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
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
X

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
6
SCREW AND PLASTIC
COVER FOR HANDTOOL
PRELOAD ADJUSTMENT
RATCHET
RELEASE LEVER
3
1
2
M4 X 12LG
PAN HEADSCREW
M4 WING NUT
M4 FLAT WASHER
7 8
9
5
4 REPAIR KIT. ALL PARTS REQUIRED FOR
REPAIR. (ONLY MAIN SPRING SHOWN)
(2)
10

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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