Molex 207129 Series User manual

Hand Crimp Tool for CTX280 SWS Receptacle Terminals

Doc No: ATS-6 82 24HM Release Date: 01-15-14 UNCONTROLLED COPY Page 1 of 9

Revision: A Revision Date: 01-15-14

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. 63823-2470

Hand Crimp Tool

Order No. 63823-2400

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: 0.5 - 1.0 mm2 metric wires.

Terminal

Series No.

Terminal Order No

Wire Size

and Type







Insulation Diameter

Strip Length



Reel Form Only

mm²

Type

In.

98675

1001

98675

1005

98675

1011

98675

1015

0.5-1.0 T ZHID 1.40-1.95 .055-.077 4. 0-4.80

.169-.189

98675

1041

98675

1045

98675

1051

98675

1055

98675

1061

98675

1065

98675

1101

98675

1105

98675

1111

98675

1115

4865

1001

4865

1005

4865

1041

4865

1045

0.5-1.0 T ZHID 1.40-1.95 .055-.077 4. 0-4.80

.169-.189

4865

1061

4865

1065

4865

1101

4865

1105

4808

1001

4808

1005

4808

1041

4808

1045

0.5-1.0 T ZHID 1.40-1.95 .055-.077 4. 0-4.80

.169-.189

4808

1061

4808

1065

4808

1101

4808

1105







See crimp specification for th

e 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 24HM Release Date: 01-15-14 UNCONTROLLED COPY Page 2 of 9

Revision: A Revision Date: 01-15-14

CRIMP SPECIFICATION

Terminal Series No.

Bell mouth







Condu tor Brush

Bend up Bend Down

Twist Roll

In.

Degree

Max.

Degree

Max.

98675

4808

4865

0.40

0.60

.016

.024

0.20

0.60

.008

.024



Not to exceed above the conductor crimp height.

After crimping, the crimp profiles should measure the following:

Terminal

Plating

Terminal

Order No.

Wire Size

Condu tor

Pull For e

Minimum Profile

Crimp Height

Crimp Width

In.

Lb.

Standard

Performance

Tin

4808

1001

4808

1005

4865

1001

0.50 1.05-1.15

.041-.045

2.02-2.12

.079-.08

70.0 15.7

4865

1005

98675

1001

986

1005

98675

1011

98675

1015

High

Performance

Tin

4808

1041

4808

1045

4808

1101

0.50 1.07-1.1

.042-.044

2.02-2.12

.079-.08

70.0 15.7

4808

1105

4865

1041

4865

1045

4865

1101

4865

1105

98675

1041

98675

1045

98675

1051

98675

1055

98675

1101

98675

1105

98675

1111

98675

1115

High

Performance

Silver

4808-1061

4808-1065

4865-1061

0.50 1.10-1.16

.04 -.046

2.02-2.12

.079-.08

70.0 15.7

4865-1065

98675-1061

98675-1065

Standard

Performance

Tin

4808

1001

4808

1005

4865

1001

0.75 1.1 -1.2

.044-.048

2.02-2.12

.079-.08

90.0 20.2

4865

1005

98675

1001

98675

1005

98675

1011

98675

1015

High

Performance

Tin

4808

1041

1045

4808

1101

0.75 1.1 -1.2

.044-.048

2.02-2.12

.079-.08

90.0 20.2

4808

1105

4865

104

4865

1045

4865

1101

4865

1105

98675

1041

98675

1045

98675

1051

98675

1055

98675

1101

98675

1105

98675

1111

98675

1115

High

Performance

Silver

4808-1061

4808-1065

4865-1061

0.75 1.08-1.18

.04 -.047

2.02-2.12

.079-.08

90.0 20.2

4865-1065

98675-1061

98675-1065

Standard

Performance

Tin

4808

1001

4808

1005

4865

1001

1.00 1.15-1.25

.045-.049

2.02-2.12

.079-.08

115.0

25.8

4865

1005

98675

1001

98675

1005

98675

1011

98675

1015

High

Performance

Tin

4808

1041

4808

1045

4808

1101

1.00 1.17-1.2

.046-.048

2.02-2.12

.079-.08

115.0

25.8

4808

105

4865

1041

4865

1045

4865

1101

4865

1105

98675

1041

98675

1045

98675

1051

98675

1055

98675

1101

98675

1105

98675

1111

98675

1115

High

Performance

Silver

4808-1061

4808-1065

4865-1061

1.00 1.17-1.2

.046-.048

2.02-2.12

.079-.08

115.0

25.8

4865-1065

98675-1061

98675-1065

Seam note:

Seam shall not be open and no wire allowed out of the crimping area

Hand Crimp Tool for CTX280 SWS Receptacle Terminals

Doc No: ATS-6 82 24HM Release Date: 01-15-14 UNCONTROLLED COPY Page of 9

Revision: A Revision Date: 01-15-14

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

Terminal Series No. Wire Size





Insulation Diameter

Single Wire Seal

sulation

Crimp Height

Crimp Width

In.

Order No.

Color

In.

98675

4865

4808

0.50

1.40

1.60

.055

.06

See Note

4. 0

4.50

.169

.177

4.95

5.05

.195

.199

0.75

1.60

1.80

.06

.071

4.40

4.60

.17

.181

4.95

5.05

.195

1.00

1.75

1.95

.069

.077

4.50

4.70

.177

.185

4.95

5.05

.195

.199





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.

. See Product Application Specification AS-98675-002 for Applicable Seal number and Color.

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.

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.

Hand Crimp Tool for CTX280 SWS Receptacle Terminals

Doc No: ATS-6 82 24HM Release Date: 01-15-14 UNCONTROLLED COPY Page 4 of 9

Revision: A Revision Date: 01-15-14

LOCATOR

Figure 6

WIRE

INSULATION

PUNCH

CONDUCTOR ANVIL

INSULATION

ANVIL

WIRES AGAINST

LOCATOR STOP

CONDUCTOR

PUNCH

TERMINAL

SEAL

TERMINAL

PRE

STRIPPED

WIRE WITH SEAL

Figure 5

WIRE STOP

BLADE

SWING OPEN

TERMINAL

PUSH HE

RE TO

OPEN WIRE STOP

LOCATOR

TERMINAL

IN PLACE

Figure 4

LOCATOR LATCH

IN OPEN POSITION

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.

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.

Figure 3

LATCH LOCKED

LATCH UNLOCKED

Hand Crimp Tool for CTX280 SWS Receptacle Terminals

Doc No: ATS-6 82 24HM Release Date: 01-15-14 UNCONTROLLED COPY Page 5 of 9

Revision: A Revision Date: 01-15-14

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.

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

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 24HM Release Date: 01-15-14 UNCONTROLLED COPY Page 6 of 9

Revision: A Revision Date: 01-15-14

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.

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 24HM Release Date: 01-15-14 UNCONTROLLED COPY Page 7 of 9

Revision: A Revision Date: 01-15-14

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 -2470

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 at

ions 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

Hand Crimp Tool for CTX280 SWS Receptacle Terminals

Doc No: ATS-6 82 24HM Release Date: 01-15-14 UNCONTROLLED COPY Page 8 of 9

Revision: A Revision Date: 01-15-14

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

ription

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 24HM Release Date: 01-15-14 UNCONTROLLED COPY Page 9 of 9

Revision: A Revision Date: 01-15-14

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 -2470 6 82 -2470 Tool Kit 1

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

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