Molex 207129 Series User manual

RHT 64001-2800 Hand Crimp Tool

Doc No. ATS-640012800Release 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

12 70

10 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

Wire Size: 10 – 12 AWG 5.00 – 3.00mm²

Wire Strip Length Insulation Diameter Max.

Terminal No. Terminal Eng No. (REF) In. mm In. mm

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-640012800Release 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 OF

TERMINAL

WIRE

INSULATION

PUNCH

CONDUCTOR

ANVIL INSULATION

ANVIL

Figure 3

CONDUCTOR

PUNCH

TERMINAL

BARREL

LOCATOR

RHT 64001-2800 Hand Crimp Tool

Doc No. ATS-640012800Release 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.

5. Replace the plastic cover washer and screw.

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-640012800Release Date: 05-30-03 UNCONTROLLED COPY Page 4 of 7

Revision: E Revision Date: 12-06-06

6. Check the crimp specifications after tool handle preload force is adjusted.

RHT 64001-2800 Hand Crimp Tool

Doc No. ATS-640012800Release 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.

Wire Range “X”Dimension

Conductor Crimp

Nest Color Code AWG mm²Mean Go No Go Crimp Inspection Marking

Yellow 10-12 5.00-3.00 .115 .112 .118 o

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-640012800Release 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

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

2 63810-0000 Handle 1

3 64001-2875 Locator Assembly 1

4 64001-2870 Tooling Kit 1

Tooling Kit Only

5 64001-2801 Conductor Punch 1

6 64001-2802 Conductor Anvil 1

7 64001-2804 Insulation Punch 1

8 64001-2803 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).

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

7 8

4 REPAIR KIT. ALL PARTS REQUIRED FOR

REPAIR. (ONLY MAIN SPRING SHOWN)

(2)

RHT 64001-2800 Hand Crimp Tool

Doc No. ATS-640012800Release 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.

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