molex 207129 Series User manual

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
Mm
In.
mm
In.
98675
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
4865
-
1044
4865
-
1048
4.0
–
5.0
T ZHID
.40
–
.90
.1 4
-
.154
4. 0
-
4.80
.169
-
.189
4808
4808
-
1004
4808
-
100
8
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
mm
In.
mm
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
mm
2
mm
In.
mm
In.
N
Lb.
A
B
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
mm
2
mm
In.
Order No.
Color
mm
In.
mm
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
2
ANVILS
POWER
CRIMP
HEAD
Figure
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 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
L
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
OR
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
0
-
1050
Hand Crimp Frame (Short)
N/A
N/A
8
6 81
0
-
100
0
Hand Crimp Frame (Long)
N/A
N/A
8
6 816
-
0200
Battery Power
Tool (110 V)
6 816
-
0 00
Power Crimp Head
9
6 816
-
0250
Battery Power
Tool (220 V)
6 816
-
0 00
Power Crimp Head
9
Appli ations
for the Tool Kit
Hand Crimp Tool
Battery Powered Tool
Figure
8
Figure
9
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
2
1
1
M4 X 18mm
LONG BHCS
M4 X 10mm
LONG BHCS
2
3
WITH TOOL KIT
LOCATOR ONLY
HAND TOOL PARTS LIST
Item Number
Order Number
Des ript
ion
Quantity
1
6 810
-
1000
Hand Crimp Frame (Long)
1
2
6 8
2
-
21
70
Tool Kit with
Locator
1
6 8
2
-
21
75
Locator (only)
R
EF

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
1
2
2
M
4
by
8
Long
BHCS
M
4
by
18
Long
BHCS
M
4
by
10
Long
BHCS
1
POWER HEAD PARTS LIST
Item
Order No
Engineering No.
Des ription
Quantity
1
6 816-0 00 6 816-0 00 Power Crimp Head 1
2
6 82 -2170 6 82 -2170 Tool Kit 1
Visit our Web site at http://www.molex.com