handcrimptoolforobdii4.00mm(.157")wireto wirecrimpterminal docno:ats6381195hm releasedate:080307 uncontrolledcopy page1of6 revision:b revisiondate:081010 type4a applicationtooling specificationsheet modularcrimphead orderno.638119570 handcrimptool orderno.638119500 features % afullcycleratchetinghandtoolensurescomplete crimps % ergonomicallydesignedsofthandles % preciselydesignedcrimpingprofileswithsimpleco ntactpositioning % easyhandlingduetooutstandingforceratio % modularcrimpheadisremovableandcanbeuseint heairpoweredtoolorderno.638160100, accompaniedbyairpoweredcrimpadapter(orderno. 638160700). % canalsobeusedinthebatterypoweredtoolorder no.638160200(110v)or638160250(220v), accompaniedbybatterypoweredcrimpadapter(order no.638160600). scope products :obdii4.00mm(.157")wiretowirecrimptermina l,0.300.85mm2and1822awg. terminal seriesno. terminalorderno. wiresize actualmm2 wiretype insulationdiameter striplength mm in. mm in. 50420 504208100(loose) 504208000(reel)* avs0.3,avs0.3f 0.37 jaso 1.601.90 .063.075 3.003.70 .118.146 22awg 0.35 txl 1.601.90 .063.075 3.003.70 .118.146 avs0.5,avs0.5f avss0.5,avss0.5f cavs0.5 0.56 jaso 1.602.10 .063.083 3.003.70 .118.146 20awg 0.50 txl 1.602.10 .063.083 3.003.70 .118.146 avs0.75f,avss0.75f 0.79 jaso 1.802.30 .071.090 3.003.70 .118.146 avs0.85,avss0.85 cavs0.85 0.88 jaso 1.802.30 .071.090 3.003.70 .118.146 18awg 0.80 txl 1.802.30 .071.090 3.003.70 .118.146 *note:whenusingreeledparts,thecutofftabmu stbemaintainedbelow0.20mm(.008)
handcrimptoolforobdii4.00mm(.157")wireto wirecrimpterminal docno:ats6381195hm releasedate:080307 uncontrolledcopy page2of6 revision:b revisiondate:081010 insulation crimp seenote brush strip length bellmouth crimpheight bend down bendup rolling conductor crimp twisting definitionofterms theaboveterminaldrawingisagenericterminalre presentation.itisnotanimageofaterminallis tedinthe scope. insulationcrimpnote : duetotheterminalsinsulationgripdesignand/or insulationdiameterrange,thistoolusesoverlap formgeometryintheinsulationpunch.this producesanoverlapinsulationcrimp(a620C compliant).whiletheinsulationpunchprofilemay appearlopsided,thisisanormalconditionfort his tool.seefiguretotheright.(sometoolswith multiplecrimppocketsmaynothavetheoverlap profileonallpockets). crimpspecifications: aftercrimping,theconductorprofileshouldmeasur ethefollowing. terminal seriesno. wiresize actual mm2 wire type conductor profileawg crimpheight(ref.) crimpwidth(ref.) 0.3mm 2 22awg 0.75+0.85mm 2 18awg 0.5mm 2 20awg mm in. mm in. 50420 0.3,0.3f 0.37 jaso 0.860.95 .034.037 1.60 .063 x 22awg 0.35 txl 0.860.95 .034.037 1.60 .063 x 0.5,0.5f 0.56 jaso 0.961.06 .038.042 1.60 .063 x 20awg 0.50 txl 0.961.06 .038.042 1.60 .063 x 0.75f 0.79 jaso 1.101.17 .043.046 1.60 .063 x 0.85 0.88 jaso 1.101.17 .043.046 1.60 .063 x 18awg 0.80 txl 1.101.17 .043.046 1.60 .063 x overlap insulation crimp overlapformgeometry anvil punch wire
handcrimptoolforobdii4.00mm(.157")wireto wirecrimpterminal docno:ats6381195hm releasedate:080307 uncontrolledcopy page3of6 revision:b revisiondate:081010 terminal seriesno. wiresize actualmm2 wiretype insulation pullforce minimum crimpheight(ref.) crimpwidth(ref.) mm in. mm in. n lb. 50420 0.3,0.3f 0.37 jaso 2.20 .087 2.30 .091 58.8 13.2 22awg 0.35 txl 2.20 .087 2.30 .091 58.8 13.2 0.5,0.5f 0.56 jaso 2.35 .093 2.40 .094 88.2 19.8 20awg 0.50 txl 2.35 .093 2.40 .094 88.2 19.8 0.75f 0.79 jaso 2.50 .098 2.60 .102 107.8 24.2 0.85 0.88 jaso 2.50 .098 2.60 .102 117.6 26.5 18awg 0.80 txl 2.50 .098 2.60 .102 117.6 26.5 t tt t toolqualificationnotes: 1. pullforceshouldbemeasuredwithnoinfluencefro mtheinsulationcrimp. 2. theabovespecificationsareguidelinestoanoptim umcrimp. operation openthetoolbysqueezingthehandlestogether,at theendoftheclosingstroke,theratchetmechani smwill releasethehandles,andthehandtoolwillspring open. crimpingterminals 1. liftthewirestopbladeup. 2. inserttheterminalfullyintothecorrectprofile untiltheterminalisfullyseatedandstops. 3. bringdownthewirestopblade. 4. slidetheprestrippedwireintothewirestopblad e.seefigure1.besuretoholdthewireinplac euntilthe terminalisfullycrimped.seefigure2. 5. closethetooluntiltheratchetreleases,thetool handleswillthenspringopen. 6. liftthewirestopbladeupifitisstillindown position. 7. carefullyremovethecrimpedterminal. note: tomaintaingoodbrushcontrolandaconsistentb ellmouththecrimpinginstructionsmustbefollowe d. note: thetamperproofratchetactionwillnotreleaset hetooluntilithasbeenfullyclosed. terminal pre stripped wire locator figure1 wirestop blade figure2 conductor punch wire locator terminal insulation punch insulation anvil conductor anvil wirestop blade retainer spacer
handcrimptoolforobdii4.00mm(.157")wireto wirecrimpterminal docno:ats6381195hm releasedate:080307 uncontrolledcopy page4of6 revision:b revisiondate:081010 maintenance itisrecommendedthateachoperatorofthetoolbe madeawareof,andresponsiblefor,thefollowing maintenancesteps: 1. removedust,moisture,andothercontaminantswith acleanbrush,orsoft,lintfreecloth. 2. donotuseanyabrasivematerialsthatcoulddamage thetool. 3. makecertainallpins;pivotpointsandbearingsur facesareprotectedwithathincoatofhighqualit ymachine oil.donotoilexcessively.thetoolwasenginee redfordurabilitybutlikeanyotherequipmentit needs cleaningandlubricationforamaximumservicelife oftroublefreecrimping.lightoil(suchas30w eight automotiveoil)usedattheoilpoints,every5,000 crimpsor3months,willsignificantlyenhancethe toollife. 4. wipeexcessoilfromhandtool,particularlyfromc rimpingarea.oiltransferredfromthecrimpingar eaonto certainterminationsmayaffecttheelectricalchar acteristicsofanapplication. 5. whentoolisnotinuse,keepthehandlesclosedto preventobjectsfrombecominglodgedinthecrimpi ngdies, andstorethetoolinaclean,dryarea. miscrimpsorjams shouldthistooleverbecomestuckorjammedinap artiallyclosedposition, donot forcethehandles openor closed .thetoolwillopeneasilybyliftingtheratchet releaselever.seefigure6. warranty thistoolisforelectricalterminalcrimpingpurpo sesonly.thistoolismadeofthebestqualityma terials.allvital componentsarelonglifetested.alltoolsarewar rantedtobefreeofmanufacturingdefectsforape riodof30 days.shouldsuchadefectoccur,wewillrepairo rexchangethetoolfreeofcharge.thisrepairor exchangewill notbeapplicabletoaltered,misused,ordamagedt ools.thistoolisdesignedforhanduseonly.an yclamping, fixturing,oruseofhandleextensionsvoidsthisw arranty. caution: repetitiveuseofthistoolshouldbeavoided. cautions: 1. manuallypoweredhandtoolsareintendedforlowvo lumeorfieldrepair.thistoolis not intendedfor productionuse.repetitiveuseofthistoolshould beavoided. 2. insulatedrubberhandlesarenotprotectionagainst electricalshock. 3. weareyeprotectionatalltimes. 4. useonlythemolexterminalsspecifiedforcrimping withthistool. notes: 1. thistoolshouldonlybeusedfortheterminalsand wiregaugesspecifiedonthissheet. 2. thistoolisnotadjustableforcrimpheight;howev ercrimpforceisadjustable(seeinstructionsabov e). variationsintools,terminals,wirestranding,and insulationtypesmayaffectcrimpheight. 3. thistoolisintendedforstandardconductorsizes. itmaynotgiveagoodinsulationcrimpsupportf orall insulationsizes. 4. molexdoesnotrepairhandtools(seewarrantyabov e).thereplacementpartslistedaretheonlypart s availableforrepair.ifthehandlesorcrimptool ingisdamagedorworn,anewtoolmustbepurchase d. 5. pullforceshouldbeusedasthefinalcriteriafor anacceptablecrimp.pullforceismeasuredwith no influencefromtheinsulationcrimp.theinsulatio nshouldbestrippedlong(1/2in.)sotheinsulati ongrips ontheterminaldonotgripthewireinsulationor theconductor.refertomolexqualitycrimping handbook638000029foradditionalinformationonc rimpingandcrimptesting.
handcrimptoolforobdii4.00mm(.157")wireto wirecrimpterminal docno:ats6381195hm releasedate:080307 uncontrolledcopy page5of6 revision:b revisiondate:081010 modular crimp head battery power crimp adapter locking pins lockingpins battery powered tool air power tool modular crimphead locking pins locking pins air power crimp adapter 6. molexdoesnotcertifycrimphandtools. caution :molexcrimpspecificationsarevalidonlywhenu sedwithmolexterminalsandtooling. applicationsforthemodularcrimphead warning : never operate,service,install,oradjustthismodularc rimpheadwithoutproperinstruction andwithoutfirstreadingandunderstandingtheins tructionsinthepropermanualorspecificationshe et. seechartbelowforthecorrectmanualorspecifica tionsheet. warning : never installtoolingorservicethistoolwhileitisin toanypowersource.disconnectthe powerbyunpluggingorturnofftheactuatorfromi tspowersource. caution: keepfingersawayfromthecrimpingareawhenopera tingthistool.itmaycausesevereinjury. caution: wearsafetyglasseswhenoperatingorservingthis tool. thechartbelowshowsallapplicationsforthismod ularcrimphead. modularcrimphead orderno. tool orderno. tool description adapter orderno. adapter description figure no. 638119570 638160000 handcrimpframe(short) n/a n/a 3 638160050 handcrimpframe(long) n/a n/a 3 638160200 batterypowertool(110v) 638160600 batterypowercrimpadapter 4 638160250 batterypowertool(220v) 638160600 batterypowercrimpadapter 4 638160100 airpowertool 638160700 airpowercrimpadapter 5 applicationsforthemodularcrimphead handcrimptool batterypoweredtool airpoweredto ol figure3 figure4 figure5 modular crimp head locking pins handcrimp framelong orshort
handcrimptoolforobdii4.00mm(.157")wireto wirecrimpterminal docno:ats6381195hm releasedate:080307 uncontrolledcopy page6of6 revision:b revisiondate:081010 ratchet releaselever handle spring crimping spring(2) 3 6 4 figure6 m4xflat washer 2 5 1 m4x14mm longbhcs partslist handcrimptool638119500 item ordernumber description quantity 1 638119570 modularcrimphead 1(ref) 2 638160050 handcrimpframe(long) 1(ref) 3 638119575 locator 1 4 638160001 lockingpin 2 5 636000525 handlespring 1 6 636000520 crimpingspring 2 http://www.molex.com
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