Molex 207129 Series Bedienungsanleitung

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

Ha d Crimp Tool

Order No.

819

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

0.75 . 3- .23

.044-.048

2.02-2. 2

.079-.083

.00 .20- .30

.047-.05

2.02-2. 2

.079-.083

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

638 6-0250

Battery Power Tool (220 V)

638 6-0600

Battery Power Crimp Adapter

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)

Figure 6

M4 FLAT

WASHER

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

http://www.molex.com

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