handcrimptool:forquickdisconnect,highreliabi lityterminal(hrt) docno:ats6382363hm releasedate:091610 uncontrolledcopy page1of6 revision:b revisiondate:101410 type4a insulation crimp seenote brush strip length terminal strip conductor crimpheight cutoff tab seam bellmouth wire applicationtooling specificationsheet modularcrimphead orderno.638236370 handcrimptool orderno.638236300 features % afullcycleratchetinghandtoolensurescomplete crimps % ergonomicallydesignedsofthandles % preciselydesignedcrimpingprofileswithsimpleco ntactpositioning % easyhandlingduetooutstandingforceratio % modularcrimpheadisremovableandcanbeuseint heairpoweredtoolorderno.638160100, accompaniedbyairpoweredcrimpadapter(orderno. 638160700). % canalsobeusedinthebatterypoweredtoolorder no.638160200(110v)or638160250(220v), accompaniedbybatterypoweredcrimpadapter(order no.638160600). scope products :quickdisconnect,highreliabilityterminal(hrt) ,femalefor0.501.00mm2wire. terminalseriesno. terminalorderno. wiresize insulationdiameter striplength reelformonly mm2/awg mm in. mm in. 94512 945120100 945120101 0.50 2.60max .102max 5.306.30 .209.248 0.75 1.00 customertocutoffterminalfromreel:0.20mm(.00 8)maximumcutofftab. seecrimpspecificationfortheindividualinsulati ondiameter. definitionofterms
handcrimptool:forquickdisconnect,highreliabi lityterminal(hrt) docno:ats6382363hm releasedate:091610 uncontrolledcopy page2of6 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: aftercrimping,thecrimpprofilesshouldmeasuret hefollowing. terminalseriesno. wiresize conductorcrimp profile height width mm 2 mm in. mm in. 0.5 0.75 1.0 94512 0.50 1.401.50 .055.059 2.40 .095 x 0.75 1.451.55 .057.061 2.40 .095 x 1.00 1.551.65 .061.065 2.40 .095 x terminal seriesno. wiresize insulationcrimp pullforceminimum height(ref) width(ref) mm 2 mm in. mm in. n lb. 94512 0.50 2.90 .114 3.50 .138 78.45 17.64 0.75 3.10 .122 3.50 .138 117.68 26.46 1.00 3.10 .122 3.50 .138 156.91 35.27 toolqualificationnotes: 1. pullforceshouldbemeasuredwithnoinfluencefro mthe insulationcrimp. 2. theabovespecificationsareguidelinestoanoptim umcrimp. operation openthetoolbysqueezingthehandlestogether,at theendofthe closingstroke,theratchetmechanismwillrelease thehandles,and thehandtoolwillspringopen. crimpingterminals 1. liftthewirestopbladeup. 2. inserttheterminalfullyintothecorrectprofile untiltheterminalisfullyseatedandstops. 3. bringdownthewirestopblade. 4. slidetheprestrippedwireintothewirestopblad e.seefigure1.besuretoholdthewireinplac euntilthe terminalisfullycrimped.seefigure2. 5. closethetooluntiltheratchetreleases,thetool handleswillthenspringopen. 6. liftthewirestopbladeupifitisstillindown position. 7. carefullyremovethecrimpedterminal. terminal prestripped wire locator figure1 wirestop blade overlap insulation crimp overlapformgeometry anvil punch wire
handcrimptool:forquickdisconnect,highreliabi lityterminal(hrt) docno:ats6382363hm releasedate:091610 uncontrolledcopy page3of6 revision:b revisiondate:101410 note: tomaintaingoodbrushcontrolandaconsistentb ellmouththecrimpinginstructionsmustbefollowe d. note: thetamperproofratchetactionwillnotreleaset hetooluntilithasbeenfullyclosed. maintenance itisrecommendedthateachoperatorofthetoolbe made awareof,andresponsiblefor,thefollowingmainte nance steps: 1. removedust,moisture,andothercontaminantswith a cleanbrush,orsoft,lintfreecloth. 2. donotuseanyabrasivematerialsthatcoulddamage thetool. 3. makecertainallpins;pivotpointsandbearingsur faces areprotectedwithathincoatofhighqualitymach ine oil.donotoilexcessively.thetoolwasenginee redfor durabilitybutlikeanyotherequipmentitneedscl eaning andlubricationforamaximumservicelifeoftroub le freecrimping.lightoil(suchas30weightautomo tiveoil)usedattheoilpoints,every5,000crimp sor3 months,willsignificantlyenhancethetoollife. 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. figure2 conductor punch wire locator terminal insulation punch insulation anvil conductor anvil wirestop blade retainer spacer
handcrimptool:forquickdisconnect,highreliabi lityterminal(hrt) docno:ats6382363hm releasedate:091610 uncontrolledcopy page4of6 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.
handcrimptool:forquickdisconnect,highreliabi lityterminal(hrt) docno:ats6382363hm releasedate:091610 uncontrolledcopy page5of6 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. 638236370 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
handcrimptool:forquickdisconnect,highreliabi lityterminal(hrt) docno:ats6382363hm releasedate:091610 uncontrolledcopy page6of6 revision:b revisiondate:101410 ratchet releaselever handle spring crimping spring(2) 3 6 4 figure6 2 5 1 m4x14mm longbhcs partslist handcrimptool638236300 item ordernumber description quantity 1 638236370 modularcrimphead 1 2 638160050 handcrimpframe(long) 1 3 638236375 locator 1 4 638160001 lockingpin 2 5 636000525 handlespring 1 6 636000520 crimpingspring 2 http://www.molex.com
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