handcrimptoolfor6.35mm(.250)tabsliponmale crimpterminals docno:ats6382383hm releasedate:101510 uncontrolledcopy page1of6 revision:a revisiondate:101510 applicationtooling specificationsheet modularcrimphead orderno.638238370 handcrimptool orderno.638238300 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 :6.35mm(.250)tabsliponmalecrimpterminals, 2022awg,0.300.50mm 2 wires. terminalseriesno. terminal orderno. wiresizeandtype insulationdiameter striplength awg mm2 type mm in. mm in. 35725 357253000 357253010 20 ul1015,ul1007 1.702.60 .067.102 4.805.20 .189.205 22 ul1015,ul1007 1.502.50 .059.098 0.50 avs,avss 1.602.10 .063.083 0.30 avs,avss 1.401.90 .055.075 insulationcrimptomeetipc/whmaa620class2co mpliance. terminalwillaccommodatetheul1015,ul1007anda vs,avsswires. customertocutoffterminalfromreel:0.50mm(.02 0)maximumcutofftab. type 4a
handcrimptoolfor6.35mm(.250)tabsliponmale crimpterminals docno:ats6382383hm releasedate:101510 uncontrolledcopy page2of6 revision:a revisiondate:101510 insulationcrimp seenote brush striplength bellmouth conductor crimpheight bend down bendup rolling conductor crimp twisting cutofftab seam definitionofterms insulationcrimpnote : duetotheterminalsinsulationgripdesignand/or insulationdiameterrange,thistoolusesoverlap formgeometryintheinsulationpunch.thisproduce s anoverlapinsulationcrimp(a620Ccompliant).whi le theinsulationpunchprofilemayappearlopsided, thisisanormalconditionforthistool.seefigur eto theright.(sometoolswithmultiplecrimppockets may nothavetheoverlapprofileonallpockets). crimpspecifications: terminalseriesno. bellmouth conductorbrush mm in. mm in. 35725 0.300.60 .012.024 0.300.80 .012.032 terminalseriesno. bendupbenddown twistroll seam seamshallnotbeopen andnowireallowedout ofthecrimpingarea degree degree 35725 3 3 3 5 overlap insulation crimp overlapformgeometry anvil punch wire
handcrimptoolfor6.35mm(.250)tabsliponmale crimpterminals docno:ats6382383hm releasedate:101510 uncontrolledcopy page3of6 revision:a revisiondate:101510 figure2 wire terminal locator insulation punch insulation anvil wirestop blade conductor anvil conductor punch wire insulation punch terminal wirestopblade figure1 aftercrimping,theconductorprofileshouldmeasur ethefollowing. terminal seriesno. wiresize conductorcrimp pullforce minimum profile height width awg mm 2 mm in. mm in. n lb. 20awg /0.50mm2 22awg /0.30mm2 35725 20 1.391.49 .055.059 1.902.10 .075.083 88.2 19.8 x 22 1.311.41 .052.056 1.902.10 .075.083 58.8 13.2 x 0.50 1.391.49 .055.059 1.902.10 .075.083 88.2 19.8 x 0.30 1.311.41 .052.056 1.902.10 .075.083 58.8 13.2 x terminalseriesno. wiresize insulationcrimp height(max) width awg mm 2 mm in. mm in. 35725 20 2.90 .114 2.803.00 .110.118 22 2.70 .106 2.803.00 .110.118 0.50 2.90 .114 2.803.00 .110.118 0.30 2.70 .106 2.803.00 .110.118 t tt t toolqualificationnotes: 1. pullforceshouldbemeasuredwithnoinfluencefro mtheinsulationcrimp. 2. theabovespecificationsareguidelinestoanoptim umcrimp. operation openthetoolbysqueezingthehandlestogether,at theendoftheclosingstroke,theratchetmechani smwill releasethehandles,andthehandtoolwillspring open. crimpingterminals 1. placetheterminalintothecorrectdieprofileunt iltheterminalstoppedbythelocator. 2. bringthewirestopbladedown;makesurethewire stoplocatedbehindtheconductorgrip. 3. placeaprestripedwireintotheterminaluntilth eendofwiretouchingthewirestop.seefigure2 .
handcrimptoolfor6.35mm(.250)tabsliponmale crimpterminals docno:ats6382383hm releasedate:101510 uncontrolledcopy page4of6 revision:a revisiondate:101510 4. closethetooluntiltheratchetreleases,thetool handleswillthenspringopen. 5. carefullyremovethecrimpedterminal. note: thetamperproofratchetactionwillnotreleaset hetooluntilithasbeenfullyclosed. 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,wirestrandingand insulationtypesmayaffectcrimpheight. 3. thistoolisintendedforstandardconductorsizes. itmaynotgiveagoodinsulationcrimpsupportf orall insulationsizes.
handcrimptoolfor6.35mm(.250)tabsliponmale crimpterminals docno:ats6382383hm releasedate:101510 uncontrolledcopy page5of6 revision:a revisiondate:101510 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 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. 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. 638238370 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 lock ing pins handcrimp framelong orshort
handcrimptoolfor6.35mm(.250)tabsliponmale crimpterminals docno:ats6382383hm releasedate:101510 uncontrolledcopy page6of6 revision:a revisiondate:101510 ratchet releaselever handle spring crimping spring(2) 3 6 4 figure6 m4x14mm longbhcs 2 5 1 partslist handcrimptool638238300 item ordernumber description quantity 1 638238370 modularcrimphead 1(ref) 2 638160050 handcrimpframe(long) 1(ref) 3 638238375 locator 1 4 638160001 lockingpin 2 5 636000525 handlespring 1 6 636000520 crimpingspring 2 http://www.molex.com
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