Molex 200218-2600 User guide

Hand Crimp Tool for CTX-J 100 Receptacle Terminal

Doc No: ATS-2002182600 Release Date: 03-28-17 UNCONTROLLED COPY Page 1 of 8

Revision: E Revision Date: 07-16-20

Application Tooling Specification

FEATURES

A full cycle ratcheting hand tool ensures complete crimps

Ergonomic soft grip handles for comfortable crimping

A precision user-friendly terminal locator wire stop holds terminals in the proper crimping position

Right- and left-handed applications

Dies and locator from this tool can be used in the Battery Powered Tool Order No. 63816-0270

(110 V) or 63816-0280 (220 V), with the use of the 63816-0800 Crimp Head

Many different tool kits can be used with a single Battery Powered Crimp Tool

This tool is IPC/WHMA A-620 Class 2 compliant

This tool is RoHS compliant; however, RoHS compliance is not required

SCOPE

Products: CTX-J 100 Receptacle Terminal, 0.50mm2, 0.75mm2and 1.25mm2wires.

Terminal

Series No.

Terminal Order No.

Wire

Insulation Diameter (2)

Strip Length

Reel (1)

Wire Type

Wire Size

In.

560205

560205-0102

AVSSH, AESSX

AVSS

0.50mm²

1.60-1.70

.063-.067

3.80-4.20

.150-.165

560205-0101

AVSSH, AESSX

0.75mm²

1.80-1.90

.071-.075

AVSS

0.85mm²

AVSSH, AESSX

AVSS

1.25mm²

2.10-2.20

.083-.087

CIVUS

1.25mm²

1.80-2.00

.071-.079

1. Customer to cut off terminal from reel: 0.25mm (.010”) maximum cutoff tab.

2. Insulation crimp to meet IPC/WHMA-A-620 Class 2 compliance.

DEFINITION OF TERMS

BEND UP

ROLL

TWIST

SEAM

WIRE

INSULATION

CRIMP

BEND

DOWN

STRIP LENGTH

CONDUCTOR

BRUSH

BELL MOUTH

CUT OFF

TAB

CONDUCTOR

CRIMP HEIGHT

Order Number

200218-2600

TYPE 4D

Hand Crimp Tool for CTX-J 100 Receptacle Terminal

Doc No: ATS-2002182600 Release Date: 03-28-17 UNCONTROLLED COPY Page 2 of 8

Revision: E Revision Date: 07-16-20

CRIMP SPECIFICATION

After crimping, the conductor profiles should measure the following:

Terminal

Series No.

Bell Mouth

Conductor Brush

Bend Up

Bend Down

Twist

Roll

In.

Degree

560205

0.35-0.65

.014-.026

0.10-0.80

.004-.031

Terminal

Series

No.

Wire Size

Conductor Crimp

Insulation Crimp

Pull Force

Minimum

Profile

mm2

Height

Width (Ref.)

Height (Ref.)

Width (Ref.)

mm2

0.5

0.75

0.85

1.25

560205

0.50

0.94-1.04

1.75

2.20

1.95

0.75

1.05-1.15

2.15

2.30

2.45

100

0.85

1.08-1.18

2.15

2.30

2.45

130

1.25

1.24-1.34

2.15

2.45

180

Bell Mouth

Front

0.05 Max

Rear

0.35-0.65mm

Side

No Bulge

Conductor Brush Length and Height

Bulge After Crimping

Extruded Wire Length

0.1-0.8mm

Extruded Wire Height

0.10mm Max

No Bulge on Wire Grip Front

Wire Insulation

No Bulge on Side

Bell Mouth (Rear)

Bell Mouth (Front)

Extruded Wire Length (Brush)

Extruded Wire Height

Target

Hand Crimp Tool for CTX-J 100 Receptacle Terminal

Doc No: ATS-2002182600 Release Date: 03-28-17 UNCONTROLLED COPY Page 3 of 8

Revision: E Revision Date: 07-16-20

RELEASE

LOCATOR BUTTON

LOCATOR

PUSHED THROUGH

TOOLING

LOCATOR

BUTTON

PUSHED IN

LOCATOR

Figure 3

TERMINAL

Tool Qualification Notes

1. (Ref) means that the dimension provided is approximate due to the wide range of wires,

conductor stranding, insulation diameter, and insulation hardness.

2. An occasional pull force test should be performed. It must exceed the minimum pull force

specification.

3. Pull force should be measured with no influence from the insulation crimp. To ensure this, strip

the wire long enough so the terminal insulation grips do not contact the wire insulation.

OPERATION

CAUTION: Crimp only the Molex terminals listed in the scope for this tool. Do not crimp hardened

objects as damage can occur to the tool frame or crimp dies.

CAUTION: This hand tool was designed to produce the proper conductor crimp height by releasing

the movable handle after the last ratchet. Fully squeezing the movable handle past the last ratchet

to the hard stop will produce conductor crimp heights lower than the minimum conductor crimp

height specification.

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. See Figure 1.

Crimping Terminals

1. Select the desired terminal listed in the preceding

charts.

2. Make sure the center of the locator is in the down

position. With the locator attached, push the locator

button on the back of the hand tool to bring the

locator forward through the tooling. See Figure 2.

3. While holding the locator button in, load the terminal

into the proper nest opening in the locator based on

the wire gauge or terminal type markings on the

hand tooling. See Figure 3.

4. Release the locator button, allowing the locator to

return to the crimping position.

5. Close the tool handle until the first ratchet position engages. See

Figure 4.

PARTIALLY

CLOSE HANDLE

TOOLING

PARTIALLY

CLOSED

Figure 4

FIRST RATCHET

POSITION

OPEN

POSITION

SQUEEZE

HANDLES

TOGETHER

HANDLE WILL

SPRING OPEN

Figure 1

LOCATOR

IN DOWN

POSTION

PUSH ON

THE

LOCATOR

BUTTON

Figure 2

Hand Crimp Tool for CTX-J 100 Receptacle Terminal

Doc No: ATS-2002182600 Release Date: 03-28-17 UNCONTROLLED COPY Page 4 of 8

Revision: E Revision Date: 07-16-20

6. Insert the properly stripped

wire through the terminal

and against the wire stop.

See Figure 5.

7. Crimp the terminal by

squeezing the tool handles

until the ratchet mechanism

cycle has been completed.

Release the handles to open

the jaws.

Note:

To achieve proper extruded

wire length and height, the wire can only lightly touch the wire stop when crimping. If the

wire is pushed hard against the wire stop, the wire extrusion length and height may be out

of specification.

To achieve the proper conductor crimp height, the movable crimp handle must be released

after the last ratchet. If the movable handle is squeezed past the last ratchet and to the hard

stop, conductor crimp heights lower than the minimum conductor crimp height specification

will be achieved.

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

8. Remove the crimped terminal from the terminal locator by

pulling on the wire.

9. Visually inspect the crimped terminal for proper crimp

location.

10. On some large O.D. wires, it may not be possible to insert

the wire with the tool partially closed. Those wires should be

inserted with the hand tool in the open position. Insert the

wire above the terminal in the punch and against the wire

stop, and then close the tool. See Figure 6.

Locator Replacement

See the parts list on the last page of this

document for the proper locator order number.

Follow the steps below to replace the locator:

1. Open the hand crimp tool.

2. Squeeze gently on the lower area shown in

Figure 7A with your thumb and index

finger. The lower tabs of the locator should

disengage from the hand tool.

3. Lift and pull away from the hand tool. The

top locator hooks should slip out of the top

slots easily. See Figure 7A.

4. To reinstall the new locator, make sure the

hand tool is in the open position.

5. Press the red insert down as far as it will

go, as shown in Figure 7B.

6. Holding onto the lower part of the locator

with your thumb and index finger, insert

the locator’s top hooks into the hand tool

top slots.

SQUEEZE

HERE

SQUEEZE

HERE

LOCATOR

Figure 7A

TOP HOOKS

TOP SLOTS OF

HAND TOOL

LOWER TABS

MAKE SURE

CENTER OF LOCATOR

IS IN THE

DOWN POSITION

Figure 7B

TERMINAL

Figure 6

WIRE

STOP

TERMINAL

PRE-STRIPPED

WIRE

TERMINAL

WIRE AGAINST

THE WIRE STOP

WIRE STOP IS PART

OF THE LOCATOR

WIRE

Figure 5

Hand Crimp Tool for CTX-J 100 Receptacle Terminal

Doc No: ATS-2002182600 Release Date: 03-28-17 UNCONTROLLED COPY Page 5 of 8

Revision: E Revision Date: 07-16-20

7. Rotate the locator down, and press the lower tabs into the two bottom slots of the hand

tool. To secure the locator into place, the lower tabs must snap into place on the hand tool

frame.

Right- or Left-Handed Operation

This hand tool can be converted from a right-handed application to a left-handed application. It is

necessary to reverse the tooling if using the left-handed application along with the locator. Follow

the steps below:

1. The locator must be removed before

reversing the tooling.

2. Remove the M3 BHCS, which is holding the

upper tooling.

3. Flip the upper tooling to the opposite side

and replace the M3 BHCS. Make sure the

small markings on the front and back of

the hand tool frame match up and are on

the outside of the hand tool frame. See

Figures 8 and 9.

4. Do the same thing with the lower tooling,

and tighten the M3 screws. Be sure the

small markings line up.

5. Reinstall the locator by following the

instructions in the locator replacement

section.

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

a 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 are protected

with a thin coat of high-quality machine oil. Do not oil excessively.

The tool was engineered for durability, but like any other equipment,

it needs cleaning and lubrication for a maximum service life of

trouble-free crimping. Light oil (such as 30 weight automotive oil)

used at the oil points every 5,000 crimps or every 3 months will

significantly enhance the tool life.

4. Wipe excess oil from hand tool, particularly from crimping area. Oil

transferred from the crimping area onto certain terminations may

affect the electrical characteristics of an application.

5. When tool is not in use, keep the handles closed to prevent objects

from becoming lodged in the crimping dies, and store the tool in a clean, dry area.

Figure 8

PUSH ON

HANDLE

JAWS OPEN

PULL OPEN

TOOLING

M3 BHCS

MATCH

UP MARKS

FRONT

BACK

Figure 9

LUBRICATION POINTS

(BOTH SIDES) LIGHT

OIL

(EVERY 3 MONTHS OR

5,000 CRIMPS)

Figure 10

Hand Crimp Tool for CTX-J 100 Receptacle Terminal

Doc No: ATS-2002182600 Release Date: 03-28-17 UNCONTROLLED COPY Page 6 of 8

Revision: E Revision Date: 07-16-20

Miscrimps or Jams

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 pressing up on the ratchet release lever in the movable

handle. See Figure 11.

How to Adjust Tool Preload (See Figure 12)

Hand tool frame preload is factory preset to ensure crimp quality. It may be necessary over the life

of the tool to adjust tool handle preload force. Listed below are the steps required to adjust the

crimping force of the hand tool to obtain proper crimp conditions:

1. Open the hand tool.

2. Close the handle 2 ratchet clicks.

3. Hold the hand tool in the palm of

your hand as shown in Figure 12.

Using your index finger, squeeze the

link toward the top of the hand tool

frame. This will release the preload

adjustment wheel.

4. Rotate the setting wheel

counterclockwise (CCW) to increase

handle force. The numbers will

display higher. To decrease handle

force, rotate the setting wheel

clockwise (CW).

5. Release the link to lock the setting

wheel in place.

6. Check the crimp specifications or conduct a pull test after tool handle preload force is

adjusted.

Warranty

This tool is for electrical terminal crimping purposes only. This tool 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. Should such a defect occur, Molex will repair or

exchange the tool free of charge. This repair or exchange will not be applicable to altered,

misused or damaged tools. This tool is designed for hand use only. Any clamping, fixturing or

use of handle extensions voids this warranty.

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 use 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.

RATCHET RELEASE

LEVER

Figure 11

HANDLE CLOSED

2 CLICKS

SQUEEZE THE

LINK IN THE

HANDLE

HOLD THE HAND

TOOL IN POSITION

SETTING WHEEL

Figure 12

Hand Crimp Tool for CTX-J 100 Receptacle Terminal

Doc No: ATS-2002182600 Release Date: 03-28-17 UNCONTROLLED COPY Page 7 of 8

Revision: E Revision Date: 07-16-20

Certification

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

customers to re-certify hand tools:

This tool is qualified to pull force only. See the Molex website for the Quality Crimp

Handbook for more information on pull testing.

If the tool does not meet minimum pull force values, handle preload should be increased

and the pull test rerun. (See How to Adjust Preload).

When the hand tool is no longer capable of achieving minimum pull force, it should be taken

out of service and replaced.

Hand Crimp Tool for CTX-J 100 Receptacle Terminal

Doc No: ATS-2002182600 Release Date: 03-28-17 UNCONTROLLED COPY Page 8 of 8

Revision: E Revision Date: 07-16-20

Figure 13

PARTS LIST

Item Number

Order Number

Description

Quantity

REF

63827-2600

Hand Crimp Tool

Figure 13

63827-2675

Locator Assembly

63810-0104

Spring, Return

63810-0105

Spring, Ratchet

Application Tooling Support

Phone: (402) 458-TOOL (8665)

E-Mail: [email protected]

Website: www.molex.com/applicationtooling

Molex is a registered trademark of Molex, LLC in the United States of America and may be registered in other countries; all other

trademarks listed herein belong to their respective owners.

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