handcrimptoolforboardincrimpterminals docno:ats6382366hm releasedate:022311 uncontrolledcopy page1of7 revision:a revisiondate:022311 applicationtooling specificationsheet modularcrimphead orderno.638236670 handcrimptool orderno.638236600 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 :4.00mm(.157)pitchboardincrimpterminal,18 22awg,0.85mm2;to0.30mm2metricwire. terminal series terminalorderno. wiresize insulationdiameter wirestriplength reel loose wirestyle mm2/awg mm in. mm in. 50098 500988000 500988100 18 1.62.6 .063.102 2.503.00 .098.118 20 22 avs 0.85 avs 0.50 avs 0.30 av 0.85 av 0.50 av 0.75f av 0.50f customertocutoffterminalfromreel:0.20mm(.00 8)maximumcutofftab. seecrimpspecificationfortheindividualinsulati ondiameter. type4a
handcrimptoolforboardincrimpterminals docno:ats6382366hm releasedate:022311 uncontrolledcopy page2of7 revision:a revisiondate:022311 definitionofterms thisillustrationisagenericterminalrepresentat ionandnotanexactimageofanyterminallistedi nthescope. insulationcrimpnote : duetotheterminalsinsulationgripdesignand/or insulationdiameterrange,thistoolusesoverlap formgeometryintheinsulationpunch.thisproduce s anoverlapinsulationcrimp(a620Ccompliant). whiletheinsulationpunchprofilemayappear lopsided,thisisanormalconditionforthistoo l.see figuretotheright.(sometoolswithmultiplecrim p pocketsmaynothavetheoverlapprofileonall pockets). crimpspecifications: aftercrimping,thecrimpprofilesshouldmeasuret hefollowing. terminal seriesno. wiresize conductorcrimp profile height width(ref.) wirestyle mm2/awg mm in. mm in. 18awg .75.85mm 20awg .50mm 22awg .30mm 50098 18 1.121.22 .044.048 1.65 .065 x 20 0.931.03 .037.041 1.65 .065 x 22 0.870.92 .034.036 1.65 .065 x avs 0.85 1.121.22 .044.048 1.65 .065 x avs 0.50 0.961.06 .038.042 1.65 .065 x avs 0.30 0.910.96 .036.038 1.65 .065 x av 0.85 1.141.24 .045.049 1.65 .065 x av 0.50 0.961.06 .038.042 1.65 .065 x av 0.75f 1.071.17 .042.046 1.65 .065 x av 0.50f 0.931.03 .037.041 1.65 .065 x insulation crimp seenote brush strip length bellmouth cond.crimp height bend down bendup rolling conductor crimp twisting cutofftab seam overlap insulation crimp overlapformgeometry anvil punch wire
handcrimptoolforboardincrimpterminals docno:ats6382366hm releasedate:022311 uncontrolledcopy page3of7 revision:a revisiondate:022311 wire conductor punch terminal wirestop blade figure2 terminal seriesno. wiresize insulationdiameter insulationcrimp pullforce minimum height(ref.) width(ref.) wirestyle mm2/awg mm in. mm in. mm in. n lb. 50098 18 2.02.2 .079.087 2.20 .087 2.75 .108 88.0 19.78 20 1.71.8 .067.071 1.90 .075 2.75 .108 58.7 13.20 22 1.61.7 .063.067 1.95 .077 2.30 .091 39.1 8.79 avs 0.85 2.22.3 .087.091 2.20 .087 2.75 .108 88.0 19.87 avs 0.50 2.02.0 .079.083 2.00 .079 2.75 .108 58.7 13.20 avs 0.30 1.81.9 .071.075 1.95 .077 2.30 .091 39.1 8.79 av 0.85 2.42.6 .094.102 2.20 .087 2.75 .108 88.0 19.78 av 0.50 2.22.4 .087.094 2.05 .081 2.75 .108 58.7 13.20 av 0.75f 2.42.6 .094.102 2.20 .087 2.75 .108 88.0 19.78 av 0.50f 2.22.4 .087.094 2.05 .081 2.75 .108 58.7 13.20 toolqualificationnotes: 1. pullforceshouldbemeasuredwithnoinfluencefro mthe insulationcrimp. 2. theabovespecificationsareguidelinestoanoptim um crimp. operation openthetoolbysqueezingthehandlestogether,at theendof theclosingstroke,theratchetmechanismwillrele asethe handles,andthehandtoolwillspringopen. crimpingterminals 1. withthehandtoolintheopenposition,pivotthe terminal locatoropenbypullinguponthelocatorknoband liftthe wirestopbladeup.seefigure1. 2. inserttheterminalintothecorrectprofileuntil theterminalisfullyseatedandstops.makesure thewire stopbladeisfullyseatedontheterminalbehindt he conductorgripsection. 3. gentlypivotthelocatorclosed. 4. bringdownthewirestopblade. 5. slidetheprestrippedwireintotheterminal;make sureto aimthewirebrushtowardsthetippointonthewir estop blade.seefigure2.alignthewiresothatitis paralleland sittingintotheterminal.maintainalightandco nstant pressureonthewirethatisseatedintheterminal atall times.(donotletgoofthewire.)besuretoho ldthewire andterminalinplaceuntiltheterminalisfullyc rimped.see figure3. 6. closethetooluntiltheratchetreleases. 7. liftthewirestopbladeup. 8. carefullyremovethecrimpedterminal. note: thetamperproofratchetactionwillnotreleaset hetooluntilithasbeenfullyclosed. terminal seatedin locator locator open figure1 handtool open
handcrimptoolforboardincrimpterminals docno:ats6382366hm releasedate:022311 uncontrolledcopy page4of7 revision:a revisiondate:022311 incorrect figure5 correct incorrect wire conductor punch wirestop blade insulation punch locator conductoranvil insulation anvil terminal figure3 note: tomaintaingoodbrushcontrolandaconsistentb ellmouththecrimpinginstructionsmustbefollowe d. terminallocatorreplacement/changeover thissectiondescribestheprocedureforchangingl ocators. removal 1. withthetoolintheopenposition,pivotthetermi nal locatoroutward. 2. removethem4bhcs.seefigure4. installation 1. placetheproperlocator,onthehandtool.instal lthem4bhcs.seefigure4. 2. tightenthescrewenoughtoholdthelocator.make surethelocatorcanstillfloatfreelywithhand pressure. 3. inserttheproperterminalfullyintothecorrectp rofileslotuntiltheterminalisfullyseatedand stops.then gentlypivotthelocatorclosed. 4. withhandpressure,slowlyslidethelocatortothe correctposition.seefigure5. 5. gentlypivotthelocatoropenwithoutdisturbingth elocation. 6. holdthelocatorfirmlyinplaceandslowlytighten them4bhcs. maintenance itisrecommendedthateachoperatorofthetoolbe madeawareof,andresponsiblefor,thefollowing maintenancesteps: 1. removedust,moisture,andothercontaminantswith acleanbrush,orsoft,lintfreecloth. 2. donotuseanyabrasivematerialsthatcoulddamage thetool. m4bhcs pivotlocator figure4
handcrimptoolforboardincrimpterminals docno:ats6382366hm releasedate:022311 uncontrolledcopy page5of7 revision:a revisiondate:022311 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. 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.
handcrimptoolforboardincrimpterminals docno:ats6382366hm releasedate:022311 uncontrolledcopy page6of7 revision:a revisiondate:022311 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 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 figureno. 638236670 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 figure6 figure7 figure8 modular crimp head locking pins handcrimp framelong orshort
handcrimptoolforboardincrimpterminals docno:ats6382366hm releasedate:022311 uncontrolledcopy page7of7 revision:a revisiondate:022311 ratchet releaselever handle spring crimping spring(2) locator 2 1 figure9 m4x6mm longbhcs 3 4 6 5 partslist handcrimptool638236600 item ordernumber description quantity 1 638236670 modularcrimphead 1(ref) 2 638160050 handcrimpframe(short) 1(ref) 3 638236675 locator 1 4 638160001 lockingpin 2 5 636000525 handlespring 1 6 636000520 crimpingspring 2 http://www.molex.com
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