Molex 207129 Series Manuel utilisateur

Hand Crimp Tool for CTX150 Mat Seal Receptacle Terminals

Doc No: ATS-6 81940HM Release Date: 01-05-09 UNCONTROLLED COPY Page 1 of 6

Revision: C Revision Date: 02-20-14

INSULATION

CRIMP

BRUSH

STRIP

LENGTH

CRIMP HEIGHT

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP

TWISTING

SEAM

TYPE 4A

Application Tooling

Speci ication Sheet

Modular Crimp Head

Order No. 63819-4070

Hand Crimp Tool

Order No. 63819-4000

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.6 816-0100,

accompanied by Air Powered Crimp Adapter (Order No. 6 816-0700).

% Can also be used in the Battery Powered Tool Order No.6 816-0200 (110 V) or 6 816-0250 (220 V),

accompanied by Battery Powered Crimp Adapter (Order No. 6 816-0600).

SCOPE

Products: CTX150 Mat Seal Receptacle Crimp Terminal for 0.75, 0.85, and 1.00mm2 wires.

Terminal

Series

Terminal Order No.

Wire Size

Insulation Diameter

●

Strip Length (Re )



Reel Form only

Wire

Type

In.

502 07

502 07-0112

502 07-0122

502 07-0212

502 07-0222

502 07-0412

502 07-0422

502 07-0512

502 07-0522

ZHID

0.75

1.60-2.00

.06 -.079

4.50-5.00

.177-.197

AVSS

0.85

ZHID

.00

4805 4805-0112

4805-0212 4805-0412 4805-0512

ZHID

0.75

1.60-2.00

.06 -.079

4.50-5.00

.177-.197

AVSS

0.85

ZHID

1.00

4864 4864-0112

4864-0212 4864-0412 4864-0512

ZHID

0.75

1.60-2.00

.06 -.079

4.50-5.00

.177-.197

AVSS

0.85

ZHID

1.00



Customer to cut off terminal from reel: 0. 0mm (.012”) maximum Cut

off Tab.

● Note: This tool has a new insulation stop plate, to control the brush within specs,

The wire insulation strip length needs to be stripped at 4.60 mm Ref.

DEFINITION OF TERMS

Hand Crimp Tool for CTX150 Mat Seal Receptacle Terminals

Doc No: ATS-6 81940HM Release Date: 01-05-09 UNCONTROLLED COPY Page 2 of 6

Revision: C Revision Date: 02-20-14

CRIMP SPECIFICATION

Terminal

Series

Bell mouth

Conductor Brush

end up Bend Down

Twist Roll

In.

Degree (Max)

502 07

4805

4864

0.20-0.55

.008-.022

0.20-1.20

.008-.047

1.5 1.5 4 6

After crimping, the crimp profiles should measure the following.

Terminal

Plating

Terminal

Order No.

Wire Size

Conductor

Pull Force

Minimum

Crimp Height

Crimp Width

(Max)

Wire Type

In.

Lb.

Standard

Performance

Tin

502 07

0112

4805

0112

4864

0112

T -ZHID 0.75

1.10-1.20

.04 -.047

1.70 .067 115.0

25.9

502 07

0122

4805

0212

4864

0212

502 07-0212

502 07-0222

High

Performance

Tin

502 07

0412

4805

0412

4864

0412

T -ZHID 0.75

1.10-1.20

.04 -.047

1.70 .067 115.0

25.9

502 07

0422

4805

0512

4864

0512

502 07-0512

502 07-0522

Standard

Performance

Tin

502 07

0112

4805

0112

4864

0112

AVSS 0.85

1.00-1.10

.0 9-.04

2.10 .08 1 0.0

29.

502 07

0122

4805

0212

4864

0212

502 07-0212

502 07-0222

Standard

Performance

Tin

502 07

0112

4805

0112

4864

0112

T -ZHID 1.00

1.00-1.10

.0 9-.04

2.10 .08 120.0

27.0

502 07

0122

4805

0212

4864

0212

502 07-0212

502 07-0222

High

Performance

Tin

502 07

0412

4805

0412

4864

0412

T -ZHID 1.00

1.00-1.10

.0 9-.04

2.10 .08 120.0

27.0

502 07

0422

4805

0512

4864

0512

502 07-0512

502 07-0522

Terminal Series No.

Wire Size

Insulation Crimp (Re .)

Pro ile

Height (Max)

Width (Max)

0.75mm

1.0mm

0.85mm

Wire Type

In.

502 07

4805

4864

ZHID

0.75

2. 0

.091

2.45

.097

AVSS

0.85

2. 0

.091

2.45

.097

ZHID

1.00

2.50

.098

2.45

.097

Tool Quali ication Notes:

1. Pull Force should be measured with no influence from the insulation crimp.

2. The above specifications are guidelines to an optimum crimp.

. This tool has a new insulation stop plate, to control the brush within specification, the wire insulation strip

length needs to be stripped at 4.60 mm Ref.

Hand Crimp Tool for CTX150 Mat Seal Receptacle Terminals

Doc No: ATS-6 81940HM Release Date: 01-05-09 UNCONTROLLED COPY Page of 6

Revision: C Revision Date: 02-20-14

INSULATION

OF THE WIRE

STOPS HERE

INSULATION

PUNCH

TERMINAL

LOCATOR

INSULATION

STOP

Figure1

CONDUCTOR

PUNCH

Notes:

1. This tool should only be used for the terminals and wire gauges specified on this sheet.

2. This tool is not adjustable for crimp height; however crimp force is adjustable (See instructions above).

Variations in tools, terminals, wire stranding, and insulation types may affect crimp height.

. This tool is intended for standard conductor sizes. It may not give a good insulation crimp support for all

insulation sizes.

4. Molex does not repair hand tools (see warranty above). The replacement parts listed are the only parts

available for repair. If the handles or crimp tooling is damaged or worn, a new tool must be purchased.

5. Pull force should be used as the final criteria for an acceptable crimp. Pull force is measured with no

influence from the insulation crimp. The insulation should be stripped long (1/2 in.) so the insulation grips

on the terminal do not grip the wire insulation or the conductor. Refer to Molex Quality Crimping

Handbook 6 800-0029 for additional information on crimping and crimp testing.

6. Molex does not certify crimp hand tools.

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. Insert the terminal fully into the correct profile until the terminal is fully seated and stops.

2. Slide the pre-stripped wire into the insulation stop. See Figure 1. The wire strands pass thru the

insulation stop slot, while the end of the insulation touches the stop. Be sure to hold the wire in place until

the terminal is fully crimped. See Figure 2.

. Close the tool until the ratchet releases.

4. Carefully remove the crimped terminal.

Note: To maintain good brush control and a consistent bell mouth the crimping instructions must be followed.

Figure 2

CONDUCTOR

PUNCH

WIRE

INSULATION

LOCATOR

TERMINAL

INSULATION

PUNCH

INSULATION

ANVIL

CONDUCTOR

ANVIL

INSULATION

STOP

Hand Crimp Tool for CTX150 Mat Seal Receptacle Terminals

Doc No: ATS-6 81940HM Release Date: 01-05-09 UNCONTROLLED COPY Page 4 of 6

Revision: C Revision Date: 02-20-14

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.

. 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 0 weight

automotive oil) used at the oil points, every 5,000 crimps or 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.

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.

Warranty

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 0

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: Repetitive use of this tool should be avoided.

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: Molex crimp specifications are valid only when used with Molex terminals and tooling.

Hand Crimp Tool for CTX150 Mat Seal Receptacle Terminals

Doc No: ATS-6 81940HM Release Date: 01-05-09 UNCONTROLLED COPY Page 5 of 6

Revision: C Revision Date: 02-20-14

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

Applications or 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.

Modula

r Crimp Head

Order No.

Tool

Order no.

Tool

Description

Adapter

Order No.

Adapter

Description

Figure

No.

6 819-4070

6 816

0000

Hand Crimp Frame (Short)

N/A

6 816

0050

Hand Crimp Frame (Long)

N/A

6 816

0200

Battery Power

Tool (110 V)

6 816

600

Battery Power Crimp Adapter

6 816

0250

Battery Power

Tool (220 V)

6 816

0600

Battery Power Crimp Adapter

6 816

0100

Air

Tool

6 816

0700

Air Power Crimp Adapter

Applications or the Modular Crimp Head

Hand Crimp Tool

Battery Powered T

ool

Air Powered Tool

Figure

MODULAR

CRIMP

HEAD

LOCKING

PINS

HAND CRIMP

FRAME LONG

OR SHORT

Hand Crimp Tool for CTX150 Mat Seal Receptacle Terminals

Doc No: ATS-6 81940HM Release Date: 01-05-09 UNCONTROLLED COPY Page 6 of 6

Revision: C Revision Date: 02-20-14

RATCHET

RELEASE LEVER

HANDLE

SPRING

CRIMPING

SPRING (2)

Figure 6

M4 X FLAT

WASHER

M4 X 14mm

LONG BHCS

PARTS LIST

Item

Order Number

Description

Quantity

6 819

Modular

Crimp

Head

6 816

Hand Crimp

Frame

(

Long

)

6 819

Locator

6 816

0001

Lockin

6 600

0525

Handle Spring

6 600

0520

Crimping Spring

Visit our Web site at http://www.molex.com

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