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
1.00
PRELOAD
TEST POINT
PRELOAD
TEST POINT
RATCHET
RELEASE LEVER
PUSH UP
Fi
g
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
6
SCREW AND PLASTIC
COVER FOR HANDTOOL
PRELOAD ADJUSTMENT
RATCHET
RELEASE LEVER
3
1
2
M4 X 12LG
PAN HEADSCREW
M4 LOCKNUT W/
HEX NYLON INSERT
M4 FLAT WASHER
10 7
9
5
4
REPAIR KIT. ALL PARTS REQUIRED FOR
REPAIR. (ONLY MAIN SPRING SHOWN)
(2)
8
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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