toolkitfor250mplockterminal docno:ats6382355hm releasedate:030911 uncontrolledcopy page1of9 revision:a revisiondate:030911 insulation crimp seenote brush strip length conductor crimpheight cutoff tab seam bellmouth wire applicationtooling specificationsheet toolkit orderno.638235570 handcrimptool orderno.638235500 features % afullcycleratchetinghandtoolensurescomplete crimps % ergonomicallydesignedsofthandles % preciselydesignedcrimpingprofileswithsimpleco ntactpositioning % easyhandlingduetooutstandingforceratio toolkitsareeasilyinstalledintothehandcrimp toolorthe638160300powercrimpheadwhichisin stalled intothe638160200(110v)orthe638160250(220 v)batterypoweredtool. manydifferenttoolkitscanbeusedwithasingle batterypoweredtool. thistoolisipc/whmaa620class2androhscompli ant. scope products :.250mplockterminalsfor1418awgwire. terminalseriesno. terminalorderno. wiresize insulationdiameter striplength reelformonly awg mm2 mm in. mm in. 57989 579899810 14 2.00 2.23.4 .087.134 5.005.50 .197.217 16 1.30 18 0.80 customertocutoffterminalfromreel:0.50mm(.02 0)maximumcutofftab. definitionofterms theaboveterminaldrawingisagenericterminalre presentation.itisnotanimageofaterminallis tedinthe scope. type4c
toolkitfor250mplockterminal docno:ats6382355hm releasedate:030911 uncontrolledcopy page2of9 revision:a revisiondate:030911 insulationcrimpnote : duetotheterminalsinsulationgripdesign and/orinsulationdiameterrange,thistool usesoverlapformgeometryinthe insulationpunch.thisproducesanoverlap insulationcrimp(a620Ccompliant).while theinsulationpunchprofilemayappear lopsided,thisisanormalconditionforthis tool.seefiguretotheright.(sometoolswith multiplecrimppocketsmaynothavethe overlapprofileonallpockets). conditions: aftercrimping,theconductorprofilesshould measurethefollowing(seenotesbelow). terminal seriesno. wiresize conductorcrimp insulationcrimp pullforce minimum profile height width(ref) height width(ref) awg mm 2 mm in. mm in. mm in. mm in. n lbs 14 16 18 57989 14 2.00 1.771.87 .070.074 2.75 .108 2.60 .102 4.50 .177 245.17 55.12 x 16 1.30 1.571.67 .062.066 2.75 .108 2.70 .106 4.50 .177 205.94 46.30 x 18 0.80 1.451.55 .057.061 2.75 .108 3.60 .142 4.50 .177 117.68 26.46 x toolqualificationnotes: 1. pullforceshouldbemeasuredwithnoinfluence fromtheinsulationcrimp. 2. theabovespecificationsareguidelinestoanop timumcrimp. note: acrimpheightchartisprovidedwiththismanuala sreferenceonly. duetothewiderangeofwires,strands, insulationdiameters,anddurometers,actualcrimp heightmeasurementsmayveryslightly.anoccasion al, destructive,pullforcetestshouldbepreformedto checkhandtoolcrimp.pullforcevaluemust exceedthe minimumpullforcespecificationslisted. caution: installonlymolexterminalslistedabovewiththis tool.donotcrimphardenedobjectsasdamage canoccurtothetoolordie. installation toinstallthetoolkitintothepowercrimpheadf ollowthestepsbelow: anvilsandpunchesinstallation 1. inserttheanvilsintothebottomslotsofthenest .installthem4x10longbhcsandtighteninpla ce. 2. insertthepunchesintothetopslotsofthenest. installthem4x18longbhcsandtighteninplace .see figure1. locatorinstallationandremoval followthestepsbelowtoinstallorreplacethelo cator.seefigure2. overlap insulation crimp overlapformgeometry anvil punch wire
toolkitfor250mplockterminal docno:ats6382355hm releasedate:030911 uncontrolledcopy page3of9 revision:a revisiondate:030911 anvils power crimp head figure1 punches m4x10long bhcs m4x18long bhcs swing locator open pressdown onthebrass pivotshaft liftupon thelocator figure2 toinstallthelocator 1. positionthelocatorwiththeholeoverthebrassp ivotshaftandsnapitintoplace. toremovethelocator 1. openthecrimphandtool. 2. swingtheexistinglocatoropenandawayfromtheh andtool. 3. firmlypressdownonthebrasspivotshaftwithyou rthumb,whilepullingthelocatorup.slipthelo catoroffthe topofthebrasspivotshaft. operation openthetoolbysqueezingthehandlestogether,at theendoftheclosingstroke,theratchetmechani smwill releasethehandles,andthehandtoolwillspring open. crimpingterminals 1. selectthedesiredterminallistedinthepreceding charts. 2. turnthelocatorlocklatchdowntounlock.see figure3. 3. swingtheterminallocatorawayfromthecrimptool showninfigure4.someterminalswithlarge insulationgripsmayinterferewiththecrimptooli ng whenswingingthelocatorintoposition.thetermi nal mustthenbeloadedintothelocatorinthe closed/crimpposition.seefigure5. 4. pressdownonthewirestoponthelocatorasshown infigure1.inserttheproperterminalintothepr oper nestopening.makesurewhenchoosingthenestope ning,itwillcorrespondwiththea,borcprofile onthe handtool. 5. returnthelocatortoitsoriginalposition. 6. turnthelocatorlocklatchuptolock.makesure thattheterminalisvisuallycenteredoverthepun ch. figure3 latchlocked latchunlocked
toolkitfor250mplockterminal docno:ats6382355hm releasedate:030911 uncontrolledcopy page4of9 revision:a revisiondate:030911 swingopen terminal pushhereto openwirestop locator terminal inplace figure4 locatorlatch inopenposition figure6 wireinterminal jaws partially closed wireagainst wirestop handle open locator closed figure5 terminal pushhereto openwirestop 7. inserttheproperwireovertheterminal. 8. gentlytouchthewirestopwiththeendofthewire .seefigure6and7. 9. compresstheterminalbysqueezingthetoolhandles untiltheratchetmechanismcyclehasbeencomplet ed. releasehandlestoopenthejaws. 10. removethecrimpedterminalfromtheterminallocat orbypressingdownonthewirestopandgentlypul lingon thewire.theterminallocatorcanbeineitherpo sition. 11. visuallyinspectthecrimpedterminalforpropercr implocation. note :thetamperproofratchetactionwillnotrelease thetooluntilithasbeenfullyclosed. forthebatterypowertool: 1. cyclethebatterypowertooltocrimptheterminal tothewire. 2. removethecrimpedterminalfromtheterminallocat orbypressingdownonthewirestopandgentlypul lingon thewire.theterminallocatorcanbeineitherpo sition. 3. visuallyinspectthecrimpedterminalforpropercr implocation.
toolkitfor250mplockterminal docno:ats6382355hm releasedate:030911 uncontrolledcopy page5of9 revision:a revisiondate:030911 maintenance itisrecommendedthateachoperatorofthetool bemadeawareof,andresponsiblefor,the followingmaintenancesteps: 1. removedust,moistureandother contaminantswithacleanbrush,orsoft,lint freecloth. 2. donotuseanyabrasivematerialsthatcould damagethetool. 3. makecertainallpins;pivotpointsandbearing surfacesinthetoolheadareprotectedwitha thincoatofhighqualitymachineoil.donotoil excessively.thistoolwasengineeredfordurabili ty,butlikeanyfinepieceofequipment,itneeds cleaning andlubricationforamaximumservicelifeoftroub lefreecrimping.theuseoflightoil,suchas30 weight automotiveoil,every5,000crimpsormonthly,will significantlyenhancethetoollifeandensureas table calibration.seefigure8aor8bforlubricationp oints. 4. storethetoolinacleananddryareawhennotin use. miscrimpsorjamsforcrimphandtoolsonly (seefigure11) shouldthistooleverbecomestuckorjammedinap artiallyclosedposition, donot forcethehandlesopenor closed. thetoolwillopeneasilybyrotatingthe smallslottedscrewmarkedwithanarrow.see figure11. warranty thistoolkitisforelectricalterminalcrimping purposesonly.thistoolkitismadeofthebest qualitymaterials.allvitalcomponentsarelong lifetested.alltoolsarewarrantedtobefreeof manufacturingdefectsforaperiodof30days. shouldsuchadefectoccur,wewillrepairor exchangethetoolkitfreeofcharge.thisrepair orexchangewillnotbeapplicabletoaltered, misused,ordamagedtools. caution :molexcrimpspecificationsarevalidonlywhenu sedwithmolexterminalsandtooling. cautions 1. manuallypoweredhandtoolsareintendedforlowvo lumeorfieldrepair.thistoolis not intendedfor productionuse.repetitiveuseofthistoolshould beavoided. 2. insulatedrubberhandlesarenotprotectionagainst electricalshock. figure7 wire insulation punch conductoranvil locator insulationanvil wiresagainst locatorstop conductor punch terminal lubrication points (bothsides) lightoil (everymonth or 5,000crimps) figure8a figure8b
toolkitfor250mplockterminal docno:ats6382355hm releasedate:030911 uncontrolledcopy page6of9 revision:a revisiondate:030911 3. weareyeprotectionatalltimes. 4. useonlythemolexterminalsspecifiedforcrimping withthistool. caution: repetitiveuseofthistoolshouldbeavoided. certification molexdoesnotcertifyorrecertifycommercialgra dehandtoolsbutrathersuppliesthefollowinggui delinesfor customerstorecertifyhandtools. % thistoolisqualifiedtopullforceonly.torec ertify,crimpaterminaltoawire,whichhasbeen stripped 12.7mm(1/2)long,sothereisnocrimpingofthe insulation.pulltheterminalandwireataraten ofasterthan 25mm(1.00)perminute.seethemolexwebsitefo rthequalitycrimphandbookformoreinformationo npull testing. % whenthehandtoolisnolongercapableofachievin gminimumpullforce,itshouldbetakenoutofser viceand replaced. % thistoolisverydifficulttodisassembleandreas semble.customerrepairisnotrecommended. thechartbelowshowsallapplicationsforthistoo lkit. toolkit orderno. tool orderno. tool description powerhead orderno. adapter description figure no. 639235570 638101050 handcrimpframe(short) n/a n/a 9 638101000 handcrimpframe(long) n/a n/a 9 638160200 batterypowertool(110v) 638160300 powercrimphead 10 638160250 batterypowertool(220v) 638160300 powercrimphead 10 applicationsforthetoolkit handcrimptool batterypoweredtool figure9 figure10 power crimp head lockingpins battery powered tool toolingkit handcrimp framelong andshort toolingkit
toolkitfor250mplockterminal docno:ats6382355hm releasedate:030911 uncontrolledcopy page7of9 revision:a revisiondate:030911 warning : never operateservice,installtoolkits,oradjustthep owercrimpheadwithoutproper instructionandwithoutfirstreadingandunderstan dingtheinstructionsinthepropermanualor specificationsheet.seechartaboveforthecorre ctmanualorspecificationsheet. warning : never installtoolingorservicethistoolwhileitisin toanypowersource.makesurethe poweristurnedoff. caution: keepfingersawayfromthecrimpingareawhenopera tingthistool.itmaycausesevereinjury. caution: wearsafetyglasseswhenoperatingorservingthis tool.
toolkitfor250mplockterminal docno:ats6382355hm releasedate:030911 uncontrolledcopy page8of9 revision:a revisiondate:030911 ratchet releasescrew figure11 m4x8mm longbhcs 2 1 3 m4x18mm longbhcs m4x10mm longbhcs 2 4 withtoolkit locatoronly handtoolpartslist itemnumber ordernumber description quantity 1 638101000 handcrimpframe(long) 1 2 638235570 toolkitwithlocator 1 3 638114773 locatorbase 1 4 638235575 locator(only) ref
toolkitfor250mplockterminal docno:ats6382355hm releasedate:030911 uncontrolledcopy page9of9 revision:a revisiondate:030911 figure12 1 2 2 m4by8long bhcs m4by18long bhcs m4by10long bhcs 1 powerheadpartslist item orderno engineeringno. description quantity 1 638160300 638160300 powercrimphead 1 2 638235570 638235570 toolkit 1 http://www.molex.com
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