molex 207129 Series User manual

Tool Kit for CTX280 Receptacle Terminals: >2.0 - 3.0mm² metric, Type I O wire
Doc No: AT -6381981HM Release Date: 12-29-09 UNCONTROLLED COPY Page 1 of 9
Revision: B Revision Date: 09-24-10
CONDUCTOR
BRUSH
STRIP LENGTH
SEAM
CONDUCTOR
CRIMP
CUT-OFF
TAB
BELL MOUTH
BEND UP
TWISTING
ROLLING
BEND
DOWN
WIRE
INSULATION CRIMP
▲SEE NOTE
Application Toolin
Specification Sheet
Tool Kit
Order No. 63819-8170
Hand Crimp Tool
Order No. 63819-8100
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 63816-0300 Power Crimp Head which is installed
into the 63816-0200 (110 V) or the 63816-0250 (220 V) Battery Powered Tool.
 Many different Tool kits can be used with a single Battery Powered Tool.
 This tool is IPC/WHMA-A-620 Class 2 and RoH compliant.
SCOPE
Products: CTX280 Receptacle Terminals: >2.0 - 3.0mm² metric, Type I O wire.
Terminal Series No.
Terminal Order No. Wire Size and Type
 Insulation Diameter
Strip Len th
Reel Form Only Mm2 Type mm In. mm In.
98675
98675-0003
98675-0013
98675-0023
98675-0033
2.50 I O 2.70-3.00 .106-.118
4.30-4.80 .169-.189
3.00 I O 3.00-3.40 .118-.134
Customer to cut off terminal from reel: 0.30mm (.012”) maximum Cut-off Tab.
 ee crimp specification for the individual Insulation Diameter.
DEFINITION OF TERMS
TYPE 4C

Tool Kit for CTX280 Receptacle Terminals: >2.0 - 3.0mm² metric, Type I O wire
Doc No: AT -6381981HM Release Date: 12-29-09 UNCONTROLLED COPY Page 2 of 9
Revision: B Revision Date: 09-24-10
▲Insulation Crimp Note:
Due to the terminal’s insulation grip design
and/or insulation diameter range, this tool
uses “overlap” form geometry in the
insulation punch. This produces an overlap
insulation crimp (A620 – compliant). While
the insulation punch profile may appear
“lopsided”, this is a normal condition for this
tool. ee figure to the right. ( ome tools with
multiple crimp pockets may not have the
“overlap” profile on all pockets).
CONDITIONS:
After crimping, the conductor profiles should
measure the following (see notes below).
Terminal Series No. Bell mouth * Conductor Brush Bend up Bend Down Twist Roll
mm In. mm In. De ree De ree
98675 0.40-0.60 .016-.024 0.20-0.60 .008-.024 1 1 2 3
* Not to exceed above the conductor crimp height.
Terminal
Series No.
Wire Size
Conductor Profile
Crimp Hei ht Crimp Width
mm2 mm In. mm In. B A
98675 2.50 1.80-1.90
.071-.075 2.85-2.95 .112-.116 X
3.00 1.90-2.00 .075-.079 2.85-2.95 .112-.116 X
Terminal
Series No.
Wire Size  Insulation Diameter
Insulation Pull Force
Minimum
Crimp Hei ht Crimp Width
mm2 mm In. mm In. mm In. N Lb.
98675 2.50 2.70-3.00 .106-.118 3.10-3.30
.122-.130 3.65-3.75 .144-.148 235.0 52.8
3.00 3.00-3.40 .118-.134 3.50-3.70 .138-.146 3.65-3.75 .144-.148 260.0 58.5
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.
OVERLAP
INSULATION
CRIMP
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
WIRE

Tool Kit for CTX280 Receptacle Terminals: >2.0 - 3.0mm² metric, Type I O wire
Doc No: AT -6381981HM Release Date: 12-29-09 UNCONTROLLED COPY Page 3 of 9
Revision: B Revision Date: 09-24-10
SWING
LOCATOR
OPEN
PRESS DOWN
ON THE BRASS
PIVOT SHAFT
LIFT UP ON
THE LOCATOR
Fi ure 2
ANVILS
POWER
CRIMP
HEAD
Fi ure 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 Punches Installation
1. Insert the Anvils into the bottom slots of the nest. Install the M4 x 10 long BHC and tighten in place.
2. Insert the Punches into the top slots of the nest. Install the M4 x 18 long BHC and tighten in place. ee
Figure 1.
Locator Installation and Removal
Follow the steps below to install or replace the locator. ee Figure 2.
To install the locator
1. Position the locator with the hole over the brass pivot shaft and snap it into place.
To remove the locator
1. Open the crimp hand tool.
2. wing the existing locator open and away from the
hand tool.
3. Firmly press down on the brass pivot shaft with your
thumb, while pulling the locator up. lip 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.
Crimpin Terminals
1. elect the desired terminal listed in the preceding charts.
2. Turn the Locator Lock Latch down to unlock. ee Figure 3.
Fi ure 3
LATCH LOCKED
LATCH UNLOCKED

Tool Kit for CTX280 Receptacle Terminals: >2.0 - 3.0mm² metric, Type I O wire
Doc No: AT -6381981HM Release Date: 12-29-09 UNCONTROLLED COPY Page 4 of 9
Revision: B Revision Date: 09-24-10
Fi ure 6
WIRE IN TERMINAL
JAW
PARTIALLY
CLOSED
WIRE AGAINST
WIRE STOP
HANDLE
OPEN
LOCATOR
CLOSED
Fi ure 5
TERMINAL
PUSH HERE TO
OPEN WIRE STOP
SWING OPEN
TERMINAL
PUSH HERE TO
OPEN WIRE STOP
LOCATOR TERMINAL
IN PLACE
Fi ure 4
LOCATOR LATCH
IN OPEN POSITION
3. wing the terminal locator away from the crimp tool shown in Figure 4. ome terminals with large insulation
grips may interfere with the crimp tooling when swinging the locator into position. The terminal must then be
loaded into the locator in the closed/crimp position. ee Figure 5.
4. Press down on the wire stop on the locator as shown in Figure 5. Insert the proper terminal into the proper nest
opening. Make sure when choosing the nest opening, it will correspond with the A or B profile on the hand tool.
5. Return the locator to its original 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 over the terminal.
8. Gently touch the wire stop with the end of the wire. ee Figure 6 and 7.
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. Remove the crimped terminal from the terminal locator by pressing down on the wire stop and gently pulling on
the wire. The terminal locator can be in either position.
11. Visually inspect the crimped terminal for proper crimp location.

Tool Kit for CTX280 Receptacle Terminals: >2.0 - 3.0mm² metric, Type I O wire
Doc No: AT -6381981HM Release Date: 12-29-09 UNCONTROLLED COPY Page 5 of 9
Revision: B Revision Date: 09-24-10
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. The terminal locator
can be in either position.
3. Visually inspect the crimped terminal for proper
crimp location.
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 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 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 30
weight automotive oil, every 5,000 crimps or
monthly, will significantly enhance the tool life
and ensure a stable calibration. ee Figure
8A or 8B for lubrication points.
4. tore the tool in a clean and dry area when
not in use.
Miscrimps or Jams for Crimp Hand Tools Only (See Fi ure 11)
hould 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. ee Figure 11.
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 30
days. hould 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.
Fi ure 7
WIRE
INSULATION
PUNCH
CONDUCTOR ANVIL
LOCATOR
INSULATION
ANVIL
WIRES AGAINST
LOCATOR STOP
CONDUCTOR
PUNCH
TERMINAL
LUBRICATION
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY MONTH
OR
5,000 CRIMPS)
Fi ure8A
Fi ure 8B

Tool Kit for CTX280 Receptacle Terminals: >2.0 - 3.0mm² metric, Type I O wire
Doc No: AT -6381981HM Release Date: 12-29-09 UNCONTROLLED COPY Page 6 of 9
Revision: B Revision Date: 09-24-10
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.
3. 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.
Certification
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. ee 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.

Tool Kit for CTX280 Receptacle Terminals: >2.0 - 3.0mm² metric, Type I O wire
Doc No: AT -6381981HM Release Date: 12-29-09 UNCONTROLLED COPY Page 7 of 9
Revision: B Revision Date: 09-24-10
The chart below shows all applications for this Tool Kit.
Tool Kit
Order No.
Tool
Order no.
Tool
Description
Power Head
Order No.
Adapter
Description
Fi ure
No.
63819-8170
63810-1050 Hand Crimp Frame ( hort) N/A N/A 9
63810-1000 Hand Crimp Frame (Long) N/A N/A 9
63816-0200 Battery Power Tool (110 V) 63816-0300 Power Crimp Head 10
63816-0250 Battery Power Tool (220 V) 63816-0300 Power Crimp Head 10
Applications for the Tool Kit
Hand Crimp Tool Battery Powered Tool
Fi ure 9 Fi ure 10
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
pecification heet. ee Chart above for the correct Manual or pecification heet.
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

Tool Kit for CTX280 Receptacle Terminals: >2.0 - 3.0mm² metric, Type I O wire
Doc No: AT -6381981HM Release Date: 12-29-09 UNCONTROLLED COPY Page 8 of 9
Revision: B Revision Date: 09-24-10
RATCHET
RELEASE SCREW
Fi ure 11
M4 X 8mm
LONG BHCS
2
1
3
M4 X 18mm
LONG BHCS
M4 X 10mm
LONG BHCS
2
4
WITH TOOL KIT
LOCATOR ONLY
HAND TOOL PARTS LIST
Item Number Order Number Description Quantity
1 63810-1000 Hand Crimp Frame (Long) 1
2 63819-8170 Tool Kit with Locator 1
3 63819-8173 Locator Base 1
4 63819-8175 Locator (only) REF

Tool Kit for CTX280 Receptacle Terminals: >2.0 - 3.0mm² metric, Type I O wire
Doc No: AT -6381981HM Release Date: 12-29-09 UNCONTROLLED COPY Page 9 of 9
Revision: B Revision Date: 09-24-10
Fi ure 12
1
2
2
M4 by 8 Lon
BHCS
M4 by 18 Lon
BHCS
M4 by 10 Lon
BHCS
1
POWER HEAD PARTS LIST
Item Order No En ineerin No. Description Quantity
1
63816-0300 63816-0300 Power Crimp Head 1
2
63819-8170 63819-8170 Tool Kit 1
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