0640011400

RHT2100 Hand Crimp Tool Hand Crimp Tool Operating Instruction And Specifications Sheet Order No. 64001-1400 Eng. No. RHT 2100 (Replaces 19285-0013 and 19285-0016 RHT 2150) FEATURES Œ A full cycle ratcheting hand tool ensures complete crimps Œ Long handles for comfortable crimping with reduced crimping force Œ A precision user-friendly terminal locator wire stop holds terminals in the proper crimping position Œ Insulation crimp adjustment allows a precise insulation crimp. To meet or exceed the requirements of UL, CSA and Military Class II Œ Single color-coded crimp pocket eliminates the possibility of using the wrong pocket SCOPE AviKrimp and InsulKrimp Terminals 14-16 AWG, (Rings, Spades, Hooks, Splices, Snap Spades, Flanged Spades and Wire Pin Terminals). Some Male Quick Disconnects and 3 to 4 Way Connectors. Also terminates ends of step down butt splices14-16 AWG to 18-22 AWG. And Heavy Duty Terminals 16-20 AWG (Green color code). Testing Wire Size **Military Mechanical *UL - 486 A *UL – 486 C (AWG) Class 2 The tensile test or pull test is a means of evaluating 22 8 8 15 the mechanical properties of the crimped 20 13 10 19 connections. The following charts show the UL 18 20 10 38 and Government specifications (MIL-T-7928) for 16 30 15 50 various wire sizes. The tensile strength is shown in 14 50 25 70 pounds and indicates the minimum acceptable force to break or separate terminal from the conductor. *UL - 486 A - Terminals (Copper conductors only). *UL - 486 C - Butt Splices, Parallel Splices, Closed End Connectors, and Wire Nuts. **Military Class 2– Military Approved Terminals only as listed 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: 14 – 16 AWG 2.00 – 1.30 mm² Terminal Wire Strip Length Insul. Dia. Max. Terminal No. Eng No. (REF) In mm In mm 19023-0012 MCT-2X .312 7.94 .175 4.45 19025-0007 MCT-5 .312 7.94 .170 4.32 19025-0008 MCT-57 .312 7.94 .170 4.32 19034-0007 B-279X .312 7.94 .175 4.45 19034-0009 B-289X .312 7.94 .169 4.30 19035-0005 B-579 .312 7.94 .174 4.42 19035-0009 B-589 .312 7.94 .174 4.42 19036-0006 B-879 .312 7.94 .170 4.32 19036-0008 B-889 .312 7.94 .170 4.32 Terminal No. 19070-0059 19070-0063 19070-0065 19070-0067 19070-0069 19070-0071 19070-0073 19070-0075 19070-0078 Wire Size: 14 – 16 AWG 2.00 – 1.30 mm² Terminal Wire Strip Length Insul. Dia. Max. In mm In mm BB-218-38X .234 5.95 .175 4.45 BB-218-56X .234 5.95 .175 4.45 BB-223-02X .234 5.95 .175 4.45 BB-223-04X .234 5.95 .175 4.45 BB-223-06X .234 5.95 .175 4.45 BB-223-08X .234 5.95 .175 4.45 BB-225-10X .234 5.95 .175 4.45 BB-225-14X .234 5.95 .175 4.45 BB-225-56X .234 5.95 .175 4.45 Doc No. 64001-1400 Release Date: 12-02-02UNCONTROLLED COPY Revision: C Revision Date: 08-06-03 Page 1 of 7 RHT2100 Hand Crimp Tool Wire Size: 14 – 16 AWG 2.00 – 1.30 mm² Wire Strip Length Insul. Dia. Max. Terminal Terminal No. Eng No. (REF) In mm In mm 19070-0083 BB-237-06X .234 5.95 .175 4.45 19070-0086 BB-237-08X .234 5.95 .175 4.45 19070-0090 BB-237-10X .234 5.95 .175 4.45 19070-0099 BB-239-08X .234 5.95 .175 4.45 19070-0102 BB-239-10X .234 5.95 .175 4.45 19073-0059 BB-818-38 .250 6.35 .170 4.32 19073-0061 BB-818-56 .250 6.35 .170 4.32 19073-0065 BB-823-04 .250 6.35 .170 4.32 19073-0067 BB-823-06 .250 6.35 .170 4.32 19073-0072 BB-823-08 .250 6.35 .170 4.32 19073-0074 BB-825-10 .250 6.35 .170 4.32 19073-0076 BB-825-14 .250 6.35 .170 4.32 19073-0079 BB-825-56 .250 6.35 .170 4.32 19073-0081 BB-837-04 .250 6.35 .170 4.32 19073-0083 BB-837-06 .250 6.35 .170 4.32 19073-0085 BB-837-08 .250 6.35 .170 4.32 19073-0087 BB-837-10 .250 6.35 .170 4.32 19073-0094 BB-839-08 .250 6.35 .170 4.32 19073-0097 BB-839-10 .250 6.35 .170 4.32 19080-0003 B-2006-MSX .312 7.94 .175 4.45 19081-0003 B-5006-MS .312 7.94 19090-0044 BB-213-04X .234 5.95 .175 4.45 19090-0046 BB-213-06X .234 5.95 .175 4.45 19090-0048 BB-213-08X .234 5.95 .175 4.45 190900071 BB-288-06X .234 5.95 .175 4.45 19090-0075 BB-288-10X .234 5.95 .175 4.45 19095-0135 BB-883-10 .250 6.35 .175 4.45 19095-0138 BB-886-08 .250 6.35 .170 4.32 19095-0140 BB-887-06 .250 6.35 .170 4.32 19095-0141 BB-887-08 .250 6.35 .170 4.32 19099-0025 BB-2707-05X .234 5.95 .175 4.45 19099-0027 BB-2707-06X .234 5.95 .175 4.45 19099-0032 BB-2716-08X .234 5.95 .175 4.45 19115-0016 BB-8193-06 .250 6.35 .170 4.32 19115-0018 BB-8194-08 .250 6.35 .170 4.32 19115-0020 BB-8195-10 .250 6.35 .170 4.32 19115-0022 BB-8707-05 .250 6.35 .170 4.32 19115-0024 BB-8707-06 .250 6.35 .170 4.32 19115-0031 BB-8717-10 .250 6.35 .170 4.32 19115-0079 BB-8716-08 .250 6.35 .170 4.32 19121-0026 BB-216-06X .234 5.95 .175 4.45 19121-0028 BB-216-08X .234 5.95 .175 4.45 19121-0030 BB-216-10X .234 5.95 .175 4.45 19121-0040 BB-283-10X .234 5.95 .175 4.45 19127-0039 BB-816-06 .250 6.35 .170 4.32 19127-0042 BB-816-08 .250 6.35 .170 4.32 19127-0099 BB-816-10 .250 6.35 .170 4.32 19131-0007 BB-287-08X .234 5.95 .175 4.45 19131-0014 BB-2781-10X .234 5.95 .175 4.45 19131-0018 BB-2781-08X .234 5.95 .175 4.45 19131-0020 BB-2781-06X .234 5.95 .175 4.45 1913-10023 BB-2471-06X .234 5.95 .175 4.45 19131-0025 BB-2471-04X .234 5.95 .175 4.45 19139-0038 BB-8471-04 .250 6.35 .170 4.32 19139-0044 BB-8781-08 .250 6.35 .170 4.32 19139-0045 BB-8781-10 .250 6.35 .175 4.45 Terminal No. 19144-0013 19144-0015 19144-0018 19144-0020 19154-0015 19154-0023 19179-0008 19179-0010 19179-0012 19183-0009 19183-0011 19198-0012 19198-0016 19198-0019 19198-0025 19204-0013 19204-0014 19204-0017 19204-0018 19206-0004 19206-0005 19212-0005 19213-0011 Terminal No. 19154-0022 Terminal No. 19095-0074 19095-0076 19095-0133 19095-0134 19095-0136 19095-0137 19095-0139 Wire Size: 14 – 16 AWG 2.00 – 1.30 mm² Terminal Wire Strip Length Insul. Dia. Max. In mm In mm BB-207-04X .312 7.94 .174 4.42 BB-207-06X .234 5.95 .175 4.45 BB-224-06X .234 5.95 .175 4.45 BB-224-08X .234 5.95 .170 4.45 B-231X .234 5.95 .175 4.45 BS-V-331X .281 7.14 .179 4.57 BB-219-06X .234 5.95 .175 4.45 BB-219-08X .234 5.95 .175 4.45 BB-219-10X .234 5.95 .175 4.45 BB-819-08 .250 6.35 .170 4.32 BB-819-10 .250 6.35 .170 4.32 BB-807-06 .234 5.95 .175 4.45 BB-824-06 .250 6.35 .170 4.32 BB-824-08 .250 6.35 .170 4.32 BB-827-10 .250 6.35 .170 4.32 B-2XCX .312 7.94 .175 4.45 B-2YCX .312 7.94 .175 4.45 B-5XC .312 7.94 .174 4.42 B-5YC .312 7.94 .174 4.42 B-204X .281 7.14 .175 4.45 BS-V-304X .281 7.14 .175 4.45 WP-2614X .250 6.35 .170 4.32 WP-8614 .187 4.76 .175 4.45 STEP DOWN BUTT SPLICE Wire Size: 14 – 16 AWG 2.00 – 1.30 mm² to 18-22 AWG .080-0.35 mm² Terminal Wire Strip Length Insul. Dia. Max. Eng No. (REF) In mm In mm BA-631X .281 7.14 .175 4.45 MILITARY CLASS 2 Wire Size: 14 – 16 AWG 2.00 – 1.30 mm² Terminal Wire Strip Length Insul. Dia. Max. Eng No. (REF) In mm In mm BB-882-2 .250 6.35 .171 4.36 BB-883-2 .250 6.35 .171 4.36 BB-880-2 .250 6.35 .171 4.36 BB-881-2 .250 6.35 .171 4.36 BB-884-2 .250 6.35 .171 4.36 BB-885-2 .250 6.35 .171 4.36 BB-886-2 .250 6.35 .171 4.36 HEAVY DUTY Wire Size: 16 – 20 AWG 1.30 – 0.50 mm² Terminal Wire Strip Length Insul. Dia. Max. Terminal No. Eng No. (REF) In mm In mm 19054-0060 AB-225-10HD .234 5.94 .170 4.32 19054-0061 AB-225-14HD .234 5.94 .170 4.32 19054-0062 AB-225-56HD .234 5.94 .170 4.32 19073-0051 AB-825-10HD .234 5.94 .170 4.32 19073-0053 AB-825-14HD .234 5.94 .170 4.32 19073-0055 AB-825-56HD .234 5.94 .170 4.32 Doc No. 64001-1400 Release Date: 12-02-02UNCONTROLLED COPY Revision: C Revision Date: 08-06-03 Page 2 of 7 RHT2100 Hand Crimp Tool JAWS OPEN OPERATION TERMINAL Open the tool by first closing the jaws sufficiently for the ratchet mechanism to release. Note: The tamper proof ratchet Crimping Terminals action will not release the tool until FRONT EDGE OF BARREL 1. Push up on the locator blade and position the terminal with the barrel facing up into the color-coded nest with front edge of the barrel against the locator (See Figure 1). LOCATOR Release the locator blade to hold the terminal in position. PUSH UP Figure 1 2. Partially close the tool to hold the terminal in place (See Figure 2). 3. Insert the properly stripped wire into the terminal barrel (See Figure 2 and 3). The wires end should butt against the wire stop position of the locator. Cycle the tool. 4. Lift the locator blade or wire stop and remove the crimped terminal. Inspect for proper crimp location, and check for insulation closure. Locator is adjustable up and down to keep terminals straight after crimping. 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 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 TERMINAL WIRE (supplied) into the bottom of the lower die (See Figure 5). A Figure 2 clockwise (CW) rotation decreases insulation crimp while a counterclockwise (CCW) rotation increases insulation crimp. After adjusting retighten the M4 screw. CONDUCTOR PUNCH INSULATION PUNCH TERMINA L LOCATOR WIRE TERMINAL CONDUCTO R CONDUCTOR PUNCH BUTT SPLICE WIRE CONDUCTO R INSULATIO N 1/16” INSIDE INSULATION INSULATIO N Figure 3 INSULATION PUNCH Figure 4 6. When crimping butt splices, or 3-way and 4-way terminals the locator must be removed. Splices must be visually aligned with the tooling 1/16” inside the insulation crimp (See Figure 4). The splice should be approximately centered inside the tooling nests (See Figure 4). Cycle the tool. Doc No. 64001-1400 Release Date: 12-02-02UNCONTROLLED COPY Revision: C Revision Date: 08-06-03 Page 3 of 7 RHT2100 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: LOOSEN 1. Remove dust, moisture and other M4 contaminants with a clean brush, or soft, lint-free cloth. 3/32” HEX 2. Do not use any abrasive materials WRENCH that could damage the tool. 3. Make certain all pins, pivot points Figure 5 and bearing surfaces are protected with a thin coat of high quality machine oil. Do not oil excessively. The 64001-1400 (RHT-2100) 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 5, 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 PRELOAD TEST 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 Fig.6). 1.00 How To Adjust Tool Preload (See PRELOAD TEST Figure 6) 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: RATCHET RELEASE LEVER PRELOAD ADJUSTMENT LOCKING 1.00 Figure 6 1. 2. 3. 4. Remove the screw and plastic cover washer. Note the setting wheel position. Lift the setting wheel off the axle. Turn the eccentric axle with a screwdriver. Turning the eccentric axle counter-clockwise (CCW) will increase handle force. 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 handle preload force is adjusted. Doc No. 64001-1400 Release Date: 12-02-02UNCONTROLLED COPY Revision: C Revision Date: 08-06-03 Page 4 of 7 RHT2100 Hand Crimp Tool PIN GAUGE IN CONDUCTOR 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. Nest Color Code Blue Wire Range AWG 14 - 16 16 – 20 HD 18 - 22* mm² 1.30 - 2.00 0.50 - 1.30 0.80 - 0.35 “X” Dimension Conductor Crimp Mean Go No Go .122 .116 .128 .122 .116 .128 .122 .116 .128 X “ CONFINING” Crimp Inspection Marking oo oo oo * 18 - 22 End of step down butt splice only. 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 Doc No. 64001-1400 Release Date: 12-02-02UNCONTROLLED COPY Revision: C Revision Date: 08-06-03 Page 5 of 7 RHT2100 Hand Crimp Tool PARTS LIST Item 1 2 3 4 Order No 64001-1400 64000-0076 63810-0000 64007-0375 64001-1470 5 6 7 8 9 10 64001-1402 64001-1401 64001-1404 64001-1403 N/A 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 Insulation Punch Insulation Anvil 4 mm Dia. by 5.0 mm Lg.Roll Pins #10-32 by 5/16” Lg. Cup Pt. Set Screw Quantity (Fig. 7) 1 1 1 1 1 1 1 1 2** 1** ** The following purchased parts are available from an Industrial supply company such as MSC (1-800645-7270). 2 M4 WING NUT M4 FLAT RATCHET RELEASE 3 SCREW AND PLASTIC COVER FOR 5 M4 X 12LG PAN 6 FOR SPRING ACCESS SWING 9 10 M4 X 30LG PAN HEAD (2) 7 8 1 REPAIR KIT. ALL PARTS REQUIRED FOR 4 Figure 7 Doc No. 64001-1400 Release Date: 12-02-02UNCONTROLLED COPY Revision: C Revision Date: 08-06-03 Page 6 of 7 RHT2100 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 Te: l(630) 969-4550 Fax: (630) 505-0049 Doc No. 64001-1400 Release Date: 12-02-02UNCONTROLLED COPY Revision: C Revision Date: 08-06-03 Page 7 of 7