Molex 207129 Series Manual de usuario

Tool Kit for CTX280 Receptacle Terminals: >2.0 - 3.0mm² metric, Type I O wire

Doc No: AT -6381981HM Release Date: 12-29-09 UNCONTROLLED COPY Page 1 of 9

Revision: B Revision Date: 09-24-10

CONDUCTOR

BRUSH

STRIP LENGTH

SEAM

CONDUCTOR

CRIMP

CUT-OFF

TAB

BELL MOUTH

BEND UP

TWISTING

ROLLING

BEND

DOWN

WIRE

INSULATION CRIMP

▲SEE NOTE

Application Toolin

Specification Sheet

Tool Kit

Order No. 63819-8170

Hand Crimp Tool

Order No. 63819-8100

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 63816-0300 Power Crimp Head which is installed

into the 63816-0200 (110 V) or the 63816-0250 (220 V) Battery Powered Tool.

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

 This tool is IPC/WHMA-A-620 Class 2 and RoH compliant.

SCOPE

Products: CTX280 Receptacle Terminals: >2.0 - 3.0mm² metric, Type I O wire.

Terminal Series No.

Terminal Order No.

Wire Size and Type

 Insulation Diameter

Strip Len th

Reel Form Only

Mm2 Type mm In. mm In.

98675

98675-0003

98675-0013

98675-0023

98675-0033

2.50 I O 2.70-3.00 .106-.118

4.30-4.80

.169-.189

3.00 I O 3.00-3.40 .118-.134

Customer to cut off terminal from reel: 0.30mm (.012”) maximum Cut-off Tab.

 ee crimp specification for the individual Insulation Diameter.

DEFINITION OF TERMS

TYPE 4C

Tool Kit for CTX280 Receptacle Terminals: >2.0 - 3.0mm² metric, Type I O wire

Doc No: AT -6381981HM Release Date: 12-29-09 UNCONTROLLED COPY Page 2 of 9

Revision: B Revision Date: 09-24-10

▲Insulation Crimp Note:

Due to the terminal’s insulation grip design

and/or insulation diameter range, this tool

uses “overlap” form geometry in the

insulation punch. This produces an overlap

insulation crimp (A620 – compliant). While

the insulation punch profile may appear

“lopsided”, this is a normal condition for this

tool. ee figure to the right. ( ome tools with

multiple crimp pockets may not have the

“overlap” profile on all pockets).

CONDITIONS:

After crimping, the conductor profiles should

measure the following (see notes below).

Terminal Series No. Bell mouth * Conductor Brush Bend up Bend Down Twist Roll

mm In. mm In. De ree De ree

98675 0.40-0.60 .016-.024 0.20-0.60 .008-.024 1 1 2 3

* Not to exceed above the conductor crimp height.

Terminal

Series No.

Wire Size

Conductor Profile

Crimp Hei ht Crimp Width

mm2 mm In. mm In. B A

98675 2.50 1.80-1.90

.071-.075

2.85-2.95

.112-.116

3.00 1.90-2.00

.075-.079

2.85-2.95

.112-.116

Terminal

Series No.

Wire Size

 Insulation Diameter

Insulation Pull Force

Minimum

Crimp Hei ht Crimp Width

mm2 mm In. mm In. mm In. N Lb.

98675 2.50 2.70-3.00 .106-.118 3.10-3.30

.122-.130

3.65-3.75

.144-.148

235.0

52.8

3.00 3.00-3.40 .118-.134 3.50-3.70

.138-.146

3.65-3.75

.144-.148

260.0

58.5

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.

OVERLAP

INSULATION

CRIMP

OVERLAP FORM GEOMETRY

ANVIL

PUNCH

WIRE

Tool Kit for CTX280 Receptacle Terminals: >2.0 - 3.0mm² metric, Type I O wire

Doc No: AT -6381981HM Release Date: 12-29-09 UNCONTROLLED COPY Page 3 of 9

Revision: B Revision Date: 09-24-10

SWING

LOCATOR

OPEN

PRESS DOWN

ON THE BRASS

PIVOT SHAFT

LIFT UP ON

THE LOCATOR

Fi ure 2

ANVILS

POWER

CRIMP

HEAD

Fi ure 1

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 Punches Installation

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

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

Figure 1.

Locator Installation and Removal

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

To install the locator

1. Position the locator with the hole over the brass pivot shaft and snap it into place.

To remove the locator

1. Open the crimp hand tool.

2. wing the existing locator open and away from the

hand tool.

3. Firmly press down on the brass pivot shaft with your

thumb, while pulling the locator up. lip 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.

Crimpin Terminals

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

2. Turn the Locator Lock Latch down to unlock. ee Figure 3.

Fi ure 3

LATCH LOCKED

LATCH UNLOCKED

Tool Kit for CTX280 Receptacle Terminals: >2.0 - 3.0mm² metric, Type I O wire

Doc No: AT -6381981HM Release Date: 12-29-09 UNCONTROLLED COPY Page 4 of 9

Revision: B Revision Date: 09-24-10

Fi ure 6

WIRE IN TERMINAL

JAW

PARTIALLY

CLOSED

WIRE AGAINST

WIRE STOP

HANDLE

OPEN

LOCATOR

CLOSED

Fi ure 5

TERMINAL

PUSH HERE TO

OPEN WIRE STOP

SWING OPEN

TERMINAL

PUSH HERE TO

OPEN WIRE STOP

LOCATOR TERMINAL

IN PLACE

Fi ure 4

LOCATOR LATCH

IN OPEN POSITION

3. wing the terminal locator away from the crimp tool shown in Figure 4. ome terminals with large insulation

grips may interfere with the crimp tooling when swinging the locator into position. The terminal must then be

loaded into the locator in the closed/crimp position. ee Figure 5.

4. Press down on the wire stop on the locator as shown in Figure 5. Insert the proper terminal into the proper nest

opening. Make sure when choosing the nest opening, it will correspond with the A or B profile on the hand tool.

5. Return the locator to its original 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 over the terminal.

8. Gently touch the wire stop with the end of the wire. ee Figure 6 and 7.

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.

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

the wire. The terminal locator can be in either position.

11. Visually inspect the crimped terminal for proper crimp location.

Tool Kit for CTX280 Receptacle Terminals: >2.0 - 3.0mm² metric, Type I O wire

Doc No: AT -6381981HM Release Date: 12-29-09 UNCONTROLLED COPY Page 5 of 9

Revision: B Revision Date: 09-24-10

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. The terminal locator

can be in either position.

3. Visually inspect the crimped terminal for proper

crimp location.

Maintenance

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.

3. 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 30

weight automotive oil, every 5,000 crimps or

monthly, will significantly enhance the tool life

and ensure a stable calibration. ee Figure

8A or 8B for lubrication points.

4. tore the tool in a clean and dry area when

not in use.

Miscrimps or Jams for Crimp Hand Tools Only (See Fi ure 11)

hould 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. ee Figure 11.

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 30

days. hould 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.

Fi ure 7

WIRE

INSULATION

PUNCH

CONDUCTOR ANVIL

LOCATOR

INSULATION

ANVIL

WIRES AGAINST

LOCATOR STOP

CONDUCTOR

PUNCH

TERMINAL

LUBRICATION

POINTS

(BOTH SIDES)

LIGHT OIL

(EVERY MONTH

5,000 CRIMPS)

Fi ure8A

Fi ure 8B

Tool Kit for CTX280 Receptacle Terminals: >2.0 - 3.0mm² metric, Type I O wire

Doc No: AT -6381981HM Release Date: 12-29-09 UNCONTROLLED COPY Page 6 of 9

Revision: B Revision Date: 09-24-10

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

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.

3. 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.

Certification

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. ee 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.

Tool Kit for CTX280 Receptacle Terminals: >2.0 - 3.0mm² metric, Type I O wire

Doc No: AT -6381981HM Release Date: 12-29-09 UNCONTROLLED COPY Page 7 of 9

Revision: B Revision Date: 09-24-10

The chart below shows all applications for this Tool Kit.

Tool Kit

Order No.

Tool

Order no.

Tool

Description

Power Head

Order No.

Adapter

Description

Fi ure

No.

63819-8170

63810-1050

Hand Crimp Frame ( hort) N/A N/A 9

63810-1000

Hand Crimp Frame (Long) N/A N/A 9

63816-0200

Battery Power Tool (110 V)

63816-0300 Power Crimp Head

63816-0250

Battery Power Tool (220 V)

63816-0300 Power Crimp Head

Applications for the Tool Kit

Hand Crimp Tool Battery Powered Tool

Fi ure 9 Fi ure 10

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

pecification heet. ee Chart above for the correct Manual or pecification heet.

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

Tool Kit for CTX280 Receptacle Terminals: >2.0 - 3.0mm² metric, Type I O wire

Doc No: AT -6381981HM Release Date: 12-29-09 UNCONTROLLED COPY Page 8 of 9

Revision: B Revision Date: 09-24-10

RATCHET

RELEASE SCREW

Fi ure 11

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 Description Quantity

1 63810-1000 Hand Crimp Frame (Long) 1

2 63819-8170 Tool Kit with Locator 1

3 63819-8173 Locator Base 1

4 63819-8175 Locator (only) REF

Tool Kit for CTX280 Receptacle Terminals: >2.0 - 3.0mm² metric, Type I O wire

Doc No: AT -6381981HM Release Date: 12-29-09 UNCONTROLLED COPY Page 9 of 9

Revision: B Revision Date: 09-24-10

Fi ure 12

M4 by 8 Lon

BHCS

M4 by 18 Lon

BHCS

M4 by 10 Lon

BHCS

POWER HEAD PARTS LIST

Item Order No En ineerin No. Description Quantity

63816-0300 63816-0300 Power Crimp Head 1

63819-8170 63819-8170 Tool Kit 1

http://www.molex.com

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