0640010700

RHT 5757-CC Hand Crimp Tool Hand Crimp Tool Operating Instruction And Specifications Sheet Order No. 64001-0700 Eng. No. RHT 5757-CC (Replaces 19285-0036) FEATURES Œ Œ Œ Œ 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 Single color-coded crimp pocket eliminates the possibility of using the wrong pocket SCOPE InsulKrimp Male and Female Fully Insulated Quick Disconnect, Perma-Seal Female Quick Disconnect 18 - 22 AWG Conductor Crimp only. 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) 22 20 18 *UL - 310 8 13 20 *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. Terminal No. 19003-0001 19003-0005 19003-0008 19003-0011 19003-0014 19003-0017 19003-0021 19003-0024 19003-0027 Wire Size: 18 – 22 AWG 0.80 – 0.35 mm² Wire Strip Length Insul. Dia. Max. Terminal Eng No. (REF) In. mm In. mm AA-2201 0.234 5.953 0.135 3.429 AA-2201VN 0.234 5.953 0.135 3.429 AA-2201X 0.234 5.953 0.230 5.842 AA-2202 0.234 5.953 0.135 3.429 AA-2202X 0.234 5.953 0.230 5.842 AA-2203 0.234 5.953 0.135 3.429 AA-2203X 0.234 5.953 0.230 5.842 AA-2204 0.234 5.953 0.135 3.429 AA-2204X 0.234 5.953 0.230 5.842 Doc No. 64001-0700 Revision: C Release Date: 12-11-02 Revision Date: 09-02-03 Terminal No. 19003-0030 19003-0033 19003-0036 19003-0038 19023-0053 19164-0012 Wire Size: 18 – 22 AWG 0.80 – 0.35 mm² Terminal Wire Strip Length Insul. Dia. Max. In. mm In. mm AA-2205 0.234 5.953 0.135 3.429 AA-2205X 0.234 5.953 0.230 5.842 AA-2213 0.234 5.953 0.135 3.429 AA-2214 0.234 5.953 0.135 3.429 AA-2207X 0.250 6.350 0.260 6.604 SAA-2140 0.203 5.159 UNCONTROLLED COPY Page 1 of 6 RHT 5757-CC Hand Crimp Tool OPERATION Open the tool by first closing the jaws sufficiently for the ratchet mechanism to release. JAWS OPEN TERMINAL 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. TAB LOCATOR LOCATOR Figure 1 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 up (See Figure 1). 3. Partially close the tool to hold the terminal in place (See Figure 2). 4. Insert the properly stripped wire into the terminal barrel (See Figure 2 and 3). Cycle the tool. CONDUCTOR PUNCH WIRE STOP BUILT INTO TERMINAL TERMINAL WIRE TERMINAL PUNCH INSERT WIRE ST 1 TAB LOCATOR Figure 2 TERMINAL BARREL LOCATOR Note: The tamper proof ratchet action will not release the tool until it has been fully closed. ND 2 TAB LOCATOR ANVIL INSERT CONDUCTOR ANVIL Figure 3 5. Remove the crimp and inspect for proper crimp location. Molex offers a Crimp Inspection Handbook for closed barrel industrial product. See our website or contact your sales engineer. 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. Doc No. 64001-0700 Revision: C Release Date: 12-11-02 Revision Date: 09-02-03 UNCONTROLLED COPY Page 2 of 6 RHT 5757-CC Hand Crimp Tool Maintenance LUBRICATION POINTS (BOTH SIDES) LIGHT OIL (EVERY 3 MONTHS OR 5,000 CRIMPS) 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 64001-0700 (RHT-5757-CC) was engineered for durability, but like any fine piece of equipment it needs cleaning and lubrication for a maximum Figure 4 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 PRELOAD crimp conditions: 1.00 TEST POINT 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. Doc No. 64001-0700 Revision: C Release Date: 12-11-02 Revision Date: 09-02-03 PRELOAD TEST POINT RATCHET RELEASE LEVER PUSH UP PRELOAD ADJUSTMENT LOCKING SCREW UNCONTROLLED COPY 1.00 Figure 5 Page 3 of 6 RHT 5757-CC Hand Crimp Tool Tool Calibration PIN GAUGE IN CONDUCTOR CRIMP 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. “X” “ Confining ” Crimp Wire Range Nest Color Code Red AWG 18 - 22 mm² 0.35 - 0.80 “X” Dimension Conductor Crimp Mean Go No Go .080 .076 .088 Crimp Inspection Marking oo 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: Repetitive use of this tool should be avoided. Doc No. 64001-0700 Revision: C Release Date: 12-11-02 Revision Date: 09-02-03 UNCONTROLLED COPY Page 4 of 6 RHT 5757-CC Hand Crimp Tool PARTS LIST Item 1 2 3 4 Order No 64001-0700 64000-0076 63810-0000 64001-0275 64001-0770 5 6 7 8 9 64001-0702 64001-0701 64001-0712 64001-0711 N/A Description Hand Crimp Tool Repair Kit (Springs, Pins and E-Rings) Handle Locator Assembly Tooling Kit Tooling Kit Only Conductor Punch Conductor Anvil Insert Punch Insert Anvil 4 mm Dia. by 5.0 mm Lg.Roll Pins Quantity (Fig. 6) 1 1 1 1 1 1 1 1 2** ** The following purchased parts are available from an Industrial supply company such as MSC (1-800-645-7270). 2 M4 LOCKNUT W/ HEX NYLON INSERT M4 FLAT WASHER RATCHET RELEASE LEVER 3 SCREW AND PLASTIC COVER FOR HANDTOOL PRELOAD ADJUSTMENT M4 X 12LG PAN HEADSCREW 5 6 9 7 FOR SPRING ACCESS SWING OPEN COVER (2) 8 1 4 M4 X 30LG PAN HEAD SCREW REPAIR KIT. ALL PARTS REQUIRED FOR REPAIR. (ONLY MAIN SPRING SHOWN) Figure 6 Doc No. 64001-0700 Revision: C Release Date: 12-11-02 Revision Date: 09-02-03 UNCONTROLLED COPY Page 5 of 6 RHT 5757-CC Hand Crimp Tool 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 = ______________ Range Conductor Nest # 2 = ____________-- Actual = ______________ Range Conductor Nest # 3 = ____________-- Actual = ______________ Technician ______________ Date of Calibration ______________ Calibration should be done every 5,000 cycles or 3 months. Tools should be lubricated during this operation. Molex Application Tooling Group 1150 E. Diehl Road Naperville, IL 60563 Tel: (630) 969-4550 Fax: (630) 505-0049 Doc No. 64001-0700 Revision: C Release Date: 12-11-02 Revision Date: 09-02-03 UNCONTROLLED COPY Page 6 of 6