handcrimptoolfor2.5mm(.098")pitchwiretowir ecrimpterminals docno:ats6382380hm releasedate:021511 uncontrolledcopy page1of6 revision:a revisiondate:021511 insulationcrimp seenote brush strip length crimpheight bend down bendup rolling conductor crimp twisting seam applicationtooling specificationsheet modularcrimphead orderno.638238070 handcrimptool orderno.638238000 features % afullcycleratchetinghandtoolensurescomplete crimps % ergonomicallydesignedsofthandles % preciselydesignedcrimpingprofileswithsimpleco ntactpositioning % easyhandlingduetooutstandingforceratio % a620class3compliantandrohscompliant % modularcrimpheadisremovableandcanbeuseint heairpoweredtoolorderno.638160100, accompaniedbyairpoweredcrimpadapter(orderno. 638160700). % canalsobeusedinthebatterypoweredtoolorder no.638160200(110v)or638160250(220v), accompaniedbybatterypoweredcrimpadapter(order no.638160600). scope products: 2.5mm(.098")pitchwiretowireterminal,2228a wg. terminal seriesno. terminalorderno. reel wiresize insulationdiameter striplength awg mm2 mm in. mm in. 50397 503978000 2228 0.350.08 1.051.90 0.043.075 2.63.1 0.1020.122 followthecutofftabspecificationsonapplicator specificationsheets. seeconditionsonpage2. definitionofterms theaboveterminaldrawingisagenericterminalre presentation.itisnotanimageofaterminallis tedinthescope. type4a
handcrimptoolfor2.5mm(.098")pitchwiretowir ecrimpterminals docno:ats6382380hm releasedate:021511 uncontrolledcopy page2of6 revision:a revisiondate:021511 insulationcrimpnote : duetotheterminalsinsulationgripdesignand/or insulationdiameterrange,thistoolusesoverlap formgeometryintheinsulationpunch.this producesanoverlapinsulationcrimp(a620C compliant).whiletheinsulationpunchprofilemay appearlopsided,thisisanormalconditionfort his tool.seefiguretotheright.(sometoolswith multiplecrimppocketsmaynothavetheoverlap profileonallpockets). crimpspecification aftercrimping,thecrimpprofilesshouldmeasuret hefollowing(seenotesonpage4). terminal orderno. wiresize conductorcrimp insulationcrimp pullforce minimum profile height(ref) width(ref) height(ref) width(max.) awg mm 2 mm in. mm in. mm in. mm in. n lb. a b c d 50397 22 0.35 0.840.89 .033.035 1.20 .047 1.601.80 .063.074 1.80. .071 39.2 8.8 x 24 0.20 0.760.81 .030.032 1.20 .047 1.601.80 .063.074 1.80. .071 29.4 6.6 x 26 0.12 0.710.76 .028.030 1.20 .047 1.601.80 .063.074 1.80. .071 19.6 4.4 x 28 0.08 0.670.72 .026028 1.20 .047 1.601.80 .063.074 1.80. .071 9.8 2.2 x toachieveipca620class3crimps,thefollowing overallwireinsulationdiameterrangesarerecomm ended: profilea:1.05mm(.041)maximumuptothemaximum terminalrating1.90mm(.075). profileb:1.101.90mm(.043.075) profilec:1.101.75mm(.043.069) profiled:1.201.75mm(.047.069) t tt t toolqualificationnotes: 1. pullforceshouldbemeasuredwithno influencefromtheinsulationcrimp. 2. theabovespecificationsareguidelinesto anoptimumcrimp. operation openthetoolbysqueezingthehandles together,attheendoftheclosingstroke,the ratchetmechanismwillreleasethehandles,and thehandtoolwillspringopen. 1. withthehandtoolintheopenposition,pivot theterminallocatoropenbypullinguponthe locatorknobandliftthewirestopbladeup. seefigure1. 2. inserttheterminalintothecorrectprofileuntil theterminalisfullyseatedandstops.makesure thewire stopbladeisfullyseatedontheterminalbehindt heconductorgripsection. 3. gentlypivotthelocatorclosed. 4. bringdownthewirestopblade. terminal seatedin locator swing locator open figure1 handtool open wire stopblade overlap insulation crimp overlapformgeometry anvil punch wire
handcrimptoolfor2.5mm(.098")pitchwiretowir ecrimpterminals docno:ats6382380hm releasedate:021511 uncontrolledcopy page3of6 revision:a revisiondate:021511 wire conductor punch terminal wirestop blade figure2 figure3 wire terminal locator insulation punch insulation anvil wirestop blade conductor anvil conductor punch 5. slidetheprestrippedwireintotheterminal;make suretoaimthewirebrushtowardsthetippointo nthe wirestopblade.seefigure2.alignthewireso thatitisparallelandsittingintotheterminal. maintaina lightandconstantpressureonthewirethatissea tedintheterminalatalltimes.(donotletgoo fthe wire.)besuretoholdthewireandterminalinpl aceuntiltheterminalisfullycrimped.seefigur e3. 6. closethetooluntiltheratchetreleases. 7. liftthewirestopbladeup. 8. carefullyremovethecrimpedterminal. note: tomaintaingoodbrushcontrolandaconsistentb ellmouththecrimpinginstructionsmustbe followed. note: thetamperproofratchetactionwillnotreleaset hetooluntilithasbeenfullyclosed. note: tomaintaingoodbrushcontrolandaconsistentb ellmouththecrimpinginstructionsmustbefollowe d. terminallocatorreplacement/changeover thissectiondescribestheprocedureforchangingl ocators. removal 1. withthetoolintheopenposition,pivotthetermi nallocatoroutward. 2. removethem4bhcs.seefigure4. installation 1. placetheproperlocator,(seechartonpage2),on thehandtool. installthem4bhcs.seefigure4. 2. tightenthescrewenoughtoholdthelocator.make surethelocator canstillfloatfreelywithhandpressure. 3. inserttheproperterminalfullyintothecorrectp rofileslotuntilthe terminalisfullyseatedandstops.thengentlypi votthelocator closed. 4. withhandpressure,slowlyslidethelocatortothe correctposition.seefigure5. 5. gentlypivotthelocatoropenwithoutdisturbingth elocation. 6. holdthelocatorfirmlyinplaceandslowlytighten them4bhcs. m4bhcs pivotlocator figure4
handcrimptoolfor2.5mm(.098")pitchwiretowir ecrimpterminals docno:ats6382380hm releasedate:021511 uncontrolledcopy page4of6 revision:a revisiondate:021511 incorrect figure5 correct incorrect maintenance itisrecommendedthateachoperatorofthetoolbe made awareof,andresponsiblefor,thefollowingmainte nance steps: 1. removedust,moisture,andothercontaminantswith a cleanbrush,orsoft,lintfreecloth. 2. donotuseanyabrasivematerialsthatcoulddamage the tool. 3. makecertainallpins;pivotpointsandbearingsur faces areprotectedwithathincoatofhighqualitymach ineoil. donotoilexcessively.thetoolwasengineeredfo rdurabilitybutlikeanyotherequipmentitneeds cleaning andlubricationforamaximumservicelifeoftroub lefreecrimping.lightoil(suchas30weightaut omotiveoil) usedattheoilpoints,every5,000crimpsor3mon ths,willsignificantlyenhancethetoollife. 4. wipeexcessoilfromhandtool,particularlyfromc rimpingarea.oiltransferredfromthecrimpingar eaonto certainterminationsmayaffecttheelectricalchar acteristicsofanapplication. 5. whentoolisnotinuse,keepthehandlesclosedto preventobjectsfrombecominglodgedinthecrimpi ngdies, andstorethetoolinaclean,dryarea. miscrimpsorjams shouldthistooleverbecomestuckorjammedinap artiallyclosedposition, donot forcethehandles openor closed .thetoolwillopeneasilybyliftingtheratchet releaselever.seefigure9. 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.
handcrimptoolfor2.5mm(.098")pitchwiretowir ecrimpterminals docno:ats6382380hm releasedate:021511 uncontrolledcopy page5of6 revision:a revisiondate:021511 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 5. pullforceshouldbeusedasthefinalcriteriafor anacceptablecrimp.pullforceismeasuredwith no influencefromtheinsulationcrimp.theinsulatio nshouldbestrippedlong(1/2in.)sotheinsulati ongrips ontheterminaldonotgripthewireinsulationor theconductor.refertomolexqualitycrimping handbook638000029foradditionalinformationonc rimpingandcrimptesting. 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. 638238070 638160000 handcrimpframe(short) n/a n/a 6 638160050 handcrimpframe(long) n/a n/a 6 638160200 batterypowertool(110v) 638160600 batterypowercrimpadapter 7 638160250 batterypowertool(220v) 638160600 batterypowercrimpadapter 7 638160100 airpowertool 638160700 airpowercrimpadapter 8 applicationsforthemodularcrimphead handcrimptool batterypoweredtool airpoweredto ol figure6 figure7 figure8 modular crimp head locking pins handcrimp framelong orshort
handcrimptoolfor2.5mm(.098")pitchwiretowir ecrimpterminals docno:ats6382380hm releasedate:021511 uncontrolledcopy page6of6 revision:a revisiondate:021511 ratchet releaselever handle spring crimping spring(2) locator 2 1 4 figure9 m4x8mm longbhcs 3 5 6 partslist handcrimptool638238000 item ordernumber description quantity 1 638238070 modularcrimphead 1 2 638160000 handcrimpframe(short) 1 3 638238075 locator 1 4 638160001 lockingpin 2 5 636000525 handlespring 1 6 636000520 crimpingspring 2 http://www.molex.com
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