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
mm
In.
mm
In.
98675
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
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
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
mm
In.
mm
In.
Degree
Max.
Degree
Max.
98675
4808
4865
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
Plating
Terminal
Order No.
Wire Size
Condu tor
Pull For e
Minimum Profile
Crimp Height
Crimp Width
mm
2
mm
In.
mm
In.
N
Lb.
A
B
C
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 X
4865
-
1005
98675
-
1001
986
75
-
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 X
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 X
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 X
4865
-
1005
98675
-
1001
98675
-
1005
98675
-
1011
98675
-
1015
High
Performance
Tin
4808
-
1041
48
08
-
1045
4808
-
1101
0.75 1.1 -1.2 .044-.048 2.02-2.12 .079-.08 90.0 20.2 X
4808
-
1105
4865
-
104
1
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 X
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 X
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 X
4808
-
1
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 X
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
2
ANVILS
POWER
CRIMP
HEAD
Figure
1
PUNCHES
M4 X 10 LONG
BHCS
M4 X 18 LONG
BHCS
Terminal Series No. Wire Size


Insulation Diameter Single Wire Seal
In
sulation
Crimp Height
Crimp Width
mm
2
mm
In.
Order No.
Color
mm
In.
mm
In.
98675 4865 4808
0.50
1.40
-
1.60
.055
-
.06
See Note 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
99
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
OR
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
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 at
ions 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

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
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
ription
Quantity
1
6 810
-
1000
Hand Crimp Frame (Long)
1
2
6 8
2
-
2
4
70
Tool Kit with
Locator
1
6 8
2
-
2
4
75
Locator (only)
R
EF

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
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 -2470 6 82 -2470 Tool Kit 1
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