molex 207129 Series User manual

Hand Crimp Tool: for CTX280 Receptacle Terminals
Doc No: ATS-638 983HM Release Date: 04-30- 2 UNCONTROLLED COPY Page of 6
Revision: A Revision Date: 04-30- 2
TYPE 4A
CONDUCTOR
BRUSH
STRIP LENGTH
SEAM
CONDUCTOR
CRIMP
CUT-OFF
TAB
BELL MOUTH
BEND UP
TWISTING
ROLLING
BEND
DOWN
WIRE
INSULATION CRIMP
▲SEE NOTE
Applicatio Tooli g
Specificatio Sheet
Modular Crimp Head
Order No.
63819
-
83
70
Ha d Crimp Tool
Order No.
63
819
-
83
00
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
% Modular Crimp Head is removable and can be use in the Air Powered Tool Order No.638 6-0 00,
accompanied by Air Powered Crimp Adapter (Order No. 638 6-0700).
% Can also be used in the Battery Powered Tool Order No.638 6-0200 ( 0 V) or 638 6-0250 (220 V),
accompanied by Battery Powered Crimp Adapter (Order No. 638 6-0600).
SCOPE
Products: CTX280 Receptacle Terminals: 0.50- .00mm2 metric, type ISO wire.
Termi al Series No. Termi al Order No. Wire Size a d Type  I sulatio Diameter Strip Le gth
Reel Form O ly Mm2 Type mm I . mm I .
98675 98675-000 , 98675-00
98675-002 , 98675-003
0.50 ISO .40- .60 .055-.063
4.30-4.80 . 69-. 89 0.75 ISO .60- .90 .063-.075
.00 ISO .75-2. 0 .069-.083
Customer to cut off terminal from reel: 0.30mm (.0 2”) maximum Cut-off Tab.
 See crimp specification for the individual Insulation Diameter.
DEFINITION OF TERMS

Hand Crimp Tool: for CTX280 Receptacle Terminals
Doc No: ATS-638 983HM Release Date: 04-30- 2 UNCONTROLLED COPY Page 2 of 6
Revision: A Revision Date: 04-30- 2
▲I sulatio 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. See figure to the right. (Some tools
with multiple crimp pockets may not have
the “overlap” profile on all pockets).
CRIMP SPECIFICATIONS:
Termi al Series No. Bell mouth * Co ductor Brush Be d up Be d Dow Twist Roll
mm I . mm I . Degree Degree
98675 0.40-0.60 .0 6-.024 0.20-0.60 .008-.024 2 3
* Not to exceed above the conductor crimp height.
After crimping, the conductor profile should measure the following.
Termi al
Series No.
Wire Size
Co ductor Profile
Crimp Height Crimp Width
mm2 mm I . mm I . 0.50mm2 1.00mm2 0.75mm2
98675
0.50 .08- . 8 .043-.047 2.02-2. 2 .079-.083 X
0.75 . 3- .23 .044-.048 2.02-2. 2 .079-.083 X
.00 .20- .30 .047-.05 2.02-2. 2 .079-.083 X
Termi al
Series No.
Wire Size  I sulatio Diameter
I sulatio Pull Force
Mi imum
Crimp Height Crimp Width
mm2 mm I . mm I . mm I . N Lb.
98675
0.50 .40- .60 .055-.063 2.20-2.40 .087-.095 2.25-2.35 .089-.093 70.0 5.7
0.75 .60- .90 .063-.075 2.40-2.60 .094-. 02 2.25-2.35 .089-.093 90.0 20.2
.00 .75-2. 0 .069-.083 2.60-2.80 . 02-. 0 2.25-2.35 .089-.093 5.0 25.8
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 and/or crimp dies.


 Tool Qualificatio Notes:
. 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 durometer available, actual crimp height measurements may very slightly. An
occasional, destructive, pull force test should be performed to check hand tool crimp. Pull Force value must
exceed the minimum pull force specification.
OVERLAP
INSULATION
CRIMP
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
WIRE

Hand Crimp Tool: for CTX280 Receptacle Terminals
Doc No: ATS-638 983HM Release Date: 04-30- 2 UNCONTROLLED COPY Page 3 of 6
Revision: A Revision Date: 04-30- 2
WIRE
CONDUCTOR
PUNCH
TERMINAL
WIRE STOP
BLADE
Figure 1
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.
Crimpi g Termi als
. Lift the wire stop blade up.
2. Insert the terminal fully into the correct profile until the
terminal is fully seated and stops.
3. Bring down the wire stop blade.
4. Slide the pre-stripped wire into the wire stop blade. See
Figure . Be sure to hold the wire in place until the
terminal is fully crimped. See Figure 2.
5. Close the tool until the ratchet releases, the tool handles
will then spring open.
6. Lift the wire stop blade up if it is still in down position.
7. Carefully remove the crimped terminal.
Note: To maintain good brush control and a consistent bell mouth the crimping instructions must be followed.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
Mai te a ce
It is recommended that each operator of the tool be made
aware of, and responsible for, the following maintenance
steps:
. 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
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 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 2
CONDUCTOR
PUNCH
WIRE
LOCATOR
TERMINAL
INSULATION
PUNCH
INSULATION
ANVIL
CONDUCTOR
ANVIL
WIRE STOP
BLADE
RETAINER
SPACER

Hand Crimp Tool: for CTX280 Receptacle Terminals
Doc No: ATS-638 983HM Release Date: 04-30- 2 UNCONTROLLED COPY Page 4 of 6
Revision: A Revision Date: 04-30- 2
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 lifting the ratchet release lever. See Figure 6.
Warra ty
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, we 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:
. 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.
Certificatio
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. To re-certify, crimp a terminal to a wire, which has been stripped
2.7mm ( /2”) long, so there is no crimping of the insulation. Pull the terminal and wire at a rate no faster than
25mm ( .00”) per minute. See the Molex web site 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 CTX280 Receptacle Terminals
Doc No: ATS-638 983HM Release Date: 04-30- 2 UNCONTROLLED COPY Page 5 of 6
Revision: A Revision Date: 04-30- 2
MODULAR
CRIMP
HEAD
BATTERY
POWER
CRIMP
ADAPTER
LOCKING
PINS
LOCKING PINS
BATTERY
POWERED
TOOL
AIR
POWER
TOOL
MODULAR
CRIMP HEAD
LOCKING
PINS
LOCKING
PINS
AIR POWER
CRIMP
ADAPTER
Applicatio s for the Modular Crimp Head
WARNING: NEVER operate, service, install, or adjust this Modular Crimp Head without proper instruction
and without first reading and understanding the instructions in the proper Manual or Specification Sheet.
See Chart below for the correct Manual or Specification Sheet.
WARNING: NEVER install tooling or service this tool while it is into any power source. Disconnect the
power by unplugging or turn off the Actuator from its power source.
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.
The chart below shows all applications for this Modular Crimp Head.
Modular Crimp Head
Order No.
Tool
Order o.
Tool
Descriptio
Adapter
Order No.
Adapter
Descriptio
Figure
No.
638 9-8370
638 6-0000 Hand Crimp Frame (Short) N/A N/A 3
638 6-0050 Hand Crimp Frame (Long) N/A N/A 3
638 6-0200 Battery Power Tool ( 0 V) 638 6-0600 Battery Power Crimp Adapter 4
638 6-0250 Battery Power Tool (220 V) 638 6-0600 Battery Power Crimp Adapter 4
638 6-0 00 Air Power Tool 638 6-0700 Air Power Crimp Adapter 5
Applicatio s for the Modular Crimp Head
Ha d Crimp Tool Battery Powered Tool Air Powered Tool
Figure 3 Figure 4 Figure 5
MODULAR
CRIMP
HEAD
LOCKING
PINS
HAND CRIMP
FRAME LONG
OR SHORT

Hand Crimp Tool: for CTX280 Receptacle Terminals
Doc No: ATS-638 983HM Release Date: 04-30- 2 UNCONTROLLED COPY Page 6 of 6
Revision: A Revision Date: 04-30- 2
RATCHET
RELEASE LEVER
HANDLE
SPRING
CRIMPING
SPRING (2)
3
6
4
Figure 6
M4 FLAT
WASHER
2
5
1
M4 X 14mm
LONG BHCS
PARTS LIST
Ha d Crimp Tool 63819-8300
Item Order Number Descriptio Qua tity
638 9-8370 Modular Crimp Head (Ref)
2 638 6-0050 Hand Crimp Frame (Long) (Ref)
3 638 9-8375 Locator
4 638 6-000 Locking Pin 2
5 63600-0525 Handle Spring
6 63600-0520 Crimping Spring 2
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