handcrimptoolfor2.50mm(.098)wiretoboardcr impterminals docno:ats6382375hm releasedate:092710 uncontrolledcopy page1of7 revision:b revisiondate:101410 insulation crimp seenote brush strip length bellmouth cond.crimp height bend down bendup rolling conductor crimp twisting cutofftab seam applicationtooling specificationsheet modularcrimphead orderno.638237570 handcrimptool orderno.638237500 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: 2.50mm(.098)wiretoboardcrimpterminals,222 8awg. terminal seriesno. terminal orderno. wiresize insulationdiameter striplength reel awg mm2 mm in. mm in. 50752 507528000 507528100 2228 0.350.08 1.151.80 .045.071 2.002.50 .078.098 customertocutoffterminalfromreel:0.20mm(.00 8)maximumcutofftab . seeconditionsonpage2. definitionofterms theaboveterminaldrawingisagenericterminalre presentation.itisnotanimageofaterminallis tedinthe scope. type4a
handcrimptoolfor2.50mm(.098)wiretoboardcr impterminals docno:ats6382375hm releasedate:092710 uncontrolledcopy page2of7 revision:b revisiondate:101410 insulationcrimpnote : duetotheterminalsinsulationgripdesignand/or insulationdiameterrange,thistoolusesoverlap form geometryintheinsulationpunch.thisproducesan overlapinsulationcrimp(a620Ccompliant).while the insulationpunchprofilemayappearlopsided,thi sisa normalconditionforthistool.seefiguretother ight. (sometoolswithmultiplecrimppocketsmaynothav e theoverlapprofileonallpockets). crimpspecifications: terminalseriesno. bellmouth conductorbrush bendupbenddown twi stroll mm in. mm in. degree degree 50752 0.050.40 .002.016 0.000.60 .000.023 3 3 3 6 aftercrimping,thecrimpprofilesshouldmeasuret hefollowing. terminal orderno. 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. 22 24 26 28 50752 22 0.35 0.840.89 .033.035 1.20 .047 1.8 .071 1.80 .071 39.2 8.8 x 24 0.20 0.760.81 .030.032 1.20 .047 1.8 .071 1.80 .071 29.4 6.6 x 26 0.12 0.710.76 .028.030 1.20 .047 1.7 .067 1.80 .071 19.6 4.4 x 28 0.08 0.670.72 .026.028 1.20 .047 1.7 .067 1.80 .071 9.8 2.2 x toachieveipca620class3crimps,thefollowing overallwireinsulationdiameterrangesarerecomm ended: profile22:1.501.65mm(.059.065) profile24:1.301.50mm(.051.059) profile26:1.201.40mm(.047.055) profile28:1.201.30mm(.047.051) toolqualificationnotes : 1. pullforceshouldbemeasuredwithno influencefromtheinsulationcrimp. 2. theabovespecificationsareguidelines toanoptimumcrimp. operation openthetoolbysqueezingthehandles together,attheendoftheclosingstroke,the ratchetmechanismwillreleasethehandles,and thehandtoolwillspringopen. 1. withthehandtoolintheopenposition,pivot theterminallocatoropenbypullingupon thelocatorknobandliftthewirestopblade up.seefigure1. terminal seatedin locator swing locator open figure1 handtool open wire stopblade overlap insulation crimp overlapformgeometry anvil punch wire
handcrimptoolfor2.50mm(.098)wiretoboardcr impterminals docno:ats6382375hm releasedate:092710 uncontrolledcopy page3of7 revision:b revisiondate:101410 wire conductor punch terminal wirestop blade figure2 wire conductor punch wirestop blade insulation punch locator conductor anvil insulation anvil terminal figure3 2. inserttheterminalintothecorrectprofileuntil theterminalisfullyseatedandstops.makesure thewire stopbladeisfullyseatedontheterminalbehindt heconductorgripsection. 3. gentlypivotthelocatorclosed. 4. bringdownthewirestopblade. 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 surethe locatorcanstillfloatfreelywithhandpressure. m4bhcs pivotlocator figure4
handcrimptoolfor2.50mm(.098)wiretoboardcr impterminals docno:ats6382375hm releasedate:092710 uncontrolledcopy page4of7 revision:b revisiondate:101410 incorrect figure5 correct incorrect 3. inserttheproperterminalfullyintothecorrectp rofileslot untiltheterminalisfullyseatedandstops.then gently pivotthelocatorclosed. 4. withhandpressure,slowlyslidethelocatortothe correct position.seefigure5. 5. gentlypivotthelocatoropenwithoutdisturbingth e location. 6. holdthelocatorfirmlyinplaceandslowlytighten them4 bhcs. 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.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.
handcrimptoolfor2.50mm(.098)wiretoboardcr impterminals docno:ats6382375hm releasedate:092710 uncontrolledcopy page5of7 revision:b revisiondate:101410 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. 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.
handcrimptoolfor2.50mm(.098)wiretoboardcr impterminals docno:ats6382375hm releasedate:092710 uncontrolledcopy page6of7 revision:b revisiondate:101410 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. 638237570 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
handcrimptoolfor2.50mm(.098)wiretoboardcr impterminals docno:ats6382375hm releasedate:092710 uncontrolledcopy page7of7 revision:b revisiondate:101410 ratchet releaselever handle spring crimping spring(2) locator 2 1 4 figure9 m4x8mm longbhcs 3 5 6 partslist handcrimptool638237500 item ordernumber description quantity 1 638237570 modularcrimphead 1 2 638160000 handcrimpframe(short) 1 3 638237575 locator 1 4 638160001 lockingpin 2 5 636000525 handlespring 1 6 636000520 crimpingspring 2 http://www.molex.com
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