Molex 207129 Series User manual

64001-7100 Hand Crimp Tool

Doc No. ATS-640017100 Release Date: 11-21-06 UNCONTROLLED COPY Page 1 of 6

Revision: A Revision Date: 11-21-06

Hand Crimp Tool

Operating Instruction Sheet and Specifications

Part No. 64001-7100

(Replaces 19078-0001)

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 Cass II



Single crimp pocket eliminates the possibility of using the wrong pocket

SCOPE

Products: AviKrimpFemale Fully Insulated Quick Disconnect 22-16 AWG DOUBLES (Expanded Flare and Oval Barrel)

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

22 (2) 8

20 (2) 13

18 (2) 20

16 (2) 30

*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: 16 – 22 AWG DOUBLES 1.30 – 0.35mm²

Wire Strip Length Insulation Diameter Max.

Terminal No. Terminal

Eng No. (REF) In mm In mm

19600-1300 19600-1300 .312 7.94 .175 4.45

19600-1302 19600-1302 .312 7.94 .175 4.45

19600-1304 19600-1304 .312 7.94 .175 4.45

64001-7100 Hand Crimp Tool

Doc No. ATS-640017100 Release Date: 11-21-06 UNCONTROLLED COPY Page 2 of 6

Revision: A Revision Date: 11-21-06

OPERATION

Open the tool by first closing the jaws

sufficiently for the ratchet mechanism to

release.

Crimping Terminals

1. There are 2 tab locator blades supplied

with the tool. One is for .187 and .250

tabs; the other is for .205 tabs and .110 tabs. Make sure the proper blade is installed on the top of the locator and the other is

stored on the bottom of the locator.

2. Push the terminal onto the tab locator all the way to the stop in the color-coded nest. The barrel of the terminal should be facing

up. See Figure 1.

3. Partially close the tool to hold the terminal in place. See Figure 2.

4. Insert the properly stripped wires into the terminal barrel. See Figure 2 and 3. The wire’s end should butt against the wire stop

stamped into each terminal. Cycle the tool.

Note: The tamper proof ratchet action will not release the tool until it has been fully closed.

5. Remove the crimp and inspect for proper crimp

location, and check for insulation closure. Molex

offers a Crimp Inspection Handbook for closed barrel

industrial product. See our website or contact your

sales engineer.

6. 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.

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.

LOCATOR

JAWS

OPEN

TAB

LOCATOR

Figure 1

TERMINAL

WIRES

TERMINAL

Figure 2

Figure 3

2ND TAB

LOCATOR

WIRES

TERMINAL

BARREL

INSULATION

PUNCH

CONDUCTOR

ANVIL

LOCATOR

INSULATION

ANVIL

1ST TAB

LOCATOR

WIRE STOP BUILT

INTO TERMINAL

CONDUCTOR

PUNCH

TERMINAL

64001-7100 Hand Crimp Tool

Doc No. ATS-640017100 Release Date: 11-21-06 UNCONTROLLED COPY Page 3 of 6

Revision: A Revision Date: 11-21-06

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. This

hand tool 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

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 pressing 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

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

crimp force is adjusted.

Figure 5

PRELOAD

ADJUSTMENT

LOCKING SCREW

1.00

PRELOAD

TEST POINT

PRELOAD

TEST POINT

RATCHET

RELEASE LEVER

PUSH UP

ure 4

LUBRICATION POINTS

(BOTH SIDES)

LIGHT OIL (EVERY 3 MONTHS

OR 5,000 CRIMPS)

3/32”HEX

WRENCH

LOOSEN

M4 SCREW

64001-7100 Hand Crimp Tool

Doc No. ATS-640017100 Release Date: 11-21-06 UNCONTROLLED COPY Page 4 of 6

Revision: A Revision Date: 11-21-06

“X ”NOT POSSIBLE TO PIN GAUGE, MEASURE A

CRIMPED UNINSULATED TERMINAL OR SLUG*

*SOLDER, LEAD OR

SIMILAR SOFT METAL

Tool Calibration

A Certificate of Calibration (See Last Page) was supplied with the tool. To recalibrate this Tool, a soft metal slug or solder should be

crimped in the conductor nest and the “X”Dimension measured 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.

Wire Range “X”Dimension

Conductor Crimp

Nest Color Code

Awg mm²Mean Go No Go

Crimp Inspection

Marking

Yellow 16-22 (2) 1.30-0.35 .095 .092 .099 ---

CAUTION: Repetitive use of this tool should be avoided.

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.

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.

64001-7100 Hand Crimp Tool

Doc No. ATS-640017100 Release Date: 11-21-06 UNCONTROLLED COPY Page 5 of 6

Revision: A Revision Date: 11-21-06

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 LOCKNUT W/

HEX NYLON INSERT

M4 FLAT WASHER

10 7

REPAIR KIT. ALL PARTS REQUIRED FOR

REPAIR. (ONLY MAIN SPRING SHOWN)

(2)

PARTS LIST

Item Order No Description Quantity

64001-7100 Hand Crimp Tool Figure 6

1 64000-0076 Repair Kit (Springs, Pins and E-Rings) 1

2 63810-0000 Handle 1

3 64001-0275 Locator Assembly 1

4 64001-7170 Tooling Kit 1

Tooling Kit Only

5 64001-7101 Conductor Punch 1

6 64001-7102 Conductor Anvil 1

7 64001-7104 Insulation Punch 1

8 64001-7103 Insulation Anvil 1

9 N/A 4mm 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).

64001-7100 Hand Crimp Tool

Doc No. ATS-640017100 Release Date: 11-21-06 UNCONTROLLED COPY Page 6 of 6

Revision: A Revision Date: 11-21-06

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.

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