molex 64001-5900 User manual

64001-5900 Hand Crimp Tool
Doc No. ATS-640015900 Release Date: 11-22-05 UNCONTROLLED
COPY Page 1 of 8
Revision: B Revision Date: 12-06-06
Hand Crimp Tool
Operating Instruction Sheet
And Specifications
Part No. 64001-5900
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Male Quick Disconnect Terminal for 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
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
19025-0005
CMCT-5
.375
9.53
.225
5.70

64001-5900 Hand Crimp Tool
Doc No. ATS-640015900 Release Date: 11-22-05 UNCONTROLLED
COPY Page 2 of 8
Revision: B Revision Date: 12-06-06
Figure 2
TERMINAL
WIRE
TERMINAL
LOCATOR
WIRE
INSULATION
PUNCH
Figure 3
CONDUCTO
R
PUNCH
TERMINA
L
BARREL
CONDUCTOR ANVIL
INSULATION ANVIL
OPERATION
Open the tool by first closing the jaws sufficiently for the
ratchet mechanism to release.
Crimping Terminals
1. Push up on the locator blade and position the terminal
with the barrel facing up into the color-coded nest with
front edge of the barrel against the locator. See Figure
1. Release the locator blade to hold the terminal in
position.
2. Partially close the tool to hold the terminal in place. See
Figure 2.
3. Insert the properly stripped wire into the terminal barrel. See Figure 2 and 3. The wires
end should butt against the wire stop position of the locator. Cycle the tool.
Note: The tamper proof ratchet action will not release the tool
until it has been fully closed.
4. Lift the locator blade or wire stop and remove the crimped terminal. Inspect for proper
crimp location, and check for insulation closure. Locator is adjustable up and down to
keep terminals straight after crimping.
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
FRONT
EDGE
OF
BARREL
LOCATOR
PUSH UP

64001-5900 Hand Crimp Tool
Doc No. ATS-640015900 Release Date: 11-22-05 UNCONTROLLED
COPY Page 3 of 8
Revision: B Revision Date: 12-06-06
Note: Whenever crimping without the locator, make sure the seam of the terminal is
oriented up or down in the tool if using unbrazed product, as this will provide higher pull
force values.

64001-5900 Hand Crimp Tool
Doc No. ATS-640015900 Release Date: 11-22-05 UNCONTROLLED
COPY Page 4 of 8
Revision: B Revision Date: 12-06-06
PRELOAD
ADJUSTMENT
LOCKING
SCREW
1.00
1.00
RATCHET
RELEASE
LEVER
PUSH UP
PRELOAD
TEST
POINT
PRELOAD
TEST
POINT
Figure 5
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 64001-5900 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 Fig.5).
LUBRICATION POINTS
(BOTH SIDES)
LIGHT OIL (EVERY 3
MONTHS
OR 5,000 CRIMPS)
LOOSEN M4
SCREW
Figure 4
3/32” HEX
WRENCH

64001-5900 Hand Crimp Tool
Doc No. ATS-640015900 Release Date: 11-22-05 UNCONTROLLED
COPY Page 5 of 8
Revision: B Revision Date: 12-06-06
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.
5. Replace the plastic cover washer and screw.
6. Check the crimp specifications after tool handle preload force is adjusted.
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 5) 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
.160
.157
.168
N/A
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.
PIN GAUGE IN
CONDUCTOR
CRIMP
“CONFINING”
CRIMP
X

64001-5900 Hand Crimp Tool
Doc No. ATS-640015900 Release Date: 11-22-05 UNCONTROLLED
COPY Page 6 of 8
Revision: B Revision Date: 12-06-06
CAUTION: Molex crimp specifications are valid only when used with Molex
terminals, applicators and tooling.

64001-5900 Hand Crimp Tool
Doc No. ATS-640015900 Release Date: 11-22-05 UNCONTROLLED
COPY Page 7 of 8
Revision: B Revision Date: 12-06-06
Figure 6
M4 X 30LG
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
10
7
8
9
5
4
REPAIR KIT. ALL PARTS
REQUIRED FOR
REPAIR. (ONLY MAIN SPRING
SHOWN)
(2)
PARTS LIST
Item
Order No.
Description
Quantity
64001-5900
Hand Crimp Tool
Figure 6
1
64000-0076
Repair Kit (Springs, Pins and E-Rings)
1
2
63810-0000
Handle
1
3
64001-4875
Locator Assembly
1
4
64001-5970
Tooling Kit
1
Tooling Kit Only
5
64001-5904
Conductor Punch
1
6
64001-5905
Conductor Anvil
1
7
64001-4804
Insulation Punch
1
8
64001-4803
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).

64001-5900 Hand Crimp Tool
Doc No. ATS-640015900 Release Date: 11-22-05 UNCONTROLLED
COPY Page 8 of 8
Revision: B 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]
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Yamato, Kanagawa, Japan
81-462-65-2324
[email protected]
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Jurong, Singapore
65-6-268-6868
[e-mail]
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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