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

*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.

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

PUNCH

TERMINA

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

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

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

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

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

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)

PARTS LIST

Item

Order No.

Description

Quantity

64001-5900

Hand Crimp Tool

Figure 6

64000-0076

Repair Kit (Springs, Pins and E-Rings)

63810-0000

Handle

64001-4875

Locator Assembly

64001-5970

Tooling Kit

Tooling Kit Only

64001-5904

Conductor Punch

64001-5905

Conductor Anvil

64001-4804

Insulation Punch

64001-4803

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).

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]

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

Table of contents

Other molex Crimping Tools manuals

Popular Crimping Tools manuals by other brands

Panduit

Panduit CT-1000 Operation & instruction manual

JST

JST CS 10 instruction manual

Danfoss

Danfoss ET4200 Operator's manual

Tyco Electronics

Tyco Electronics PRO-CRIMPER III instruction sheet

TE Connectivity

TE Connectivity 2063528-1 instruction sheet

Tyco Electronics

Tyco Electronics 69156-1 instruction sheet

CRH

CRH CRL CBLHCT1 instruction manual

Emerson

Emerson Klauke ES 105CFM manual

KIMBALL MIDWEST

KIMBALL MIDWEST 27-798 Operating instructions manual

Danfoss

Danfoss ET4350 Operator's manual

Milwaukee

Milwaukee M18 Operator's manual

HOGERT

HOGERT HT1P169 user manual

Textron

Textron ESG105L instruction manual

Tyco Electronics

Tyco Electronics 90035-3 instruction sheet

Emerson

Emerson Klauke ES 20RMCCFB manual

Continental Refrigerator

Continental Refrigerator PC150HD quick start guide

TE Connectivity

TE Connectivity ERGOCRIMP 1-1579001-3 instruction sheet

Tyco Electronics

Tyco Electronics CERTI-CRIMP 90418-1 instruction sheet

molex 64001-5900 User manual

Popular Crimping Tools manuals by other brands