64001-3200

RHT-5770 Hand Crimp Tool Hand Crimp Tool Operating Instruction and Specifications Sheet Part No. 64001-3200 Eng. No. RHT 5770 (Replaces 19285-0050 and 19285-0143) FEATURES Œ Œ Œ Œ A full cycle ratcheting hand tool ensures complete crimps Long handles for comfortable crimping with reduced crimping force 3-nested tool eliminates the need for additional tools A precision user-friendly terminal locator / wire stop holds terminals in the proper crimping position for each of the three nests SCOPE Perma-Seal Terminals and Splices 10–22 AWG (Rings, Spades, Hooks, 3 and 4-Ways, and Splices). 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 specifications for various wire sizes. The tensile strength is shown in pounds and indicates the minimum acceptable force to break or separate terminal from the conductor. Wire Size (AWG) 22 20 18 16 14 12 10 UL – 486 A 8 13 20 30 50 70 80 UL – 486 C 8 10 10 15 25 35 40 *UL - 486 A - Terminals (copper conductors only) *UL - 486 C - Butt Splices, Parallel 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 19040-0001 19164-0003 19164-0004 19164-0005 19164-0006 19164-0007 19164-0008 19164-0011 19164-0013 19164-0085 19164-0086 Wire Size: 18 – 22 AWG 0.80 – 0.35 mm² Wire Strip Length Terminal Eng No. (REF) In. mm 19040-0001 .300 7.60 SA-221-10 .281 7.14 SA-222-14 .281 7.14 SA-226-38 .281 7.14 SA-235-06 .281 7.14 SA-235-08 .281 7.14 SA-235-10 .281 7.14 SA-2YCX .281 7.14 SAA-22-18 .281 7.14 SA-221-06 .281 7.14 SA-221-08 .281 7.14 Terminal No. Wire Size: 14 – 16 AWG 2.00 – 1.30 mm² Terminal Eng No. (REF) Wire Strip Length Insul. Dia. Max. Terminal No. Insul. Dia. Max. In. mm .190 4.83 .215 5.46 .215 5.46 .215 5.46 .215 5.46 .215 5.46 .215 5.46 .215 5.46 .210 5.33 .215 5.46 .215 5.46 Doc No. 64001-3200 Release Date: 11-11-03 Revision: B Revision Date: 05-24-04 19040-0002 19164-0020 19164-0021 19164-0026 19164-0027 19164-0028 19164-0029 19164-0030 19164-0031 19164-0032 19164-0033 19164-0034 19164-0042 19164-0044 19164-0141 19164-0142 19040-0002 SB-218-38 SB-219-10 SB-225-14 SB-225-56 SB-227-06 SB-227-08 SB-227-10 SB-237-04 SB-237-06 SB-237-08 SB-237-10 SB-2YCX SBB-16-14 SB-219-06 SB-219-08 UNCONTROLLED COPY In. .300 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .375 .281 .281 mm 7.60 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 9.53 7.14 7.14 In. .200 .235 .235 .235 .235 .235 .235 .235 .235 .235 .235 .235 .235 .200 .235 .235 mm 5.08 5.97 5.97 5.97 5.97 5.97 5.97 5.97 5.97 5.97 5.97 5.97 5.97 5.08 5.97 5.97 Page 1 of 8 RHT-5770 Hand Crimp Tool Terminal No. Terminal No. 19040-0003 19164-0056 19164-0058 19164-0060 19164-0061 19164-0062 Wire Size: 10 – 12 AWG 5.00 – 3.00 mm² Wire Strip Length Terminal Eng No. (REF) In. mm 19040-0003 .300 7.60 SC-12-10 .375 9.53 SC-201-12 .438 11.12 SC-228-04 .438 11.12 SC-228-06 .438 11.12 SC-228-08 .438 11.12 Insul. Dia. Max. In. mm .280 7.11 .280 7.11 .310 7.87 .310 7.87 .310 7.87 .310 7.87 19164-0065 19164-0066 19164-0067 19164-0068 19164-0069 19164-0070 19164-0072 19164-0073 19164-0074 Wire Size: 10 – 12 AWG 5.00 – 3.00 mm² Terminal Eng No. (REF) Wire Strip Length In. mm SC-230-10 .438 11.12 SC-230-14 .438 11.12 SC-230-56 .438 11.12 SC-240-38 .438 11.12 SC-241-06 .438 11.12 SC-241-08 .438 11.12 SC-268-10 .438 11.12 SC-268-14 .438 11.12 SC-2YCX .438 11.12 Insul. Dia. Max. In. mm .310 7.87 .310 7.87 .310 7.87 .310 7.87 .310 7.87 .310 7.87 .310 7.87 .310 7.87 .310 7.87 JAWS OPEN OPERATION Open the tool by first closing the jaws sufficiently for the ratchet mechanism to release. TERMINAL Crimping Terminals LOCATOR 1. Push up on the locator blade and position the terminal with the barrel facing up into the color-coded nest, centering the barrel in the lower jaw as shown in Figure 1. Release the locator blade to hold the terminal in position. Note: The locator is used to hold the terminal, not to position the terminal. 2. Partially close the hand tool jaws until the connector is held snug in place. See Figure 2. 3. Insert the properly stripped wire into the terminal barrel (See Figure 2 and 3). 4. Complete the crimp by closing the hand tool handles until they release. Figure 1 PUSH UP Note: The tamper proof ratchet action will not release the tool until it has been fully closed. 5. Lift the locator blade 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. Molex offers a Crimp Inspection Handbook for closed barrel industrial product. See our website or contact your sales engineer. CONDUCTOR PUNCH LOCATOR TERMINAL BARREL TERMINAL WIRE TERMINAL Figure 2 WIRE Doc No. 64001-3200 Release Date: 11-11-03 Revision: B Revision Date: 05-24-04 Figure 3 UNCONTROLLED COPY CONDUCTOR ANVIL Page 2 of 8 RHT-5770 Hand Crimp Tool Doc No. 64001-3200 Release Date: 11-11-03 Revision: B Revision Date: 05-24-04 UNCONTROLLED COPY Page 3 of 8 RHT-5770 Hand Crimp Tool CONDUCTOR PUNCH Crimping Butt Splices When crimping butt splices, or 3-way and 4-way terminals the locator must be removed. 1. Position the splice into the nest. 2. Partially close the tool to hold the splice in place. 3. Insert the properly stripped wire into the splice. The wires end should butt against the tab in the terminal (See Figure 4). Cycle the tool. 4. Remove the crimped splice. Inspect for proper crimp location. 5. Rotate the butt splice terminal 180°, so that the opposite end of splice is in the nest. 6. Repeat steps 2 thru 4. TAB OF TERMINAL WIRE CONDUCTOR ANVIL BUTT SPLICE TERMINAL Figure 4 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. Maintenance It is recommended that each operator of the tool be made aware of, and responsible for, the following maintenance steps: LUBRICATION POINTS (BOTH SIDES) LIGHT OIL (EVERY 3 MONTHS OR 5,000 CRIMPS) 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. Figure 5 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 64001-3200 (RHT-5770) 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 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 6). Doc No. 64001-3200 Release Date: 11-11-03 Revision: B Revision Date: 05-24-04 UNCONTROLLED COPY Page 4 of 8 RHT-5770 Hand Crimp Tool 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: PRELOAD TEST POINT 1.00 1. Remove the screw and plastic cover washer. Note the setting wheel position. PRELOAD 1.00 2. Lift the setting wheel off the axle. Turn the RATCHET TEST POINT eccentric axle with a screwdriver. RELEASE LEVER PUSH UP 3. Turning the eccentric axle counter-clockwise (CCW) PRELOAD Figure 6 ADJUSTMENT will increase handle force. LOCKING SCREW 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. PIN GAUGE IN 6. Check the crimp specifications after tool handle preload force is adjusted. CONDUCTOR CRIMP 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 before 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 Red Blue Yellow Wire Range AWG mm² 18 - 22 0.35 - 0.80 14 - 16 1.30 - 2.00 10 - 12 3.30 - 5.00 “X” Dimension Conductor Crimp Mean Go No Go .092 .090 .094 .107 .104 .109 .141 .138 .144 “ CONFINING” CRIMP Crimp Inspection Marking ------- 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 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 alter, 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. Doc No. 64001-3200 Release Date: 11-11-03 Revision: B Revision Date: 05-24-04 UNCONTROLLED COPY Page 5 of 8 RHT-5770 Hand Crimp Tool Caution: Repetitive use of this tool should be avoided. Doc No. 64001-3200 Release Date: 11-11-03 Revision: B Revision Date: 05-24-04 UNCONTROLLED COPY Page 6 of 8 RHT-5770 Hand Crimp Tool PARTS LIST Item 1 2 3 4 5 6 Order No Description Quantity 64001-3200 Hand Crimp Tool (Fig. 7) 64000-0076 Repair Kit (Springs, Pins and E-Rings) 1 63810-0000 Handle 1 64001-3275 Locator Assembly 1 64001-3270 Tooling Kit 1 Tooling Kit Only 64001-3201 Conductor Punch 1 64001-3202 Conductor Anvil 1 M4 WING NUT M4 FLAT WASHER 2 3 RATCHET RELEASE LEVER SCREW AND PLASTIC COVER FOR HANDTOOL PRELOAD ADJUSTMENT 5 M4 X 12LG PAN HEAD SCREW 6 FOR SPRING ACCESS SWING OPEN COVER 4 1 M4 X 30LG PAN HEAD SCREW REPAIR KIT. ALL PARTS REQUIRED FOR REPAIR. (ONLY MAIN SPRING SHOWN) Figure 7 Doc No. 64001-3200 Release Date: 11-11-03 Revision: B Revision Date: 05-24-04 UNCONTROLLED COPY Page 7 of 8 RHT-5770 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 Gage 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. 64001-3200 Release Date: 11-11-03 Revision: B Revision Date: 05-24-04 UNCONTROLLED COPY Page 8 of 8