Hand Crimp Tool For CTX150 SWS Receptacle Terminals
HAND CRIMP
TOOL
Application Tooling
Specification Sheet
TYPE 4D
Order No. 63823-4600
FEATURES
A full cycle ratcheting hand tool ensures complete crimps
Ergonomic soft grip handles for comfortable crimping
A precision user-friendly terminal locator wire stop holds terminals in the proper crimping position
Right and Left handed applications
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 compliant as indicated
This tool is RoHS compliant, however RoHS compliant is not required
SCOPE
Products: CTX150 SWS Receptacle Terminals 0.75-1.00 mm2.
Terminal
Series No.
502307
34806
Terminal Order No.
Wire Size
Insulation Diameter
Strip Length
Reel
Wire Type
mm²
mm
In.
mm
In.
502307-3002 502307-3107 T3-ZHID 0.75 mm2 1.60-1.80 .063-.071
502307-3007 502307-3402
4.50-5.00 .177-.197
502307-3102 502307-3502 T3-ZHID 1.00 mm2 1.75-1.95 .069-.077
34806-3002 34806-3107 T3-ZHID 0.75 mm2 1.60-1.80 .063-.071
34806-3007 34806-3402
4.50-5.00 .177-.197
34806-3102 34806-3502 T3-ZHID 1.00 mm2 1.75-1.95 .069-.077
Customer to cut off terminal from reel: 0.30mm .012”) maximum Cut-off Tab.
DEFINITION OF TERMS
0.05 - 0.40 (REF)
SEAL POSITION
STRIP LENGTH
BEND UP
CONDUCTOR
BRUSH
BELL MOUTH
ROLLING
SEAL
TWISTING
WIRE
CONDUCTOR
CRIMP
CUT-OFF
TAB
Doc No: ATS-638234600
Revision: A
Release Date: 12-20-13
Revision Date: 12-20-13
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.
502307
34806
Wire Size
Terminal
Series No.
502307
34806
Wire Type
T3-ZHID
T3-ZHID
T3-ZHID
T3-ZHID
mm²
0.75 mm2
1.00 mm2
0.75 mm2
1.00 mm2
Terminal Series No.
502307
34806
0.20-0.55
Conductor Brush
mm
In.
.008-.022
0.20-1.20
Bend up Bend down
Twist Roll
Degree Max.
Degree Max.
1
1
2
Conductor
Crimp Width
Crimp Height
Max.
mm
In.
mm
In.
1.10-1.20 .043-.047 1.70 .067
1.00-1.10 .039-.043 2.10 .083
1.10-1.20 .043-.047 1.70 .067
1.00-1.10 .039-.043 2.10 .083
3
.008-.047
Seam
Seam shall not be
open and no wire allowed
out of the crimping area
Insulation
Crimp Height
mm
3.08-3.18
3.00-3.10
3.08-3.18
3.00-3.10
In.
.121-.125
.118-.122
.121-.125
.118-.122
Crimp Width
mm
3.00-3.20
3.05-3.25
3.00-3.20
3.05-3.25
In.
.118-.126
.120-.128
.118-.126
.120-.128
Pull Force
Minimum
N
115
120
115
120
Lb.
25.9
27.0
25.9
27.0
Wire Size
Profile
Single Wire Seal
Wire Type
mm²
0.75 mm2 1.00 mm2 Order No.
Color
Seal Allowed Wire Ø
T3-ZHID 0.75 mm2
X
T3-ZHID 1.00 mm2
X
See Note 3 See Note 3
See Note 3
T3-ZHID 0.75 mm2
X
T3-ZHID 1.00 mm2
X
Cable Seal Position On a Wire
(Before crimping)
0.05-0.40mm Reference
SEAL POSTION ON WIRE
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 manual as Reference Only. Due to 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.
OPERATION
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.
Doc No: ATS-638234600
Revision: A
Release Date: 12-20-13
Revision Date: 12-20-13
UNCONTROLLED COPY
Page 2 of 7
Hand Crimp Tool For CTX150 SWS Receptacle Terminals
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
HANDLE WILL
SPRING OPEN
Crimping Terminals
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,
SQUEEZE
push the locator button on the back of the
PUSH ON THE
HANDLES
Figure 2
hand tool to bring the locator forward
LOCATOR BUTTON
TOGETHER
through the tooling. See Figure 2.
3. While holding the locator button in, load the
Figure 1
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.
LOCATOR
PUSHED THRU
TOOLING
RELEASE LOCATOR
BUTTON
TERMINAL
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 wire stop. See Figure 4.
WIRE AGAINST
THEWIRE STOP
WIRE STOP IS
PART OF THE
LOCATOR
WIRE AND SEAL
POSITIONED IN
LOWER PART OF
THE PUNCHES
WIRE AND
SEAL POSITON
TERMINAL
Figure 4
TERMINAL
6. 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.
Doc No: ATS-638234600
Revision: A
Release Date: 12-20-13
Revision Date: 12-20-13
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Page 3 of 7
Hand Crimp Tool For CTX150 SWS Receptacle Terminals
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 wire stop
then close the tool. See Figure 5.
WIRE STOP
Figure 5
TERMINAL
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 6A 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
6A.
LOCATOR
SQUEEZE
HERE
SQUEEZE
HERE
Figure 6A
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
TOP SLOTS OF
HANDTOOL
JAWS OPEN
PULL OPEN
TOOLING
TOOLING
M3 BHCS
TOP HOOKS
Figure 7
Figure 6B
PUSH ON
HANDLE
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 6B.
6. Holding onto the lower part of the locator with your thumb and index finger, insert the locators top hooks (2)
into the hand tool 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.
Doc No: ATS-638234600
Revision: A
Release Date: 12-20-13
Revision Date: 12-20-13
UNCONTROLLED COPY
Page 4 of 7
Hand Crimp Tool For CTX150 SWS Receptacle Terminals
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
1. The locator must be removed before reversing the
UP MARKS
tooling.
2. Remove the M3 BHCS which is holding the upper
tooling.
Figure 8
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
BACK
FRONT
frame, match up and are on the outside of the hand
tool frame. See Figure 7 and 8.
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:
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 are protected with
a thin coat of high quality machine oil. Do not oil excessively. The tool
LUBRICATION POINTS
was engineered for durability but like any other equipment it needs
(BOTH SIDES) LIGHT OIL
cleaning and lubrication for a maximum service life of trouble free crimping.
(EVERY 3 MONTHS OR
5,000 CRIMPS)
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
Figure 9
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.
RATCHET RELEASE
LEVER
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
pressing up on the ratchet release lever in the movable handle. See Figure
10.
How to Adjust Tool Preload (See Figure 11)
Figure 10
This hand tool is factory preset to 25-45 LBS. 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:
Doc No: ATS-638234600
Revision: A
Release Date: 12-20-13
Revision Date: 12-20-13
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Hand Crimp Tool For CTX150 SWS Receptacle Terminals
1. Hold the hand tool in the palm of your
hand as shown in Figure 12. Using
the index finger squeeze the link
towards 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.
RATCHET
RELEASE LEVER
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITIN
Figure 11
SETTING
WHEEL
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, 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:
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.
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, 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. 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.
Doc No: ATS-638234600
Revision: A
Release Date: 12-20-13
Revision Date: 12-20-13
UNCONTROLLED COPY
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Hand Crimp Tool For CTX150 SWS Receptacle Terminals
PARTS LIST
Item Number
REF
1
2
3
Order Number
63823-4600
63823-4675
63810-0104
63810-0105
Description
Hand Crimp Tool
Locator Assembly
Spring, Return
Spring, Ratchet
Quantity
Figure 12
1
1
1
2
1
RATCHET
RELEASE LEVER
Figure 12
3
Visit our Web site at http://www.molex.com
Doc No: ATS-638234600
Revision: A
Release Date: 12-20-13
Revision Date: 12-20-13
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