0640011500

RHT 2200 Hand Crimp Tool Hand Crimp Tool Operating Instruction And Specifications Sheet Order No. 64001-1500 Eng. No. RHT 2200 (Replaces 19285-0018) FEATURES Œ 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 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 AviKrimp and InsulKrimpTerminals and Splices 10-12 AWG, (Rings, Spades, Hooks, Snap Spades and Flanged Spades, Wire Pin Terminals and also 3 to 4 way connectors). Also terminates ends of step down butt splice 10-12 to 14-16 AWG. Testing Mechanical Wire Size (AWG) *UL - 486 A *UL – 486 C The tensile test, or pull test, is a means of evaluating 16 N/A 15 the mechanical properties of the crimped connections. 14 N/A 25 12 70 35 The following charts show the UL specifications for 10 80 40 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. *UL - 486 A - Terminals (Copper conductors only) *UL - 486 C - Butt Splices 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. 19070-0119 19070-0121 19070-0123 19070-0130 19070-0132 19070-0136 19070-0143 19070-0145 19070-0150 19070-0153 19070-0155 19073-0145 19073-0147 19073-0160 19073-0163 Wire Size: 10 – 12 AWG 5.00 – 3.00 mm² Terminal Wire Strip Length Insul. Dia. Max. Eng No. (REF) In mm In mm C-228-06X .375 9.53 250 6.35 C-228-08X .375 9.53 .250 6.35 C-228-10X .375 9.53 .250 6.35 C-230-10X .375 9.53 .250 6.35 C-230-14X .375 9.53 .250 6.35 C-230-56X .375 9.53 .250 6.35 C-236-06X .375 9.53 .250 6.35 C-236-08X .375 9.53 .250 6.35 C-240-14X .375 9.53 .250 6.35 C-240-38X .375 9.53 .250 6.35 C-240-56X .375 9.53 .250 6.35 C-801-12 .375 9.53 .225 5.72 C-801-12X .375 9.53 .250 6.35 C-828-06 .375 9.53 .225 5.72 C-828-06X .375 9.53 .250 6.35 Doc No. 64001-1500 Release Date: 01-15-03 Revision: C Revision Date: 01-10-06 Terminal No. 19073-0165 19073-0168 19073-0170 19073-0173 19073-0179 19073-0181 19073-0182 19073-0185 19073-0188 19073-0191 19073-0192 19073-0195 19073-0200 19073-0202 19073-0203 Wire Size: 10 – 12 AWG 5.00 – 3.00 mm² Terminal Wire Strip Length Insul. Dia. Max. Eng No. (REF) In mm In mm C-828-08 .375 9.53 .225 5.72 C-828-08X .375 9.53 .250 6.35 C-828-10 .375 9.53 .225 5.72 C-828-10X .375 9.53 .250 6.35 C-830-10 .375 9.53 .225 5.72 C-830-10X .375 9.53 .250 6.35 C-830-10XLBK .375 9.53 .225 5.92 C-830-10XX .375 9.53 .320 8.13 C-830-14 .375 9.53 .225 5.72 C-830-14X .375 9.53 .250 6.35 C-830-14XLBK .375 9.53 .225 5.92 C-830-14XX .375 9.53 .320 8.13 C-830-56 .375 9.53 .225 5.72 C-830-56X .375 9.53 .250 6.35 C-830-56XLBK .375 9.53 .225 5.92 UNCONTROLLED COPY Page 1 of 7 RHT 2200 Hand Crimp Tool Terminal No. 19073-0206 19073-0216 19073-0220 19073-0222 19073-0225 19073-0227 19073-0229 19073-0231 19073-0233 19073-0236 19073-0238 19073-0242 19073-0244 19073-0272 19073-0273 19073-0274 19081-0005 19090-0083 19090-0085 19099-0044 19099-0048 19099-0050 19115-0033 19115-0035 19115-0037 19115-0039 19115-0041 19115-0042 19115-0046 19115-0048 19127-0086 Wire Size: 10 – 12 AWG 5.00 – 3.00 mm² Terminal Wire Strip Length Insul. Dia. Max. Eng No. (REF) In mm In mm C-830-56XX .375 9.53 .320 8.13 C-836-06 .375 9.53 .225 5.72 C-836-06X .375 9.53 .250 6.35 C-836-08 .375 9.53 .225 5.72 C-836-08X .375 9.53 .250 6.35 C-840-10 .375 9.53 .225 5.72 C-840-10X .375 9.53 .250 6.35 C-840-14 .375 9.53 .225 5.72 C-840-14X .375 9.53 .250 6.35 C-840-38 .375 9.53 .225 5.72 C-840-38X .375 9.53 .250 6.35 C-840-56 .375 9.53 .225 5.72 C-840-56X .375 9.53 .250 6.35 C-830-10XXBK .375 9.53 .320 8.13 C-830-14XXBK .375 9.53 .320 8.13 C-830-56XXBK .375 9.53 .320 8.13 C-5006-MS .375 9.53 .225 5.72 C-212-08X .375 9.53 .250 6.35 C-212-10X .375 9.53 .250 6.35 C-2710-06X .375 9.53 .225 5.72 C-2718-08X .375 9.53 .225 5.72 C-2719-10X .375 9.53 .225 5.72 C-8196-06 .375 9.53 .225 5.72 C-8197-08 .375 9.53 .225 5.72 C-8198-10 .375 9.53 .225 5.72 C-8199-14 .375 9.53 .225 5.72 C-8710-05 .375 9.53 .225 5.72 C-8710-06 .375 9.53 .225 5.72 C-8718-08 .375 9.53 .225 5.72 C-8719-10 .375 9.53 .225 5.72 C-817-08 .375 9.53 .225 5.72 Terminal No. 19127-0089 19139-0060 19144-0037 19144-0039 19144-0042 19144-0046 19154-0028 19154-0037 19183-0019 19198-0039 19198-0044 19198-0047 19198-0050 19198-0056 19198-0057 19204-0025 19204-0026 19204-0029 19204-0030 19206-0010 19212-0001 19213-0007 Terminal No. 19154-0035 Wire Size: 10 – 12 AWG 5.00 – 3.00 mm² Terminal Wire Strip Length Insul. Dia. Max. Eng No. (REF) In mm In mm C-817-10 .375 9.53 .225 5.72 C-8105-08 .375 9.53 .225 5.72 C-241-06X .375 9.53 .250 6.35 C-241-08X .375 9.53 .250 6.35 C-241-10X .375 9.53 .250 6.35 C-268-14X .375 9.53 .250 6.35 C-246X .225 5.95 .225 5.72 CS-V-346X .281 7.14 .225 5.72 C-811-10 .375 9.53 .225 5.72 C-8105-06 .375 9.53 .225 5.72 C-841-06 .375 9.53 .225 5.72 C-841-08 .375 9.53 .225 5.72 C-841-10 .375 9.53 .225 5.72 C-868-14 .375 9.53 .225 5.72 C-868-14X .281 7.14 .250 6.35 C-2XCX .375 9.53 .225 5.72 C-2YCX .375 9.53 .225 5.72 C-5XC .375 9.53 .225 5.72 C-5YC .375 9.53 .225 5.72 CS-V-303X .281 7.14 .260 6.60 WP-2210X .281 7.14 .250 6.35 WP-8210 .281 7.14 .225 5.72 STEP DOWN BUTT SPLICE Wire Size: 10 – 12 AWG 5.00 – 3.00 mm² to 14 -16 AWG 2.00-1.30 mm² Terminal Wire Strip Length Insul. Dia. Max. Eng No. (REF) In mm In mm CB-646X .281 7.14 .260 6.60 JAWS OPEN OPERATION Open the tool by first closing the jaws sufficiently for the ratchet mechanism to release. TERMINAL Crimping Terminals 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). Release the locator blade to hold the terminal in position. 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. FRONT EDGE OF BARREL LOCATOR Figure 1 PUSH UP Note: The tamper proof ratchet action will not release the tool until it has been fully closed. Doc No. 64001-1500 Release Date: 01-15-03 Revision: C Revision Date: 01-10-06 UNCONTROLLED COPY Page 2 of 7 RHT 2200 Hand Crimp 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. 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 5). A clockwise (CW) rotation decreases insulation crimp while a counter-clockwise (CCW) rotation increases insulation crimp. After adjusting retighten the M4 screw. 6. When crimping butt splices, or 3-way and 4-way terminals the locator must be removed. Splices must be aligned with the tooling visually in the insulation crimp (See Figure 4). The splice should be approximately centered inside the tooling nests (See Figure 4). Cycle the tool. CONDUCTO R CONDUCTOR PUNCH INSULATION PUNCH TERMINA L LOCATOR TERMINAL WIRE Figure 2 INSULATION PUNCH BUTT SPLICE TERMINAL WIRE WIRE CONDUCTO R Figure 3 CONDUCTO R INSULATIO N Figure 4 INSULATIO N 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. LUBRICATION POINTS (BOTH SIDES) LIGHT OIL (EVERY 3 MONTHS OR 5,000 CRIMPS) 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. Doc No. 64001-1500 Release Date: 01-15-03 Revision: C Revision Date: 01-10-06 LOOSEN M4 3/32” HEX WRENCH Figure 5 UNCONTROLLED COPY Page 3 of 7 RHT 2200 Hand Crimp 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 64001-1500 (RHT-2200) 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. PRELOAD TEST Miscrimps or Jams 1.00 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 Fig.6). PRELOAD TEST How To Adjust Tool Preload (See 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 PRELOAD LEVER 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. PIN GAUGE IN 6. Check the crimp specifications after tool handle preload force is CONDUCTOR adjusted. Tool Calibration X 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 Yellow Wire Range AWG mm² 10 - 12 5.00 – 3.00 14 – 16* 1.30 – 2.00 “X” Dimension Conductor Crimp Mean Go No Go .160 .156 .168 .160 .156 .168 “ CONFINING” Crimp Inspection Marking o o * 14 - 16 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. Doc No. 64001-1500 Release Date: 01-15-03 Revision: C Revision Date: 01-10-06 UNCONTROLLED COPY Page 4 of 7 RHT 2200 Hand Crimp Tool 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. 64001-1500 Release Date: 01-15-03 Revision: C Revision Date: 01-10-06 UNCONTROLLED COPY Page 5 of 7 RHT 2200 Hand Crimp Tool PARTS LIST Item 1 2 3 4 Order No. 64001-1500 64000-0076 63810-0000 64001-1575 64001-1570 5 6 7 8 9 10 64001-1502 64001-1501 64001-1504 64001-1503 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 4mm Dia. by 5.0mm LongRoll Pins #10-32 by 5/16” Long 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 (1800-645-7270). 2 M4 WING NUT M4 FLAT 3 RATCHET RELEASE SCREW AND PLASTIC COVER FOR M4 X 12LG PAN 5 6 9 FOR SPRING ACCESS SWING (2) M4 X 30LG PAN HEAD 7 10 8 1 REPAIR KIT. ALL PARTS REQUIRED FOR 4 Figure 7 Doc No. 64001-1500 Release Date: 01-15-03 Revision: C Revision Date: 01-10-06 UNCONTROLLED COPY Page 6 of 7 RHT 2200 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 Visit our Web site at http://www.molex.com Doc No. 64001-1500 Release Date: 01-15-03 Revision: C Revision Date: 01-10-06 UNCONTROLLED COPY Page 7 of 7