of the tool. Pushing it forward will release the jaws. See

Figure 5.

6. Continue to close the tool handles until the anti-backup ratchet releases. Allow the handles to open.

7. Remove the crimped terminal from the tool.

8. Inspect the crimp for loose wire strands, missing crimp, or other damage. Any minor terminal bending may be

straightened by hand.

Crimping Butt and Parallel Splices

1. Position the splice into the desired nest.

2. Partially close the tool to hold the splice in place.

. Insert the properly stripped wire into the splice. The wires end should butt against the tab in the terminal. See

Figure .

4. Continue to close the tool handles until the anti-backup ratchet releases. Allow the handles to open.

5. Remove the crimped splice. Inspect for proper crimp location.

6. Rotate the butt splice terminal 180°, so that the opposite end of splice is in the nest.

7. Repeat steps 1 thru 4.

8. Crimping parallel splices insert the 1st wire into one end of splice then insert the 2nd wire into the opposite end

of the parallel splice. This procedure will crimp both wires at the same time. Make sure the wires are fully

seated into the parallel splice. Position the splice and the wires in proper coded nest with conductor crimp on

the conductor barrel of the splice. The splice should be approximately centered inside the tooling nests. See

Figure 4.

Hand Crimp Tool for Krimptite / VersaKrimp Terminals

Doc No: ATS-6401600 8 Release Date: 06-27-12 UNCONTROLLED COPY Page 4 of 5

Revision: A Revision Date: 06-27-12

Fig

ure

9. Continue to close the tool handles until the anti-backup ratchet releases. Allow the handles to open.

10. Remove the crimped terminal from the tool.

11. Inspect the crimp for loose wire strands, missing crimp, or other damage. Any minor terminal bending may

be straightened by hand.

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.

. Make certain all pins; pivot points and bearing surfaces are protected

with a thin coat of high quality machine oil. Do not oil excessively. Light oil (such as SAE 0W oil) applied at

the oil points, shown in Figure 4, every 5,000 crimps or months, is recommended.

4. Wipe excess oil from hand tool, particularly from crimping area. Oil transferred from the crimping area onto

certain terminations may affect the electrical characteristics of an application.

5. 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

If the tool ever becomes jammed in a partially closed position, DO NOT

force the handles open or closed. The tool will open by lifting the ratchet

release lever. See Figure 5.

Tool Handle Preload

Tool handle preload should NOT require adjustment upon receipt of tool.

This hand tool is set from the factory to a preload that will fully close the tool jaws without excessive force from the

operator. Over the life of the tool the tool linkage can wear and handle preload force may decrease and preload

can be adjusted. It is the operator’s responsibility to periodically perform a tensile pull test on the crimped wire. If

the pull test value falls below the specification, the preload should be adjusted. If after adjustment, the crimp does

not meet the pull test value, then the tool should be replaced.

Warranty

This tool is for electrical terminal crimping purposes only. All tools are warranted to be free of manufacturing

defects for a period of 0 days. Should such a defect occur, the tool will be repaired or exchanged free of charge.

This 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.

ServiceGrade™ crimp hand tools are low cost tools used in field repair for a limited number of terminations. If a

high quality tool is required or a higher volume of terminations required, please purchase the corresponding

PremiumGrade™ crimp hand tool. A ServiceGrade™ crimp tool may or may not have a terminal locator and in

some case may need the locator removed to operate properly.

Fig

ure

RATCHET RELEASE

LEVER

Hand Crimp Tool for Krimptite / VersaKrimp Terminals

Doc No: ATS-6401600 8 Release Date: 06-27-12 UNCONTROLLED COPY Page 5 of 5

Revision: A Revision Date: 06-27-12

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. NEVER perform crimps on active

electrical circuits.

. Wear eye protection at all times.

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

Certification

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

customers to maintain their 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 (1.00”) 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 replaced.

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

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