0638234500

Hand Crimp Tool For CTX150 SWS Receptacle Terminals HAND CRIMP TOOL Application Tooling Specification Sheet TYPE 4D Order No. 63823-4500 FEATURES A full cycle ratcheting hand tool ensures complete crimps Ergonomic soft grip handles for comfortable crimping A precision user-friendly terminal locator holds terminals in the proper crimping position Right and Left handed applications This tool is IPC/WHMA A-620 Class 2 compliant as indicated This tool is RoHS compliant; however, RoHS compliance is not required SCOPE Products: CTX150 SWS Receptacle Terminals 0.35-0.50 mm2. Terminal Series No. 502307 34806 Terminal Order No. ♦ Reel Wire Size Insulation Diameter Wire Type mm2 mm In. T3-ZHID 0.35 1.25-1.60 .049-.063 502307-3001 502307-3101 502307-3401 T3-ZHIA 0.35 1.25-1.60 .049-.063 502307-3006 502307-3106 502307-3501 T3-ZHID 0.50 1.40-1.60 .055-.063 T3-ZHID 0.35 1.25-1.60 .049-.063 34806-3001 34806-3101 34806-3401 T3-ZHIA 0.35 1.25-1.60 .049-.063 34806-3006 34806-3106 34806-3501 T3-ZHID 0.50 1.40-1.60 .055-.063 ♦ Customer to cut off terminal from reel: 0.30mm (.012”) maximum cut-off tab. Strip Length mm In. 4.50-5.00 .177-.197 4.50-5.00 .177-.197 DEFINITION OF TERMS STRIP LENGTH 0.05-0.40 (REF) SEAL POSITION BEND UP ROLLING CONDUCTOR BRUSH BELL MOUTH SEAL TWISTING WIRE CONDUCTOR CRIMP CUT-OFF TAB Doc No: 638234500 Revision: B Release Date: 08-26-13 Revision Date: 05-25-17 BEND DOWN SEAM UNCONTROLLED COPY Page 1 of 7 Hand Crimp Tool For CTX150 SWS Receptacle Terminals CONDITIONS After crimping, the conductor profiles should measure the following: Bell Mouth mm In. Terminal Series No. 502307 34806 Terminal Series No. 0.20-0.55 Bend Up 502307 1 34806 .008-.022 Bend Down Degree Max. Conductor Brush mm In. Twist 0.20-1.20 .008-.047 Roll Seam Degree Max. 1 2 3 Seam shall not be open and no wire allowed out of the crimping area After crimping, the crimp profiles should measure the following: Wire Size Terminal Series No. 502307 34806 Wire Type T3-ZHID T3-ZHIA T3-ZHID T3-ZHID T3-ZHIA T3-ZHID mm² 0.35 0.35 0.50 0.35 0.35 0.50 Terminal Series No. 502307 34806 Conductor Crimp Width Crimp Height Max. mm In. mm In. 0.81-0.87 .032-.034 1.65 .065 0.81-0.87 .032-.034 1.65 .065 0.80-0.90 .031-.035 1.65 .065 0.81-0.87 .032-.034 1.65 .065 0.81-0.87 .032-.034 1.65 .065 0.80-0.90 .031-.035 1.65 .065 Insulation Crimp Height mm 2.67-2.77 2.72-2.82 2.72-2.82 2.67-2.77 2.72-2.82 2.72-2.82 In. .105-109 .107-111 .107-111 .105-109 .107-111 .107-111 Crimp Width mm 2.95-3.15 3.00-3.20 3.00-3.20 2.95-3.15 3.00-3.20 3.00-3.20 In. .116-.124 .118-.126 .118-.126 .116-.124 .118-.126 .118-.126 Pull Force Minimum N Lb. 60 13.5 60 13.5 80 18.0 60 13.5 60 13.5 80 18.0 Wire Size Profile Single Wire Seal Wire Type mm² 0.35 mm2 0.50 mm2 Order No. Color Seal Allowed Wire Ø T3-ZHID 0.35 X T3-ZHIA 0.35 X T3-ZHID 0.50 X See Note 3 See Note 3 See Note 3 T3-ZHID 0.35 X T3-ZHIA 0.35 X T3-ZHID 0.50 X 0.05-0.40mm Reference SEAL POSTION ON WIRE Cable Seal Position On a Wire (Before crimping) 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. 3. See Product Application Specification AS-502307-002 for applicable seal number, color and seal allowed wire diameter. WIRE INSULATION SEAL Note: A crimp height chart is provided with this document as reference only. Because of the wide range of wires, strands, insulation diameters and durometers 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 specifications listed. Doc No: 638234500 Revision: B Release Date: 08-26-13 Revision Date: 05-25-17 UNCONTROLLED COPY Page 2 of 7 Hand Crimp Tool For CTX150 SWS Receptacle Terminals OPERATION HANDLE WILL SPRING OPEN CAUTION: Crimp only the Molex terminals listed in the scope for this tool. Do not crimp hardened objects because damage can occur to the tool frame or crimp dies. 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. See Figure 1. LOCATOR IN DOWN POSTION Figure 2 SQUEEZE HANDLES TOGETHER Crimping Terminals PUSH ON THE LOCATOR BUTTON Figure 1 1. Select the desired terminal listed in the preceding charts. 2. Make sure the center of the locator is in the down position. With the locator attached, push the locator button on the back of the hand tool to bring the locator forward through the tooling. See Figure 2. 3. While holding the locator button in, load the terminal into the proper nest opening in the locator based on the wire gauge or terminal type markings on the hand tooling. See Figure 3. TERMINAL LOCATOR PUSHED THROUGH TOOLING RELEASE LOCATOR BUTTON LOCATOR BUTTON PUSHED IN Figure 3 TERMINAL 4. Release the locator button, allowing the locator to return to the crimping position. 5. With the hand tool open, insert the properly stripped wire and seal under the punches into the lower part of the upper tooling until the wire is against the locator. See Figure 4. LOCATOR LOCATOR PUSHED THROUGH TOOLING LOCATOR BUTTON PUSHED IN TERMINAL Doc No: 638234500 Revision: B RELEASE LOCATOR BUTTON TERMINAL Figure 4 Release Date: 08-26-13 Revision Date: 05-25-17 UNCONTROLLED COPY Page 3 of 7 Hand Crimp Tool For CTX150 SWS Receptacle Terminals 6. The seal position should be under and inside the punches. Keep this position while crimping. 7. Crimp the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed. Release the handles to open the jaws. Note: The tamper-proof ratchet action will not release the tool until it has been fully closed. WIRE 8. Remove the crimped terminal from the terminal locator by pulling on the wire. 9. Visually inspect the crimped terminal for proper crimp location. 10. On some large O.D. wires, it may not be possible to insert the wire with the tool partially closed. Those wires should be inserted with the hand tool in the open position. Insert the wire above the terminal in the punch and against the locator, and then close the tool. See Figure 6. LOCATOR TERMINAL Figure 6 Locator Replacement See the parts list on the last page of this document for the proper locator order number. Follow the steps below to replace the locator: 1. Open the crimp hand tool. 2. Squeeze gently on the lower area shown in Figure 7A with your thumb and index finger. The lower tabs of the locator should disengage from the hand tool. 3. Lift and pull away from the hand tool. The top locator hooks should slip out of the top slots easily. See Figure 7A. LOCATOR SQUEEZE HERE MAKE SURE CENTER OF LOCATOR IS IN THE DOWN POSITION JAWS OPEN PULL OPEN SQUEEZE HERE TOOLING Figure 7A TOOLING M3 BHCS TOP SLOTS OF HAND TOOL TOP HOOKS Figure 8 PUSH ON HANDLE Figure 7B LOWER TABS 4. To reinstall the new locator, make sure the hand tool is in the open position. 5. Press the red insert down as far as it will go as shown in Figure 7B. Doc No: 638234500 Revision: B Release Date: 08-26-13 Revision Date: 05-25-17 UNCONTROLLED COPY Page 4 of 7 Hand Crimp Tool For CTX150 SWS Receptacle Terminals 6. Holding onto the lower part of the locator with your thumb and index finger, insert the locator’s top hooks (2) into the hand tool’s top slots. 7. Rotate the locator down, and press the lower tabs into the two bottom slots of the hand tool. To secure the locator into place, the lower tabs must snap into place on the hand tool frame. Right or Left Hand Operation This hand tool has an added feature that can be converted from a right handed application to a left handed application. It is necessary to reverse the tooling if using the left handed application along with the locator. Follow the steps below: MATCH UP MARKS Figure 9 1. The locator must be removed before reversing the FRONT tooling. 2. Remove the M3 BHCS, which is holding the upper tooling. 3. Flip the upper tooling to the opposite side, and replace the M3 BHCS. Make sure the small markings on the front and back of the hand tool frame match up and are on the outside of the hand tool frame. See Figures 8 and 9. 4. Do the same thing with the lower tooling, and tighten the M3 screws. Be sure the small markings line up. 5. Reinstall the locator by following the instructions in the locator replacement section. Maintenance It is recommended that each operator of the tool be made aware of and responsible for the following maintenance steps: BACK LUBRICATION POINTS (BOTH SIDES) LIGHT OIL (EVERY 3 MONTHS OR 5,000 CRIMPS) 1. Remove dust, moisture and other contaminants with a clean brush or a Figure 10 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 RATCHET RELEASE significantly enhance the tool life. LEVER 4. Wipe excess oil from the hand tool, particularly from the crimping area. Oil transferred from the crimping area onto certain terminations may affect the electrical characteristics of an application. 5. When the 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 Figure 11 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 pressing up on the ratchet release lever in the movable handle. See Figure 11. Doc No: 638234500 Revision: B Release Date: 08-26-13 Revision Date: 05-25-17 UNCONTROLLED COPY Page 5 of 7 Hand Crimp Tool For CTX150 SWS Receptacle Terminals How to Adjust Tool Preload (See Figure 12) SQUEEZE THE LINK RATCHET IN THE HANDLE RELEASE LEVER HOLD THE HAND TOOL IN POSITION This hand tool is factory preset to 25-45 pounds preload. It may be necessary over the life of the tool to adjust tool handle preload force. Listed below are the steps required to adjust the crimping force of the hand tool to obtain proper crimp conditions: 1. Hold the hand tool in the palm of your Figure 12 hand as shown in Figure 12. Using your SETTING WHEEL index finger, squeeze the link toward the top of the hand tool frame. This will release the preload adjustment wheel. 2. Rotate the setting wheel counterclockwise (CCW) to increase handle force. The numbers will display higher. To decrease handle force, rotate the setting wheel clockwise (CW). 3. Release the link to lock the setting wheel in place. 4. Check the crimp specifications or conduct a pull test after tool handle preload force is adjusted. 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 30 days. Should such a defect occur, Molex 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: 1. Manually powered hand tools are intended for low-volume use 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. Certification 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 that has been stripped 12.7mm (.50”) long so that 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 website 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 should be 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. Doc No: 638234500 Revision: B Release Date: 08-26-13 Revision Date: 05-25-17 UNCONTROLLED COPY Page 6 of 7 Hand Crimp Tool For CTX150 SWS Receptacle Terminals PARTS LIST Item Number REF 1 2 3 Order Number 63823-4500 63823-4575 63810-0104 63810-0105 Description Hand Crimp Tool Locator Assembly Spring, Return Spring, Ratchet Quantity Figure 13 1 1 1 2 1 RATCHET RELEASE LEVER Figure 13 3 Application Tooling Support Phone: (402) 458-TOOL (8665) E-Mail: applicationtooling@molex.com Website: www.molex.com/applicationtooling Molex is a registered trademark of Molex, LLC in the United States of America and may be registered in other countries; all other trademarks listed herein belong to their respective owners. Doc No: 638234500 Revision: B Release Date: 08-26-13 Revision Date: 05-25-17 UNCONTROLLED COPY Page 7 of 7