molex 64001-2800 User manual

RHT 64001-2800 Hand Crimp Tool
Doc No. ATS-640012800 Release Date: 05-30-03 UNCONTROLLED
COPY Page 1 of 7
Revision: E Revision Date: 12-06-06
Hand Crimp Tool
Operating Instruction Sheet
And Specifications
Part No. 64001-2800
(Replaces 19803-1020)
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
Single color-coded crimp pocket eliminates the possibility of using the wrong pocket
SCOPE
Products: AviKrimpFully Insulated and-Insulated Quick Disconnect Flags 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 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
70
10
80
*UL - 310 –Quick Disconnects, Flags and Couplers
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 –3.00mm²
Terminal No.
Terminal Eng No. (REF)
Wire Strip Length
Insulation Diameter Max.
In.
mm
In.
mm
19006-0019
C-5211
.344
8.73
.245
6.22
19007-0040
C-2211
.344
8.73
.260
6.60
19007-0082
C-2211V
.344
8.73
.260
6.60

RHT 64001-2800 Hand Crimp Tool
Doc No. ATS-640012800 Release Date: 05-30-03 UNCONTROLLED
COPY Page 2 of 7
Revision: E Revision Date: 12-06-06
OPERATION
Open the tool by first closing the jaws sufficiently for the
ratchet mechanism to release.
Crimping Terminals
1. Insert the terminal with the barrel into the color-coded
nest and the square edge of the flag facing out. Make
sure the back of the flag terminal is against the
locator. See Figure 1. If terminal is not flush against
the locator loosen the M4 wing nut and adjust the
locator up or down so that the flat edge of the terminal is flush against the wall of the
locator. Tighten the M4 wing nut. See Figure 3.
2. Partially close the tool to hold the terminal in place shown in Figure 2.
3. Insert the properly stripped wire into the terminal barrel. See Figure 2 and 3. The wire
ends should butt against the inside of the connector. Cycle the tool.
Note: The tamper proof ratchet action will not release the tool until it has
been fully closed.
4. Remove the crimped terminal. Inspect for proper crimp location, and check for
insulation closure.
5. 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 (CW) rotation decreases insulation crimp while a
counter-clockwise (CCW) rotation increases insulation crimp. After adjusting, retighten
the M4 screw.
TERMINAL
JAWS OPEN
Figure 1
LOCATOR
M4 WING NUT
Figure 2
TERMINAL
WIRE
FLAT EDGE
OF
TERMINAL
WIRE
INSULATIO
N
PUNCH
CONDUCTO
R
ANVI
L
INSULATION
ANVIL
Figure 3
CONDUCTO
R
PUNCH
TERMINA
L
BARREL
LOCATOR

RHT 64001-2800 Hand Crimp Tool
Doc No. ATS-640012800 Release Date: 05-30-03 UNCONTROLLED
COPY Page 3 of 7
Revision: E Revision Date: 12-06-06
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 are protected
with a thin coat of high quality machine oil. Do not oil excessively. The 64001-2800
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
1. 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.
3. Turning the eccentric axle
counter-clockwise (CCW) will
increase handle force.
4. Replace the setting wheel to
the axle, aligning the nearest
notch in the setting wheel to the dowel pin.
LUBRICATION POINTS
(BOTH SIDES)
LIGHT OIL (EVERY 3
MONTHS
OR 5,000 CRIMPS)
LOOSEN M4
SCREW
Figure 4
3/32” HEX
WRENCH
Figure 5
PRELOAD
ADJUSTMENT
LOCKING
SCREW
1.00
1.00
PRELOAD
TEST
POINT
PRELOAD
TEST
POINT
RATCHET
RELEASE
LEVER
PUSH UP

RHT 64001-2800 Hand Crimp Tool
Doc No. ATS-640012800 Release Date: 05-30-03 UNCONTROLLED
COPY Page 4 of 7
Revision: E Revision Date: 12-06-06
5. Replace the plastic cover washer and screw.
6. Check the crimp specifications after tool handle preload force is adjusted.

RHT 64001-2800 Hand Crimp Tool
Doc No. ATS-640012800 Release Date: 05-30-03 UNCONTROLLED
COPY Page 5 of 7
Revision: E Revision Date: 12-06-06
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 Tool Preload
(See Figure 6) to recalibrate.
Nest Color Code
Wire Range
“X” Dimension
Conductor Crimp
Crimp Inspection Marking
AWG
mm²
Mean
Go
No Go
Yellow
10-12
5.00-3.00
.115
.112
.118
o
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.
PIN GAUGE IN
CONDUCTOR
CRIMP
“CONFINING”
CRIMP
X

RHT 64001-2800 Hand Crimp Tool
Doc No. ATS-640012800 Release Date: 05-30-03 UNCONTROLLED
COPY Page 6 of 7
Revision: E Revision Date: 12-06-06
PARTS LIST
Item
Order No.
Description
Quantity
64001-2800
Hand Crimp Tool
Figure 6
1
64000-0076
Repair Kit (Springs, Pins and E-Rings)
1
2
63810-0000
Handle
1
3
64001-2875
Locator Assembly
1
4
64001-2870
Tooling Kit
1
Tooling Kit Only
5
64001-2801
Conductor Punch
1
6
64001-2802
Conductor Anvil
1
7
64001-2804
Insulation Punch
1
8
64001-2803
Insulation Anvil
1
9
N/A
4 mm Diameter by 5.0mm Long Roll Pins
2**
10
N/A
#10-32 by 5/16” Long Cup Pt. Set Screw
1**
** The following purchased parts are available from an Industrial supply company such as
MSC (1-800-645-7270).
Figure 6
M4 X 25LG
PAN HEAD
SCREW
FOR SPRING
ACCESS
SWING
OPEN COVER
6
SCREW AND
PLASTIC
COVER FOR
HANDTOOL
PRELOAD
ADJUSTMENT
RATCHET
RELEASE
LEVER
3
1
2
M4 X 12LG
PAN
HEADSCREW
M4 WING NUT
M4 FLAT
WASHER
7
8
9
5
4
REPAIR KIT. ALL PARTS
REQUIRED FOR
REPAIR. (ONLY MAIN SPRING
SHOWN)
(2)
10

RHT 64001-2800 Hand Crimp Tool
Doc No. ATS-640012800 Release Date: 05-30-03 UNCONTROLLED
COPY Page 7 of 7
Revision: E Revision Date: 12-06-06
Certificate of Calibration
Tool Order Number __________________
Tool Eng. 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 # 1 = ____________-- Actual = ______________
Technician ______________
Date of Calibration ______________
Calibration should be done every 5,000 cycles or 3 months.
Tools should be lubricated during this operation.
Americas Headquarters
Lisle, Illinois 60532 U.S.A.
1-800-78MOLEX
amerinf[email protected]
Far East North Headquarters
Yamato, Kanagawa, Japan
81-462-65-2324
[email protected]
Far East South Headquarters
Jurong, Singapore
65-6-268-6868
[e-mail]
European Headquarters
Munich, Germany
49-89-413092-0
[email protected]
Corporate Headquarters
2222 Wellington Ct.
Lisle, IL 60532 U.S.A.
630-969-4550
Fax: [phone]
Visit our Web site at http://www.molex.com