Molex 64001-2800 Manuale utente

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

*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.

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

TERMINAL

WIRE

INSULATIO

PUNCH

CONDUCTO

ANVI

INSULATION

ANVIL

Figure 3

CONDUCTO

PUNCH

TERMINA

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

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

No Go

Yellow

10-12

5.00-3.00

.115

.112

.118

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

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

64000-0076

Repair Kit (Springs, Pins and E-Rings)

63810-0000

Handle

64001-2875

Locator Assembly

64001-2870

Tooling Kit

Tooling Kit Only

64001-2801

Conductor Punch

64001-2802

Conductor Anvil

64001-2804

Insulation Punch

64001-2803

Insulation Anvil

N/A

4 mm Diameter by 5.0mm Long Roll Pins

2**

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

SCREW AND

PLASTIC

COVER FOR

HANDTOOL

PRELOAD

ADJUSTMENT

RATCHET

RELEASE

LEVER

M4 X 12LG

PAN

HEADSCREW

M4 WING NUT

M4 FLAT

WASHER

REPAIR KIT. ALL PARTS

REQUIRED FOR

REPAIR. (ONLY MAIN SPRING

SHOWN)

(2)

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

fesinfo@molex.com

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: 630-969-1352

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

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