handcrimptoolfor2.50mmboardincrimpterminals docno:ats6382379hm releasedate:090210 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.638237970 handcrimptool orderno.638237900 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: 2.50mm(.098")boardincrimpterminal,2228awg, ul1007andul1569wires. terminal seriesno. terminalorderno. reel wiresize insulationdiameter striplength awg mm2 mm in. mm in. 35047 350479800 350479802 2228 0.330.08 1.151.90 .045.075 2.402.90 .094.114 350479810 insulationcrimptomeetipc/whmaa620class2co mpliance. note:terminalwillaccommodatetheul1007andul15 69wires. customertocutoffterminalfromreel:0.30mm(.0 12)maximumcutofftab. definitionofterms theaboveterminaldrawingisagenericterminalre presentation.itisnotanimageofaterminallis tedinthe scope. type4a
handcrimptoolfor2.50mmboardincrimpterminals docno:ats6382379hm releasedate:090210 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 conductorbrushmax. mm in. mm in. 35047 0.200.50 .008.020 1.40 .055 terminalseriesno. bendupbenddown twistroll seam seamshallnotbeopen andnowireallowedout ofthecrimpingarea degree degree 35047 3 3 3 3 aftercrimping,theconductorprofileshouldmeasur ethefollowing. terminal seriesno. wiresize conductorcrimp insulationcrimp pullforce minimum profileawg height width height(ref) width maximum awg mm 2 mm in. mm in. mm in. mm in. n lb. 22 24 26 28 35047 22 0.33 0.820.87 .032.034 1.301.50 .051.059 1.70max .067max 1.90 .075 39.1 8.80 x 24 0.20 0.750.80 .029.031 1.301.50 .051.059 1.60max .063max 1.90 .075 29.3 6.60 x 26 0.13 0.700.75 .027.029 1.301.50 .051.059 1.55max .061max 1.90 .075 19.6 4.40 x 28 0.08 0.660.71 .026.028 1.301.50 .051.059 1.50max .059max 1.90 .075 9.8 2.20 x toolqualificationnotes: 1. pullforceshouldbemeasuredwithno influencefromtheinsulationcrimp. 2. theabovespecificationsareguidelinestoan optimumcrimp. operation openthetoolbysqueezingthehandlestogether, attheendoftheclosingstroke,theratchet mechanismwillreleasethehandles,andthe handtoolwillspringopen. 1. withthehandtoolintheopenposition,pivot theterminallocatoropenbypullinguponthe locatorknobandliftthewirestopbladeup. seefigure1. terminal seatedin locator swing locator open figure1 handtool open wire stopblade overlap insulation crimp overlapformgeometry anvil punch wire
handcrimptoolfor2.50mmboardincrimpterminals docno:ats6382379hm releasedate:090210 uncontrolledcopy page3of7 revision:b revisiondate:101410 incorrect figure5 correct incorrect pivot locator figure4 remove crimped wire figure3 wire terminal locator insulation punch insulation anvil wirestop blade conductor anvil conductorpunch wire insulation punch terminal wirestopblade figure2 2. inserttheterminalintothecorrectprofileuntil theterminalisfullyseatedandstops.makesure thewire stopbladeisfullyinupposition. 3. gentlypivotthelocatorclosed. 4. bringdownthewirestopblade.makesurethewire stopbladeisfullyseatedontheterminalbehind the conductorgripsection. 5. slidetheprestrippedwireintotheterminal;make suretoaimthewirebrushtowardsthetippointo nthe wirestopblade.seefigure2.alignthewireso thatitisparallelandsittingintotheterminal. maintaina lightandconstantpressureonthewirethatissea tedintheterminalatalltimes.(donotletgoo fthe wire.)besuretoholdthewireandterminalinpl aceuntiltheterminalisfullycrimped.seefigur e3. 6. closethetooluntiltheratchetreleases,thetool handleswillthenspringopen. 7. liftthewirestopbladeup. 8. carefullyremovethecrimpedterminal.pivotthet erminallocatorslightlyoutifnecessary.seefig ure4. note: thetamperproofratchetactionwillnotreleaset hetooluntilithasbeenfullyclosed. note: tomaintaingoodbrushcontrolandaconsistentb ellmouththecrimpinginstructionsmustbefollowe d.
handcrimptoolfor2.50mmboardincrimpterminals docno:ats6382379hm releasedate:090210 uncontrolledcopy page4of7 revision:b revisiondate:101410 terminallocatorreplacement thissectiondescribestheprocedureforchangingl ocators. removal 1. withthetoolintheopenposition,pivotthetermi nallocatoroutward. 2. removethem4bhcs.seefigure6. installation 1. placethereplacementlocatoronthehandtool.in stallthem4 bhcs.seefigure6. 2. tightenthescrewenoughtoholdthelocator.make surethe locatorcanstillfloatfreelywithhandpressure. 3. inserttheproperterminalfullyintothecorrectp rofileslotuntilthe terminalisfullyseatedandstops.thengentlypi votthelocatorclosed. 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. 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.seefigure10. 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. m4bhcs pivotlocator figure6
handcrimptoolfor2.50mmboardincrimpterminals docno:ats6382379hm releasedate:090210 uncontrolledcopy page5of7 revision:b revisiondate:101410 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,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.
handcrimptoolfor2.50mmboardincrimpterminals docno:ats6382379hm releasedate:090210 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. 638237970 638160000 handcrimpframe(short) n/a n/a 7 638160050 handcrimpframe(long) n/a n/a 7 638160200 batterypowertool(110v) 638160600 batterypowercrimpadapter 8 638160250 batterypowertool(220v) 638160600 batterypowercrimpadapter 8 638160100 airpowertool 638160700 airpowercrimpadapter 9 applicationsforthemodularcrimphead handcrimptool batterypoweredtool airpoweredto ol figure7 figure8 figure9 modular crimp head locking pins handcrimp framelong orshort
handcrimptoolfor2.50mmboardincrimpterminals docno:ats6382379hm releasedate:090210 uncontrolledcopy page7of7 revision:b revisiondate:101410 ratchet releaselever handle spring crimping spring(2) locator 2 1 4 figure10 m4x8mm longbhcs 3 5 6 partslist handcrimptool638237900 item ordernumber description quantity 1 638237970 modularcrimphead 1 2 638160000 handcrimpframe(short) 1 3 638237975 locator 1 4 638160001 lockingpin 2 5 636000525 handlespring 1 6 636000520 crimpingspring 2 http://www.molex.com
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