0640012800

RHT 64001-2800 Hand Crimp Tool Hand Crimp Tool Operating Instruction Sheet And Specifications Part No. 64001-2800 (Replaces 19803-1020) FEATURES Œ Œ Œ Œ Œ 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) 12 10 *UL - 310 70 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 Terminal No. 19006-0019 19007-0040 19007-0082 Wire Size: 10 – 12 AWG 5.00 – 3.00mm² Wire Strip Length Insulation Diameter Max. Terminal Eng No. (REF) In. mm In. mm C-5211 .344 8.73 .245 6.22 C-2211 .344 8.73 .260 6.60 C-2211V .344 8.73 .260 6.60 Doc No. ATS-640012800 Release Date: 05-30-03 UNCONTROLLED COPY Revision: E Revision Date: 12-06-06 Page 1 of 7 RHT 64001-2800 Hand Crimp Tool OPERATION JAWS OPEN Open the tool by first closing the jaws sufficiently for the ratchet mechanism to release. LOCATOR 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 Figure 1 1. If terminal is not flush against the locator loosen the M4 TERMINAL 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. CONDUCTOR PUNCH INSULATION PUNCH FLAT EDGE OF TERMINAL TERMINAL BARREL LOCATOR M4 WING NUT WIRE TERMINAL WIRE Figure 2 CONDUCTOR ANVIL Figure 3 INSULATION ANVIL 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. Doc No. ATS-640012800 Release Date: 05-30-03 UNCONTROLLED COPY Revision: E Revision Date: 12-06-06 Page 2 of 7 RHT 64001-2800 Hand Crimp Tool Maintenance It is recommended that each operator of the tool be made aware of, and responsible for, the following maintenance steps: LUBRICATION POINTS (BOTH SIDES) LIGHT OIL (EVERY 3 MONTHS OR 5,000 CRIMPS) LOOSEN M4 SCREW 1. Remove dust, moisture, and other contaminants with a clean brush, or soft, lint free cloth. 3/32” HEX 2. Do not use any abrasive materials that WRENCH could damage the tool. 3. Make certain all pins; pivot points and Figure 4 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 PRELOAD of the hand tool to obtain proper crimp 1.00 TEST POINT 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. PRELOAD TEST POINT RATCHET RELEASE LEVER PUSH UP PRELOAD ADJUSTMENT LOCKING SCREW Doc No. ATS-640012800 Release Date: 05-30-03 UNCONTROLLED COPY Revision: E Revision Date: 12-06-06 1.00 Figure 5 Page 3 of 7 RHT 64001-2800 Hand Crimp Tool 6. Check the crimp specifications after tool handle preload force is adjusted. Doc No. ATS-640012800 Release Date: 05-30-03 UNCONTROLLED COPY Revision: E Revision Date: 12-06-06 Page 4 of 7 RHT 64001-2800 Hand Crimp Tool PIN GAUGE IN CONDUCTOR CRIMP 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 Yellow X “CONFINING” CRIMP “X” Dimension Conductor Crimp Crimp Inspection Marking AWG mm² Mean Go No Go 10-12 5.00-3.00 .115 .112 .118 o Wire Range 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. Doc No. ATS-640012800 Release Date: 05-30-03 UNCONTROLLED COPY Revision: E Revision Date: 12-06-06 Page 5 of 7 RHT 64001-2800 Hand Crimp Tool PARTS LIST Item 1 2 3 4 Order No. 64001-2800 64000-0076 63810-0000 64001-2875 64001-2870 5 6 7 8 9 10 64001-2801 64001-2802 64001-2804 64001-2803 N/A N/A Description Hand Crimp Tool Repair Kit (Springs, Pins and E-Rings) Handle Locator Assembly Tooling Kit Tooling Kit Only Conductor Punch Conductor Anvil Insulation Punch Insulation Anvil 4 mm Diameter by 5.0mm Long Roll Pins #10-32 by 5/16” Long Cup Pt. Set Screw Quantity Figure 6 1 1 1 1 1 1 1 1 2** 1** ** The following purchased parts are available from an Industrial supply company such as MSC (1-800645-7270). 2 M4 WING NUT M4 FLAT WASHER RATCHET RELEASE LEVER 3 SCREW AND PLASTIC COVER FOR HANDTOOL PRELOAD ADJUSTMENT M4 X 12LG PAN HEADSCREW 5 6 (2) 9 10 7 FOR SPRING ACCESS SWING OPEN COVER 8 4 Figure 6 1 M4 X 25LG PAN HEAD SCREW REPAIR KIT. ALL PARTS REQUIRED FOR REPAIR. (ONLY MAIN SPRING SHOWN) Doc No. ATS-640012800 Release Date: 05-30-03 UNCONTROLLED COPY Revision: E Revision Date: 12-06-06 Page 6 of 7 RHT 64001-2800 Hand Crimp Tool 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. mericas Headquarters Far East North Headquarters Far East South Headquarters European Headquarters Corporate Headquarter TMF
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 Visit our Web site at http://www.molex.com Doc No. ATS-640012800 Release Date: 05-30-03 UNCONTROLLED COPY Revision: E Revision Date: 12-06-06 Page 7 of 7