handcrimptoolforwiretowireandwiretoboard terminals docno:ats6382354hm releasedate:062310 uncontrolledcopy page1of6 revision:b revisiondate:101310 type4a applicationtooling specificationsheet modularcrimphead orderno.638235470 handcrimptool orderno.638235400 features % afullcycleratchetinghandtoolensurescomplete crimps % ergonomicallydesignedsofthandles % preciselydesignedcrimpingprofileswithsimpleco ntactpositioning % easyhandlingduetooutstandingforceratio % modularcrimpheadisremovableandcanbeuseint heairpoweredtoolorderno.638160100, accompaniedbyairpoweredcrimpadapter(orderno. 638160700). % canalsobeusedinthebatterypoweredtoolorder no.638160200(110v)or638130250(220v), accompaniedbybatterypoweredcrimpadapter(order no.638160600). scope products :3.96mm(.156)pitchwiretowireand6.50mm(.25 6)pitchwiretoboardcrimpterminals, 20,24,and26awg. terminal series terminalorderno. wiresize insulationdiameter wirestriplength reelformonly awg mm 2 mm in. mm in. 50598 505988100 20 0.50 1.501.90 .059.075 2.703.30 .106.130 24 0.20 2.202.35 .087.093 26 0.12 2.102.20 .083.087 50600 506008100 20 0.50 1.501.90 .059.075 24 0.20 2.202.35 .087.093 26 0.12 2.102.20 .083.087 customertocutoffterminalfromreel:0.25mm(.01 0)maximumcutofftab. seecrimpspecificationfortheindividualinsulati ondiameter. definitionofterms thisillustrationisagenericterminalrepresentat ionandnotanexactimageofanyterminallistedi nthescope. insulation crimp seenote brush strip length bellmouth cond.crimp height bend down bendup rolling conductor crimp twisting cutofftab seam
handcrimptoolforwiretowireandwiretoboard terminals docno:ats6382354hm releasedate:062310 uncontrolledcopy page2of6 revision:b revisiondate:101310 figure2 wire terminal locator insulation punch insulation anvil wirestop blade conductoranvil conductor punch wire insulation punch terminal wirestopblade figure1 insulationcrimpnote : duetotheterminalsinsulationgripdesignand/or insulationdiameterrange,thistoolusesoverlap form geometryintheinsulationpunch.thisproducesan overlapinsulationcrimp(a620Ccompliant).while the insulationpunchprofilemayappearlopsided,thi sisa normalconditionforthistool.seefiguretother ight. (sometoolswithmultiplecrimppocketsmaynothav e theoverlapprofileonallpockets). crimpspecifications: terminal seriesno wiresize conductorcrimp insulationcrimp pullforce minimum profile height(ref.) width(ref.) height(ref.) width(ref.) awg mm 2 mm in. mm in. mm in. mm in. n lb. awg 20 awg 24 awg 26 50598 20 0.50 0.951.05 .037.041 1.60 .063 2.30 .091 2.20 .087 58.84 13.23 x 24 0.20 0.800.85 .031.034 1.60 .063 2.50 .098 2.60 .102 29.42 6.61 x 26 0.12 0.760.81 .030.032 1.60 .063 2.00 .079 2.60 .102 14.71 3.31 x 50600 20 0.50 0.951.05 .037.041 1.60 .063 2.30 .091 2.20 .087 58.84 13.23 x 24 0.20 0.800.85 .031.034 1.60 .063 2.50 .098 2.60 .102 29.42 6.61 x 26 0.12 0.760.81 .030.032 1.60 .063 2.00 .079 2.60 .102 14.71 3.31 x 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. overlap insulation crimp overlapformgeometry anvil punch wire
handcrimptoolforwiretowireandwiretoboard terminals docno:ats6382354hm releasedate:062310 uncontrolledcopy page3of6 revision:b revisiondate:101310 5. closethetooluntiltheratchetreleases,thetool handleswillthenspringopen. 6. liftthewirestopbladeupifitisstillindown position. 7. 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.
handcrimptoolforwiretowireandwiretoboard terminals docno:ats6382354hm releasedate:062310 uncontrolledcopy page4of6 revision:b revisiondate:101310 notes: 1. thistoolshouldonlybeusedfortheterminalsand wiregaugesspecifiedonthissheet. 2. thistoolisnotadjustableforcrimpheight,howev ercrimpforceisadjustable(seeinstructionsabov e). variationsintools,terminals,wirestrandingand 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. 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.
handcrimptoolforwiretowireandwiretoboard terminals docno:ats6382354hm releasedate:062310 uncontrolledcopy page5of6 revision:b revisiondate:101310 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 thechartbelowshowsallapplicationsforthismod ularcrimphead. modularcrimphead orderno. tool orderno. tool description adapter orderno. adapter description figure no. 638235470 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
handcrimptoolforwiretowireandwiretoboard terminals docno:ats6382354hm releasedate:062310 uncontrolledcopy page6of6 revision:b revisiondate:101310 ratchet releaselever handle spring crimping spring(2) 3 6 4 figure6 m4x14mm longbhcs 2 5 1 partslist handcrimptool638235400 item ordernumber description quantity 1 638235470 modularcrimphead 1(ref) 2 638160050 handcrimpframe(long) 1(ref) 3 638235475 locator 1 4 638160001 lockingpin 2 5 636000525 handlespring 1 6 636000520 crimpingspring 2 http://www.molex.com
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