handcrimptoolfor minifit?jr. crimpterminals docno:ats638191000 releasedate:120707 uncontrolledcopy page1of8 revision:b revisiondate:101410 handcrimp tool applicationtooling specificationsheet orderno.638191000 features afullcycleratchetinghandtoolensurescomplete crimps ergonomicsoftgriphandlesforcomfortablecrimpin g aprecisionuserfriendlyterminallocatorwiresto pholdsterminalsinthepropercrimpingposition rightandlefthandedapplications thistoolisipc/whmaa620class2compliantasin dicated thistoolisrohscompliant,howeverrohscompliant isnotrequired scope products :minifit?jr.maleandfemalecrimpterminals,22 28awg. terminal seriesno. terminalorderno. wiresize insulationdiameter st riplength loosepiece reel awg mm2 mm in. mm in. 5556 39000047 39000172 39000046 39000171 2228 0.35008 0.901.80 .035.071 2.793.30 .110.130 39000066 39000178 39000065 39000177 39000086 39000184 39000085 39000183 39000092 39000197 39000091 39000196 39000111 39000203 39000110 39000202 39000117 39000210 39000116 39000209 39000140 39000216 39000139 39000215 39000156 39000435 39000155 39000434 39000166 39000165 5558 39000049 39000129 39000048 39000128 2228 0.35008 0.901.80 035.071 2.793.30 .110.130 39000068 39000146 39000067 39000145 39000088 39000222 39000087 39000221 39000098 39000433 39000097 39000432 39000123 39000122 44485 444852211 444852411 444852212 444852412 2228 0.35008 0.901.80 035.071 2.793.30 .110.130 444852311 444852312 customertocutoffterminalfromreel:0.2mm(.008 )maximumcutofftab. type4d
handcrimptoolfor minifit?jr. crimpterminals docno:ats638191000 releasedate:120707 uncontrolledcopy page2of8 revision:b revisiondate:101410 insulation crimp seenote brush strip length bellmouth crimpheight bend down bendup rolling conductor crimp twisting definitionofterms theaboveterminaldrawingisagenericterminalre presentation.itisnotanimageofaterminallis tedinthe scope. insulationcrimpnote : duetotheterminalsinsulationgripdesign and/orinsulationdiameterrange,thistool usesoverlapformgeometryinthe insulationpunch.thisproducesanoverlap insulationcrimp(a620Ccompliant).while theinsulationpunchprofilemayappear lopsided,thisisanormalconditionfor thistool.seefiguretotheright.(some toolswithmultiplecrimppocketsmaynot havetheoverlapprofileonallpockets). conditions: aftercrimping,theconductorprofilesshouldmeasu rethefollowing.seenotesbelow. 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. 2224 2628 5556 22 0.35 0.690.79 .027.031 1.29 .051 1.62 .064 1.60 .063 39.0 8.78 x 24 0.20 0.670.77 .026.030 1.29 .051 1.62 .064 1.58 .062 29.0 6.52 x 26 0.12 0.640.74 .025.029 1.27 .050 1.46 .057 1.54 .061 19.0 4.27 x 28 0.08 0.620.72 .024.028 1.27 .050 1.46 .057 1.52 .060 9.8 2.20 x 5558 22 0.35 0.690.79 .027.031 1.29 .051 1.62 .064 1.60 .063 39.0 8.78 x 24 0.20 0.670.77 .026.030 1.29 .051 1.62 .064 1.58 .062 29.0 6.52 x 26 0.12 0.640.74 .025.029 1.27 .050 1.46 .057 1.54 .061 19.0 4.27 x 28 0.08 0.620.72 .024.028 1.27 .050 1.46 .057 1.52 .060 9.8 2.20 x 44485 22 0.35 0.690.79 .027.031 1.29 .051 1.62 .064 1.60 .063 39.0 8.78 x 24 0.20 0.670.77 .026.030 1.29 .051 1.62 .064 1.58 .062 29.0 6.52 x 26 0.12 0.640.74 .025.029 1.27 .050 1.46 .057 1.54 .061 19.0 4.27 x 28 0.08 0.620.72 .024.028 1.27 .050 1.46 .057 1.52 .060 9.8 2.20 x overlap insulation crimp overlapformgeometry anvil punch wire
handcrimptoolfor minifit?jr. crimpterminals docno:ats638191000 releasedate:120707 uncontrolledcopy page3of8 revision:b revisiondate:101410 release locatorbutton terminal figure3 locator pushedthru tooling terminal locator button pushedin locator toolqualificationnotes: 1. pullforceshouldbemeasuredwithnoinfluence fromtheinsulationcrimp. 2. theabovespecificationsareguidelinestoanop timumcrimp. caution: installonlymolexterminalslistedabovewiththis tool.donotcrimphardenedobjectsasdamagecan occurtothetoolordie. note: acrimpheightchartisprovidedwiththismanuala sreferenceonly. duetothewiderangeofwires,strands, insulationdiameters,anddurometersavailable,act ualcrimpheightmeasurementsmayveryslightly.a n occasional,destructive,pullforcetestshouldbe performedtocheckhandtoolcrimp.pullforce valuemust exceedtheminimumpullforce specificationslisted. operation openthetoolbysqueezingthehandles together.attheendoftheclosingstroke,the ratchetmechanismwillreleasethehandlesand thehandtoolwillspringopen.seefigure1. crimpingterminals 1. selectthedesiredterminallistedinthe precedingcharts. 2. makesurethecenterofthelocatorisinthe downposition.withthelocatorattached, pushthelocatorbuttononthebackofthehandtoo ltobringthelocatorforwardthroughthetooling. see figure2. 3. whileholdingthelocatorbuttonin,loadthetermi nalintothepropernestopeninginthelocatorbas edonthe wiregaugeorterminaltypemarkingsonthehandto oling.seefigure3. 4. releasethelocatorbutton,allowingthelocatorto returntothecrimpingposition. 5. closethetoolhandleuntilthefirstratchetposit ionengages.seefigure4. 6. inserttheproperlystrippedwirethroughthetermi nalandagainstthewirestop.seefigure5. locator indown postion pushonthe locatorbutton figure2 squeeze handles together handlewill springopen figure1
handcrimptoolfor minifit?jr. crimpterminals docno:ats638191000 releasedate:120707 uncontrolledcopy page4of8 revision:b revisiondate:101410 figure5 terminal wireagainstthe wirestop wire wirestopispart ofthelocator prestripped wire terminal 7. crimptheterminalbysqueezingthetoolhandlesun tiltheratchetmechanismcyclehasbeencompleted. releasethehandlestoopenthejaws. note :thetamperproofratchetactionwillnotrelease thetooluntilithasbeenfullyclosed. 8. removethecrimpedterminalfromtheterminallocat orbypullingon thewire. 9. visuallyinspectthecrimpedterminalforpropercr implocation. 10. onsomelargeo.d.wires,itmaynotbepossibleto insertthewire withthetoolpartiallyclosed.thosewiresshould beinsertedwiththe handtoolintheopenposition.insertthewireab ovetheterminalin thepunchandagainstthewirestopthenclosethe tool.seefigure6. locatorreplacement seethepartslistonthelastpageofthisdocumen tfortheproperlocatorordernumber.followthe stepsbelowto replacethelocator. 1. openthecrimphandtool. 2. squeezegentlyonthelowerareashowninfigure7a withyourthumbandindexfinger.thelowertabs ofthe locatorshoulddisengagefromthehandtool. partially closehandle tooling partially closed figure4 firstratchet position open position terminal figure6 wire wirestop
handcrimptoolfor minifit?jr. crimpterminals docno:ats638191000 releasedate:120707 uncontrolledcopy page5of8 revision:b revisiondate:101410 figure8 pushon handle jawsopen pullopen tooling tooling m3bhcs match upmarks front back figure9 3. 4. liftandpullawayfromthehandtool.thetoploc atorhooksshouldslipoutofthetopslotseasily. seefigure 7a. 5. toreinstallthenewlocator,makesurethe handtoolisintheopenposition. 6. presstheredinsertdownasfarasitwillgo asshowninfigure7b. 7. holdingontothelowerpartofthelocator withyourthumbandindexfinger,insertthe locatorstophooks(2)intothehandtooltop slots. 8. rotatethelocatordownandpressthe lowertabsintothetwobottomslotsofthe handtool.tosecurethelocatorintoplace, thelowertabsmustsnapintoplaceonthe handtoolframe. rightorlefthandoperation thishandtoolhasanaddedfeaturethatcan beconvertedfromarighthandedapplicationto alefthandedapplication.itisnecessaryto reversethetoolingifusingthelefthanded applicationalongwiththelocator.followtheste psbelow: 1. thelocatormustberemovedbeforereversingtheto oling. 2. removethem3bhcswhichisholdingtheuppertooli ng. 3. fliptheuppertoolingtotheoppositesideandrep lacethem3bhcs.makesurethesmallmarkingson the frontandbackofthehandtoolframe,matchupand areontheoutsideofthehandtoolframe.seefi gure8 and9. 4. dothesamethingwiththelowertoolingandtighte nthem3screws.besurethesmallmarkingslineu p. 5. reinstallthelocatorbyfollowingtheinstructions inthelocatorreplacementsection. makesure centeroflocator isinthe downposition figure7b squeeze here squeeze here locator figure7a tophooks topslotsof handtool lowertabs
handcrimptoolfor minifit?jr. crimpterminals docno:ats638191000 releasedate:120707 uncontrolledcopy page6of8 revision:b revisiondate:101410 figure12 squeeze thelinkin thehandle holdthehand toolinposition setting wheel ratchet releaselever maintenance itisrecommendedthateachoperatorofthetoolbe madeawareof,and responsiblefor,thefollowingmaintenancesteps: 1. removedust,moisture,andothercontaminantswith acleanbrush,or soft,lintfreecloth. 2. donotuseanyabrasivematerialsthatcoulddamage thetool. 3. makecertainallpins;pivotpointsandbearingsur facesareprotectedwith athincoatofhighqualitymachineoil.donotoi lexcessively.thetool wasengineeredfordurabilitybutlikeanyothereq uipmentitneeds cleaningandlubricationforamaximumservicelife oftroublefree crimping.lightoil(suchas30weightautomotive oil)usedattheoil points,every5,000crimpsor3months,willsignif icantlyenhancethetool life. 4. wipeexcessoilfromhandtool,particularlyfromc rimpingarea.oil transferredfromthecrimpingareaontocertainter minationsmayaffect theelectricalcharacteristicsofanapplication. 5. whentoolisnotinuse,keepthehandlesclosedto preventobjectsfrom becominglodgedinthecrimpingdies,andstorethe toolinaclean,dry area. miscrimpsorjams shouldthistooleverbecomestuckorjammedinap artiallyclosedposition, donot forcethehandlesopenorclosed. thetoolwillopeneasilyby pressingupontheratchetreleaseleverinthemov ablehandle.seefigure11. howtoadjusttoolpreload (see figure12) thishandtoolisfactorypresetto2545 lbs.preload.itmaybenecessaryover thelifeofthetooltoadjusttoolhandle preloadforce.listedbelowarethesteps requiredtoadjustthecrimpingforceof thehandtooltoobtainpropercrimp conditions: 1. holdthehandtoolinthepalmofyour handasshowninfigure10.using theindexfingersqueezethelink towardsthetopofthehandtool frame.thiswillreleasethepreload adjustmentwheel. 2. rotatethesettingwheelcounter clockwise(ccw)toincreasehandleforce.thenumb erswilldisplayhigher.todecreasehandleforce rotate thesettingwheelclockwise(cw). lubricationpoints (bothsides)lightoil (every3monthsor 5,000crimps) figure10 ratchetrelease lever figure11
handcrimptoolfor minifit?jr. crimpterminals docno:ats638191000 releasedate:120707 uncontrolledcopy page7of8 revision:b revisiondate:101410 3. releasethelinktolockthesettingwheelinplace . 4. checkthecrimpspecificationsorconductapullte staftertoolhandlepreloadforceisadjusted. 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 :molexcrimpspecificationsarevalidonlywhenu sedwithmolexterminalsandtooling. cautions: 1. manuallypoweredhandtoolsareintendedforlowvo lumeorfieldrepair.thistoolis not intendedfor productionuse.repetitiveuseofthistoolshould beavoided. 2. insulatedrubberhandlesarenotprotectionagainst electricalshock. 3. weareyeprotectionatalltimes. 4. useonlythemolexterminalsspecifiedforcrimping withthistool. certification molexdoesnotcertifyorrecertifyhandtoolsbut rathersuppliesthefollowingguidelinesforcusto merstorecertify handtools. % thistoolisqualifiedtopullforceonly.torec ertify,crimpaterminaltoawire,whichhasbeen stripped 12.7mm(1/2)long,sothereisnocrimpingofthe insulation.pulltheterminalandwireataraten ofasterthan 25mm(1.00)perminute.seethemolexwebsitefo rthequalitycrimphandbookformoreinformationo npull testing. % ifthetooldoesnotmeetminimumpullforcevalues ,handlepreloadshouldbeincreasedandthepullt est rerun,(seehowtoadjustpreload). % whenthehandtoolisnolongercapableofachievin gminimumpullforce,itshouldbetakenoutofser viceand replaced.
handcrimptoolfor minifit?jr. crimpterminals docno:ats638191000 releasedate:120707 uncontrolledcopy page8of8 revision:b revisiondate:101410 ratchet releaselever 2 figure13 1 3 partslist itemnumber ordernumber description quantity ref 638191000 handcrimptool figure13 1 638191075 locatorassembly 1 2 638100104 spring,return 1 3 638100105 spring,ratchet 1 http://www.molex.com
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