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
mm
In.
mm
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
mm
In.
mm
In.
Degree
Degree
560205
0.35-0.65
.014-.026
0.10-0.80
.004-.031
1
1
4
6
Terminal
Series
No.
Wire Size
Conductor Crimp
Insulation Crimp
Pull Force
Minimum
Profile
mm2
Height
Width (Ref.)
Height (Ref.)
Width (Ref.)
mm2
mm
mm
mm
mm
N
0.5
0.75
0.85
1.25
560205
0.50
0.94-1.04
1.75
2.20
1.95
90
X
0.75
1.05-1.15
2.15
2.30
2.45
100
X
0.85
1.08-1.18
2.15
2.30
2.45
130
X
1.25
1.24-1.34
2.15
2.45
2.45
180
X
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
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
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
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
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
2
Figure 13
1
3
PARTS LIST
Item Number
Order Number
Description
Quantity
REF
63827-2600
Hand Crimp Tool
Figure 13
1
63827-2675
Locator Assembly
1
2
63810-0104
Spring, Return
1
3
63810-0105
Spring, Ratchet
1
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.