handcrimptoolforsabremaleflatbladecrimpter minals docno:ats6382332hm releasedate:062810 uncontrolledcopy page1of6 revision:b revisiondate:101310 applicationtooling specificationsheet modularcrimphead orderno.638233270 handcrimptool orderno.638233200 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 :sabremaleflatbladecrimpterminals,1416awg (ul1007)wire. terminal seriesno. terminal orderno. wiresizeandtype insulationdiameter striplength ipc/whmaa620 terminal awg mm2 type mm in. mm in. mm in. 43178 431782001 431782002 431786001 431786002 14 2.00 ul1007 2.79 .110 2.79 .110 3.965.54 .156.218 16 1.30 ul1007 2.34 .092 2.34 .092 toachieveoptimumipca620insulationcrimps,use thisinsulationodrange. overallinsulationodspecificationforterminal. customertocutoffterminalfromreel:0.50mm(.01 9)maximumcutofftab. type 4a
handcrimptoolforsabremaleflatbladecrimpter minals docno:ats6382332hm releasedate:062810 uncontrolledcopy page2of6 revision:b revisiondate:101310 insulationcrimp seenote brush striplength bellmouth conductor crimpheight bend down bendup rolling conductorcrimp twisting cutofftab seam definitionofterms insulationcrimpnote : duetotheterminalsinsulationgripdesignand/or insulationdiameterrange,thistoolusesoverlap formgeometryintheinsulationpunch.this producesanoverlapinsulationcrimp(a620C compliant).whiletheinsulationpunchprofilemay appearlopsided,thisisanormalconditionfort his tool.seefiguretotheright.(sometoolswith multiplecrimppocketsmaynothavetheoverlap profileonallpockets). crimpspecifications: terminalseriesno. bellmouth conductorbrushmax. mm in. mm in. 43178 0.251.00 .010.039 1.50 .059 terminalseriesno. bendupbenddown twistroll seam seamshallnotbeopen andnowireallowedout ofthecrimpingarea degree degree 43178 3 3 4 8 aftercrimping,theconductorprofileshouldmeasur ethefollowing. terminalseriesno. wiresize conductorcrimp pullforceminimum profile height width awg mm 2 mm in. mm in. n lb. 14awg 16awg 43178 14 2.00 1.952.05 .077.081 3.403.50 .134.138 222 .0 50.0 x 16 1.30 1.801.90 .071.075 3.403.50 .134.138 133.0 30.0 x overlap insulation crimp overlapformgeometry anvil punch wire
handcrimptoolforsabremaleflatbladecrimpter minals docno:ats6382332hm releasedate:062810 uncontrolledcopy page3of6 revision:b revisiondate:101310 figure2 wire terminal locator insulation punch insulation anvil wirestop blade conductor anvil conductor punch wire insulation punch terminal wirestopblade figure1 terminalseriesno. wiresize insulationcrimp height(ref) width awg mm 2 mm in. mm in. 43178 14 2.00 4.104.30 .161.169 3.403.60 .134.142 16 1.30 3.954.15 .155.163 3.403.60 .134.142 t tt t toolqualificationnotes: 1. pullforceshouldbemeasuredwithnoinfluencefro mtheinsulationcrimp. 2. theabovespecificationsareguidelinestoanoptim umcrimp. operation openthetoolbysqueezingthehandlestogether,at theendoftheclosingstroke,theratchetmechani smwill releasethehandles,andthehandtoolwillspring open. crimpingterminals 1. placetheterminalintothecorrectdieprofileunt iltheterminalstoppedbythelocator. 2. bringthewirestopbladedown,makesurethewire stoplocatedbehindtheconductorgrip. 3. placeaprestripedwireintotheterminaluntilth eendofwiretouchingthewirestop.seefigure2 . 4. closethetooluntiltheratchetreleases,thetool handleswillthenspringopen. 5. carefullyremovethecrimpedterminal. note: thetamperproofratchetactionwillnotreleaset hetooluntilithasbeenfullyclosed. maintenance itisrecommendedthateachoperatorofthetoolbe madeawareof,andresponsiblefor,thefollowing maintenancesteps: 1. removedust,moisture,andothercontaminantswith acleanbrush,orsoft,lintfreecloth. 2. donotuseanyabrasivematerialsthatcoulddamage thetool.
handcrimptoolforsabremaleflatbladecrimpter minals docno:ats6382332hm releasedate:062810 uncontrolledcopy page4of6 revision:b revisiondate:101310 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.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. notes: 1. thistoolshouldonlybeusedfortheterminalsand wiregaugesspecifiedonthissheet. 2. thistoolisnotadjustableforcrimpheight;howev ercrimpforceisadjustable(seeinstructionsabov e). variationsintools,terminals,wirestrandingand insulationtypesmayaffectcrimpheight. 3. thistoolisintendedforstandardconductorsizes. itmaynotgiveagoodinsulationcrimpsupportf orall insulationsizes. 4. molexdoesnotrepairhandtools(seewarrantyabov e)thereplacementpartslistedaretheonlyparts 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.
handcrimptoolforsabremaleflatbladecrimpter minals docno:ats6382332hm releasedate:062810 uncontrolledcopy page5of6 revision:b revisiondate:101310 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 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. thechartbelowshowsallapplicationsforthismod ularcrimphead. modularcrimphead orderno. tool orderno. tool description adapter orderno. adapter description figure no. 638233270 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
handcrimptoolforsabremaleflatbladecrimpter minals docno:ats6382332hm releasedate:062810 uncontrolledcopy page6of6 revision:b revisiondate:101310 ratchet releaselever handle spring crimping spring(2) 3 6 4 figure6 m4x14mm longbhcs 2 5 1 partslist handcrimptool638233200 item ordernumber description quantity 1 638233270 modularcrimphead 1(ref) 2 638160050 handcrimpframe(long) 1(ref) 3 638233275 locator 1 4 638160001 lockingpin 2 5 636000525 handlespring 1 6 636000520 crimpingspring 2 http://www.molex.com
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