handcrimptoolforminikkcrimpterminals docno:ats6382369hm releasedate:022411 uncontrolled copy page1of7 revision:a revisiondate:022411 insulation crimp brush strip length bell mouth crimp height bend down bend up rolling conductor crimp twisting application tooling specification sheet modular crimp head order no. 63823-6970 hand crimp tool order no. 63823-6900 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: minikkcrimpterminal,2228awg. terminal series no. terminal order no. wire size insulation diameter strip length reel loose awg mm2 mm in. mm in. 5659 08070038 08070039 2228 0.350.08 1.201.70 .047.067 2.503.00 .098.118 customertocutoffterminalfromreel:0.50mm(.02 0)maximumcutofftab. seeconditionsonpage2. definition of terms theaboveterminaldrawingisagenericterminalre presentation.itisnotanimageofaterminallis tedinthescope. type 4a
handcrimptoolforminikkcrimpterminals docno:ats6382369hm releasedate:022411 uncontrolled copy page2of7 revision:a revisiondate:022411 insulation crimp note : duetotheterminalsinsulationgripdesignand/or insulationdiameterrange,thistoolusesoverlap formgeometryintheinsulationpunch.this producesanoverlapinsulationcrimp(a620C compliant).whiletheinsulationpunchprofilemay appearlopsided,thisisanormalconditionfort his tool.seefiguretotheright.(sometoolswith multiplecrimppocketsmaynothavetheoverlap profileonallpockets). crimp specification aftercrimping,thecrimpprofilesshouldmeasuret hefollowing(seenotesonpage4). terminal series no. wire size conductor crimp profile height width (ref.) awg mm 2 mm in. mm in. 22 24 26 28 5659 22 0.35 0.820.87 .032.034 1.40 .055 x 24 0.20 0.750.80 .030.032 1.40 .055 x 26 0.12 0.700.75 .028.030 1.40 .055 x 28 0.08 0.660.71 .026.028 1.40 .055 x terminal series no. wire size insulation diameter insulation crimp pull force minimum height (ref.) width (ref.) awg mm 2 mm in. mm in. mm in. n lb. 5659 22 0.35 1.601.70 .063.067 1.70 .067 1.85 .073 39.23 8.8 24 0.20 1.401.50 .055.059 1.65 .065 1.85 .073 29.42 6.6 26 0.12 1.301.45 .051.057 1.50 .059 1.75 .069 19.61 4.4 28 0.08 1.201.30 .047.051 1.50 .059 1.75 .069 9.81 2.2 tool qualification notes: 1. pullforceshouldbemeasuredwithno influencefromtheinsulationcrimp. 2. theabovespecificationsareguidelinesto anoptimumcrimp. operation openthetoolbysqueezingthehandles together,attheendoftheclosingstroke,the ratchetmechanismwillreleasethehandles, andthehandtoolwillspringopen. 1. withthehandtoolintheopenposition, pivottheterminallocatoropenbypullingup onthelocatorknobandliftthewirestop bladeup.seefigure1. terminal seated in locator swing locator open figure 1 hand tool open wire stop blade overlap insulation crimp overlap form geometry anvil punch wire
handcrimptoolforminikkcrimpterminals docno:ats6382369hm releasedate:022411 uncontrolled copy page3of7 revision:a revisiondate:022411 wire conductor punch terminal wire stop blade figure 2 figure 3 wire terminal locator insulation punch insulation anvil wire stop blade conductor anvil conductor punch 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. terminal locator replacement/change over thissectiondescribestheprocedureforchangingl ocators. removal 1. withthetoolintheopenposition,pivotthetermi nallocatoroutward. 2. removethem4bhcs.seefigure4. installation 1. placetheproperlocator,(seechartonpage2),on thehandtool. installthem4bhcs.seefigure4. 2. tightenthescrewenoughtoholdthelocator.make surethelocator canstillfloatfreelywithhandpressure. m4 bhcs pivot locator figure 4
handcrimptoolforminikkcrimpterminals docno:ats6382369hm releasedate:022411 uncontrolled copy page4of7 revision:a revisiondate:022411 incorrect figure 5 correct incorrect 3. inserttheproperterminalfullyintothecorrectp rofileslotuntiltheterminalisfullyseatedand stops.then gentlypivotthelocatorclosed. 4. withhandpressure,slowlyslidethelocatortothe correctposition.seefigure5. 5. gentlypivotthelocatoropenwithoutdisturbingth elocation. 6. holdthelocatorfirmlyinplaceandslowlytighten them4bhcs. maintenance itisrecommendedthateachoperatorofthetoolbe made awareof,andresponsiblefor,thefollowingmainte nance steps: 1. removedust,moisture,andothercontaminantswith a cleanbrush,orsoft,lintfreecloth. 2. donotuseanyabrasivematerialsthatcoulddamage the tool. 3. makecertainallpins;pivotpointsandbearingsur faces areprotectedwithathincoatofhighqualitymach ineoil. donotoilexcessively.thetoolwasengineeredfo r durabilitybutlikeanyotherequipmentitneedscl eaningandlubricationforamaximumservicelifeo ftrouble 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. miscrimps or jams shouldthistooleverbecomestuckorjammedinap artiallyclosedposition, do not 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.
handcrimptoolforminikkcrimpterminals docno:ats6382369hm releasedate:022411 uncontrolled copy page5of7 revision:a revisiondate:022411 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. applications for the modular crimp head 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.
handcrimptoolforminikkcrimpterminals docno:ats6382369hm releasedate:022411 uncontrolled copy page6of7 revision:a revisiondate:022411 modular crimp head battery power crimp adapter locking pins locking pins battery powered tool air power tool modular crimp head locking pins locking pins air power crimp adapter thechartbelowshowsallapplicationsforthismod ularcrimphead. modular crimp head order no. tool order no. tool description adapter order no. adapter description figure no. 638236970 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 applications for the modular crimp head hand crimp tool battery powered tool air powered to ol figure 6 figure 7 figure 8 modular crimp head locking pins hand crimp frame long or short
handcrimptoolforminikkcrimpterminals docno:ats6382369hm releasedate:022411 uncontrolled copy page7of7 revision:a revisiondate:022411 ratchet release lever handle spring crimping spring (2) locator 2 1 4 figure 9 m4 x 8mm long bhcs 3 5 6 parts list hand crimp tool 63823-6900 item order number description quantity 1 638236970 modularcrimphead 1 2 638160000 handcrimpframe(short) 1 3 638236975 locator 1 4 638160001 lockingpin 2 5 636000525 handlespring 1 6 636000520 crimpingspring 2 http://www.molex.com
|
