Molex 207129 Series Manual de usuario

Hand Crimp Tool for CTX280 SWS Receptacle Terminals

Doc No: ATS-6 82 21HM Release Date: 07-17-1 UNCONTROLLED COPY Page 1 of 9

Revision: A Revision Date: 07-17-1

CONDUCTOR

BRUSH

STRIP LENGTH

SEAM

CONDUCTOR

CRIMP

CUT

OFF

TAB

BELL MOUTH

BEND UP

TWISTING

ROLLING

BEND

DOWN

WIRE

SEAL

0.4

0.6 (REF)

SEAL POSITION

Appli ation Tooling

Spe ifi ation Sheet

Tool Kit

Order No. 63823-2170

Hand Crimp Tool

Order No. 63823-2100

FEATURES

% A full cycle ratcheting hand tool ensures complete crimps

% Ergonomically designed soft handles

% Precisely designed crimping profiles with simple contact positioning

% Easy handling due to outstanding force ratio

 Tool kits are easily installed into the Hand Crimp Tool or the 6 816-0 00 Power Crimp Head which is installed

into the 6 816-0200 (110 V) or the 6 816-0250 (220 V) Battery Powered Tool.

 Many different Tool kits can be used with a single Battery Powered Tool.

SCOPE

Products: CTX280 SWS Receptacle Terminals: 4.0 - 5.0 mm2 metric wires.

Terminal

Series No.

Terminal

Order No. Wire Size and Type





Insulation Diameter Strip Length



Reel Form Only

mm²

Type

In.

98675

1004

98675-1008

98675-1044

98675

1048

98675-1064

98675-1068

4.0 – 5.0 T ZHID .40 – .90

.1 4 - .154

4. 0-4.80

.169-.189

4865

1044

4865

1048

4.0

–

5.0

T ZHID

.40

–

.90

.1 4

.154

4. 0

4.80

.169

.189

4808

1004

4808

100

4.0

–

5.0

T ZHID

.40

–

.90

.1 4

.154

4. 0

4.80

.169

.189







See crimp specif

ication for the individual Insulation Diameter

Customer to cut off terminal from reel: 0. 0mm (.012”) maximum Cut-off Tab.

DEFINITION OF TERMS

TYPE 4C

Hand Crimp Tool for CTX280 SWS Receptacle Terminals

Doc No: ATS-6 82 21HM Release Date: 07-17-1 UNCONTROLLED COPY Page 2 of 9

Revision: A Revision Date: 07-17-1

CRIMP SPECIFICATION

Terminal Series No.

Bell mouth







Condu tor Brush

Bend up Bend Down

Twi

st Roll

In.

Degree

Max.

Degree

Max.

98675

4865

4808

0.40-0.60 .016-.024 0.20-0.60 .008-.024 1 1 2



Not to exceed above the conductor crimp height.

After crimping, the crimp profiles should measure the following:

Terminal

Series No.

Wire Size

Condu tor

Pull For e

Minimum Profile Seam

Seam shall not be

open and no wire allowed

out of the crimping area

Crimp

Height

Crimp

Width

In.

Lb.

98675

4865

4808

4.00 1.95-2.05 .077-.081

.45- .55 .1 6-.140

20.0

72.0 X

5.00 2.10-2.20 .08 -.087

.45- .55 .1 6-.140

20.0

72.0 X

Terminal Series No.

Wire Size 



Insulation Diameter

Single Wire Seal

Insulation

Crimp Height

Crimp Width

In.

Order No.

Color

In.

98675

4865

4808

4.00 .40- .70 .1 4-.146

0984921 66

Blue

4.90-5.10

.19 -.201

5.00-5.10

.197-.201

5.00 .70- .90 .146-.154 5.25-5.45

.207-.215

5.00-5.10

.197-.201





Tool Qualification Notes:

1. Pull Force should be measured with no influence from the insulation crimp.

2. The above specifications are guidelines to an optimum crimp.

Note:

A crimp height chart is provided with this manual as Reference Only. Due to the wide range of wires, strands,

insulation diameters, and durometers, actual crimp height measurements may very slightly. An occasional,

destructive, pull force test should be preformed to check hand tool crimp. Pull Force value must exceed the

minimum pull force specifications listed.

CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects as damage

can occur to the tool or die.

Hand Crimp Tool for CTX280 SWS Receptacle Terminals

Doc No: ATS-6 82 21HM Release Date: 07-17-1 UNCONTROLLED COPY Page of 9

Revision: A Revision Date: 07-17-1

SWING

LOCATOR

OPEN

PRESS DOWN

ON THE BRASS

PIVOT SHAFT

LIFT UP ON

THE LOCATOR

Figure

ANVILS

POWER

CRIMP

HEAD

Figure

PUNCHES

M4 X 10 LONG

BHCS

M4 X 18 LONG

BHCS

INSTALLATION

To install the Tool Kit into the Power Crimp Head follow the steps below:

Anvils and Pun hes Installation

1. Insert the Anvils into the bottom slots of the nest. Install the M4 x 10 long BHCS and tighten in place.

2. Insert the Punches into the top slots of the nest. Install the M4 x 18 long BHCS and tighten in place. See

Figure 1.

Lo ator Installation and Removal

Follow the steps below to install or replace the locator. See Figure 2.

To install the lo ator

1. Position the locator with the hole over the brass

pivot shaft and snap it into place.

To remove the lo ator

1. Open the crimp hand tool.

2. Swing the existing locator open and away from the

hand tool.

. Firmly press down on the brass pivot shaft with your

thumb, while pulling the locator up. Slip the locator

off the top of the brass pivot shaft.

OPERATION

Open the tool by squeezing the handles together, at the end of the closing stroke, the ratchet mechanism will

release the handles, and the hand tool will spring open.

Figure 3

LATCH LOCKED

LATCH UNLOCKED

Hand Crimp Tool for CTX280 SWS Receptacle Terminals

Doc No: ATS-6 82 21HM Release Date: 07-17-1 UNCONTROLLED COPY Page 4 of 9

Revision: A Revision Date: 07-17-1

OCATOR

Figure 6

WIRE

INSULATION

PUNCH

CONDUCTOR ANVIL

INSULA

TION

ANVIL

WIRES AGAINST

LOCATOR STOP

CONDUCTOR

PUNCH

TERMINAL

SEAL

TERMINAL

PRE

STRIPPED

WIRE WITH SEAL

Figu

re 5

WIRE STOP

BLADE

SWING OPEN

TERMINAL

PUSH HERE TO

OPEN WIRE STOP

LOCATOR

TERMINAL

IN PLACE

Figure 4

LOCATOR LATCH

IN OPEN POSITION

Crimping Terminals

1. Select the desired terminal listed in the preceding charts.

2. Turn the Locator Lock Latch down to unlock. See Figure .

. Swing the terminal locator away from the crimp tool shown in Figure 4.

4. Press down on the wire stop on the locator as shown in Figure 4. Insert the proper terminal into the proper

nest opening. Make sure when choosing the nest opening, it will correspond with the correct profile on the

hand tool.

5. Return the locator to closed position.

6. Turn the Locator Lock Latch up to lock. Make sure that the terminal is visually centered over the punch.

7. Insert the proper wire with the seal over the terminal.

8. Gently touch the wire stop with the end of the wire and align the seal with the grips on the terminal. See Figure 5

and 6.

Note: The tamper proof ratchet action will not release the tool until it has been fully closed.

9. Compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.

Release handles to open the jaws.

Hand Crimp Tool for CTX280 SWS Receptacle Terminals

Doc No: ATS-6 82 21HM Release Date: 07-17-1 UNCONTROLLED COPY Page 5 of 9

Revision: A Revision Date: 07-17-1

10. Unlock the locator latch and swing the locator open.

11. Remove the crimped terminal from the terminal locator by pressing down on the wire stop and gently pulling on

the wire.

12. Visually inspect the crimped terminal for an acceptable crimp.

For the Battery Power Tool:

1. Cycle the Battery Power Tool to crimp the terminal to the wire.

2. Remove the crimped terminal from the terminal locator by pressing down on the wire stop and gently pulling on

the wire.

. Visually inspect the crimped terminal for an acceptable crimp.

Maintenan e

It is recommended that each operator of the tool be made aware of, and responsible for, the following maintenance

steps:

1. Remove dust, moisture and other

contaminants with a clean brush, or soft, lint-

free cloth.

2. Do not use any abrasive materials that could

damage the tool.

. Make certain all pins; pivot points and bearing

surfaces in the tool head are protected with a

thin coat of high quality machine oil. Do not

oil excessively. This tool was engineered for

durability, but like any fine piece of

equipment, it needs cleaning and lubrication

for a maximum service life of trouble-free

crimping. The use of light oil, such as 0

weight automotive oil, every 5,000 crimps or

monthly, will significantly enhance the tool life

and ensure a stable calibration. See Figure 7A or 7B for lubrication points.

4. Store the tool in a clean and dry area when not in use.

Mis rimps or Jams for Crimp Hand Tools Only (See Figure 10)

Should this tool ever become stuck or jammed in a partially closed position, Do Not force the handles open or

closed. The tool will open easily by rotating the small slotted screw marked with an arrow. See Figure 10.

Warranty

This tool kit is for electrical terminal crimping purposes only. This tool kit is made of the best quality materials. All

vital components are long life tested. All tools are warranted to be free of manufacturing defects for a period of 0

days. Should such a defect occur, we will repair or exchange the tool kit free of charge. This repair or exchange

will not be applicable to altered, misused, or damaged tools.

CAUTION: Molex crimp specifications are valid only when used with Molex terminals and tooling.

LUBRICATION

POINTS

(BOTH SIDES)

LIGHT OIL

(EVERY MONTH

5,000 CRIMPS)

Figure 7A

Figure 7B

Hand Crimp Tool for CTX280 SWS Receptacle Terminals

Doc No: ATS-6 82 21HM Release Date: 07-17-1 UNCONTROLLED COPY Page 6 of 9

Revision: A Revision Date: 07-17-1

CAUTIONS:

1. Manually powered hand tools are intended for low volume or field repair. This tool is NOT intended for

production use. Repetitive use of this tool should be avoided.

2. Insulated rubber handles are not protection against electrical shock.

. Wear eye protection at all times.

4. Use only the Molex terminals specified for crimping with this tool.

CAUTION: Repetitive use of this tool should be avoided.

Certifi ation

Molex does not certify or re-certify commercial grade hand tools but rather supplies the following guidelines for

customers to re-certify hand tools.

% This tool is qualified to pull force only. To re-certify, crimp a terminal to a wire, which has been stripped

12.7mm (1/2”) long, so there is no crimping of the insulation. Pull the terminal and wire at a rate no faster than

25mm (1.00”) per minute. See the Molex web site for the Quality Crimp Handbook for more information on pull

testing.

% When the hand tool is no longer capable of achieving minimum pull force, it should be taken out of service and

replaced.

% This tool is very difficult to disassemble and reassemble. Customer repair is not recommended.

Hand Crimp Tool for CTX280 SWS Receptacle Terminals

Doc No: ATS-6 82 21HM Release Date: 07-17-1 UNCONTROLLED COPY Page 7 of 9

Revision: A Revision Date: 07-17-1

The chart below shows all applications for this Tool Kit.

Tool Kit

Order No.

Tool

Order no.

Tool

Des ription

Power

Head

Order No.

Adapter

Des ription Figure No.

6 82 -2170

6 81

1050

Hand Crimp Frame (Short)

N/A

6 81

100

Hand Crimp Frame (Long)

N/A

6 816

0200

Battery Power

Tool (110 V)

6 816

0 00

Power Crimp Head

6 816

0250

Battery Power

Tool (220 V)

6 816

0 00

Power Crimp Head

Appli ations

for the Tool Kit

Hand Crimp Tool

Battery Powered Tool

Figure

WARNING: NEVER operate service, install tool kits, or adjust the Power Crimp Head without proper

instruction and without first reading and understanding the instructions in the proper Manual or

Specification Sheet. See Chart above for the correct Manual or Specification Sheet.

WARNING: NEVER install tooling or service this tool while it is into any power source. Make sure the

power is turned off.

CAUTION: Keep fingers away from the crimping area when operating this tool. It may cause severe injury.

CAUTION: Wear safety glasses when operating or serving this tool.

POWER

CRIMP

HEAD

LOCKING PINS

BATTERY

POWERED

TOOL

TOOLING KIT

HAND CRIMP

FRAME LONG

AND SHORT

TOOLING KIT

INTERMINA

Hand Crimp Tool for CTX280 SWS Receptacle Terminals

Doc No: ATS-6 82 21HM Release Date: 07-17-1 UNCONTROLLED COPY Page 8 of 9

Revision: A Revision Date: 07-17-1

RATCHET

RELEASE SCREW

Figure 10

M4 X 8mm

LONG BHCS

M4 X 18mm

LONG BHCS

M4 X 10mm

LONG BHCS

WITH TOOL KIT

LOCATOR ONLY

HAND TOOL PARTS LIST

Item Number

Order Number

Des ript

ion

Quantity

6 810

1000

Hand Crimp Frame (Long)

6 8

Tool Kit with

Locator

6 8

Locator (only)

Hand Crimp Tool for CTX280 SWS Receptacle Terminals

Doc No: ATS-6 82 21HM Release Date: 07-17-1 UNCONTROLLED COPY Page 9 of 9

Revision: A Revision Date: 07-17-1

Figure 11

Long

BHCS

Long

BHCS

Long

BHCS

POWER HEAD PARTS LIST

Item

Order No

Engineering No.

Des ription

Quantity

6 816-0 00 6 816-0 00 Power Crimp Head 1

6 82 -2170 6 82 -2170 Tool Kit 1

Visit our Web site at http://www.molex.com

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