0638251700 [MOLEX]
Hand Crimp Tool for 2.80mm (.110) Sealed Crimp Terminal, Male and Female;
| 型号： | 0638251700 |
| 厂家： | 
Molex |
| 描述： | Hand Crimp Tool for 2.80mm (.110) Sealed Crimp Terminal, Male and Female |
| 文件： | 总9页 (文件大小：540K) |
| 中文： | 中文翻译 | 下载： | 下载PDF数据表文档文件 |
Hand Crimp Tool for CTX280 SWS Receptacle Terminals
TYPE 4C
Application Tooling
Specification Sheet
Tool Kit
Order No. 63823-2470
Hand Crimp Tool
Order No. 63823-2400
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
° 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.
SCOPE
Products: CTX280 SWS Receptacle Terminals: 0.5 - 1.0 mm2 metric wires.
Terminal Order No.
Wire Size and Type —Insulation Diameter
mm² Type mm In.
Strip Length
mm In.
Terminal
Series No.
·Reel Form Only
98675-1001 98675-1005 98675-1011 98675-1015
98675-1041 98675-1045 98675-1051 98675-1055
98675-1061 98675-1065 98675-1101 98675-1105
98675-1111 98675-1115
98675
0.5-1.0 T3ZHID 1.40-1.95 .055-.077 4.30-4.80 .169-.189
34865-1001 34865-1005 34865-1041 34865-1045
34865-1061 34865-1065 34865-1101 34865-1105
34808-1001 34808-1005 34808-1041 34808-1045
34808-1061 34808-1065 34808-1101 34808-1105
34865
34808
0.5-1.0 T3ZHID 1.40-1.95 .055-.077 4.30-4.80 .169-.189
0.5-1.0 T3ZHID 1.40-1.95 .055-.077 4.30-4.80 .169-.189
— See crimp specification for the individual Insulation Diameter.
·Customer to cut off terminal from reel: 0.30mm (.012”) maximum Cut-off Tab.
DEFINITION OF TERMS
BEND UP
STRIP LENGTH
0.4-0.6 (REF)
SEAL POSITION
ROLLING
TWISTING
CONDUCTOR
BRUSH
BELL MOUTH
BEND
DOWN
CONDUCTOR
CRIMP
SEAM
WIRE
CUT-OFF
TAB
SEAL
Doc No: ATS-6382324HM Release Date: 01-15-14
Revision: A Revision Date: 01-15-14
UNCONTROLLED COPY
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Hand Crimp Tool for CTX280 SWS Receptacle Terminals
CRIMP SPECIFICATION
Bell mouth
4Conductor Brush Bend up Bend Down Twist Roll
mm In. Degree Max. Degree Max.
Terminal Series No.
mm
In.
98675 34808 34865 0.40-0.60 .016-.024 0.20-0.60 .008-.024
1
1
2
3
4Not to exceed above the conductor crimp height.
After crimping, the crimp profiles should measure the following:
Conductor
Crimp Height Crimp Width
mm In. mm In.
Pull Force
Minimum
Wire Size
mm2
Profile
Terminal
Plating
Terminal
Order No.
N
Lb. A B C
34808-1001 34808-1005 34865-1001
Standard
Performance 34865-1005 98675-1001 98675-1005
0.50
1.05-1.15 .041-.045 2.02-2.12 .079-.083 70.0 15.7 X
Tin
98675-1011 98675-1015
34808-1041 34808-1045 34808-1101
34808-1105 34865-1041 34865-1045
34865-1101 34865-1105 98675-1041
98675-1045 98675-1051 98675-1055
98675-1101 98675-1105 98675-1111
98675-1115
High
Performance
Tin
0.50
1.07-1.13 .042-.044 2.02-2.12 .079-.083 70.0 15.7 X
High
Performance
Silver
34808-1061 34808-1065 34865-1061
0.50
0.75
1.10-1.16 .043-.046 2.02-2.12 .079-.083 70.0 15.7 X
1.13-1.23 .044-.048 2.02-2.12 .079-.083 90.0 20.2
34865-1065 98675-1061 98675-1065
34808-1001 34808-1005 34865-1001
Standard
Performance 34865-1005 98675-1001 98675-1005
X
Tin
98675-1011 98675-1015
34808-1041 34808-1045 34808-1101
34808-1105 34865-1041 34865-1045
34865-1101 34865-1105 98675-1041
98675-1045 98675-1051 98675-1055
98675-1101 98675-1105 98675-1111
98675-1115
High
Performance
Tin
0.75
1.13-1.23 .044-.048 2.02-2.12 .079-.083 90.0 20.2
X
X
High
Performance
Silver
34808-1061 34808-1065 34865-1061
0.75
1.00
1.08-1.18 .043-.047 2.02-2.12 .079-.083 90.0 20.2
1.15-1.25 .045-.049 2.02-2.12 .079-.083 115.0 25.8
34865-1065 98675-1061 98675-1065
34808-1001 34808-1005 34865-1001
Performance 34865-1005 98675-1001 98675-1005
Standard
X
X
X
Tin
98675-1011 98675-1015
34808-1041 34808-1045 34808-1101
34808-1105 34865-1041 34865-1045
34865-1101 34865-1105 98675-1041
98675-1045 98675-1051 98675-1055
98675-1101 98675-1105 98675-1111
98675-1115
High
Performance
Tin
1.00
1.00
1.17-1.23 .046-.048 2.02-2.12 .079-.083 115.0 25.8
1.17-1.23 .046-.048 2.02-2.12 .079-.083 115.0 25.8
High
Performance
Silver
34808-1061 34808-1065 34865-1061
34865-1065 98675-1061 98675-1065
Seam note: Seam shall not be open and no wire allowed out of the crimping area
Doc No: ATS-6382324HM Release Date: 01-15-14
Revision: A Revision Date: 01-15-14
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Hand Crimp Tool for CTX280 SWS Receptacle Terminals
Insulation
Crimp Height Crimp Width
mm In. mm In.
4.30-4.50 .169-.177 4.95-5.05 .195-.199
1.60-1.80 .063-.071 See Note 3 See Note 3 4.40-4.60 .173-.181 4.95-5.05 .195-.199
1.75-1.95 .069-.077 4.50-4.70 .177-.185 4.95-5.05 .195-.199
Wire Size —Insulation Diameter
Single Wire Seal
Order No. Color
Terminal Series No.
mm2
0.50
0.75
1.00
mm
In.
1.40-1.60 .055-.063
98675 34865 34808
4Tool 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-98675-002 for Applicable Seal number and Color.
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, actual crimp height measurements may very slightly. An occasional,
destructive, pull force test should be preformed to check hand tool crimp. Pull Force value must exceed the
minimum pull force specifications listed.
CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects as damage can
occur to the tool or die.
INSTALLATION
To install the Tool Kit into the Power Crimp Head follow the steps below:
POWER
CRIMP
HEAD
LIFT UP ON
THE LOCATOR
PUNCHES
M4 X 18 LONG
BHCS
PRESS DOWN
ON THE BRASS
PIVOT SHAFT
M4 X 10 LONG
BHCS
Figure 1
SWING
LOCATOR
OPEN
ANVILS
Figure 2
Anvils and Punches Installation
1. Insert the Anvils into the bottom slots of the nest. Install the M4 x 10 long BHCS and tighten in place.
2. Insert the Punches into the top slots of the nest. Install the M4 x 18 long BHCS and tighten in place. See
Figure 1.
Doc No: ATS-6382324HM Release Date: 01-15-14
Revision: A Revision Date: 01-15-14
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Hand Crimp Tool for CTX280 SWS Receptacle Terminals
Locator Installation and Removal
Follow the steps below to install or replace the locator. See
Figure 2.
To install the locator
1. Position the locator with the hole over the brass pivot
shaft and snap it into place.
LATCH LOCKED
LATCH UNLOCKED
To remove the locator
1. Open the crimp hand tool.
Figure 3
2. Swing the existing locator open and away from the hand tool.
3. Firmly press down on the brass pivot shaft with your thumb, while pulling the locator up. Slip the locator off the
top of the brass pivot shaft.
TERMINAL
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.
SWING OPEN
TERMINAL
IN PLACE
Crimping Terminals
1. Select the desired terminal listed in
the preceding charts.
PUSH HERE TO
OPEN WIRE STOP
LOCATOR
LOCATOR LATCH
IN OPEN POSITION
Figure 4
2. Turn the Locator Lock Latch down to unlock. See Figure 3.
3. Swing the terminal locator away from the crimp tool shown in Figure 4.
INSULATION
PUNCH
CONDUCTOR
WIRE STOP
PUNCH
BLADE
WIRES AGAINST
LOCATOR STOP
TERMINAL
SEAL
WIRE
LOCATOR
PRE-STRIPPED
WIRE WITH SEAL
Figure 5
TERMINAL
INSULATION
ANVIL
CONDUCTOR ANVIL
Figure 6
4. Press down on the wire stop on the locator as shown in Figure 4. Insert the proper terminal into the proper
nest opening. Make sure when choosing the nest opening, it will correspond with the correct profile on the
hand tool.
Doc No: ATS-6382324HM Release Date: 01-15-14
Revision: A Revision Date: 01-15-14
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Hand Crimp Tool for CTX280 SWS Receptacle Terminals
5. Return the locator to closed position.
6. Turn the Locator Lock Latch up to lock. Make sure that the terminal is visually centered over the punch.
7. Insert the proper wire with the seal over the terminal.
8. Gently touch the wire stop with the end of the wire and align the seal with the grips on the terminal. See Figure 5
and 6.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
9. Compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.
Release handles to open the jaws.
10. Unlock the locator latch and swing the locator open.
11. Remove the crimped terminal from the terminal locator by pressing down on the wire stop and gently pulling on
the wire.
12. Visually inspect the crimped terminal for an acceptable crimp.
For the Battery Power Tool:
1. Cycle the Battery Power Tool to crimp the terminal to the wire.
2. Remove the crimped terminal from the terminal locator by pressing down on the wire stop and gently pulling on
the wire.
3. Visually inspect the crimped terminal for an acceptable crimp.
Maintenance
It is recommended that each operator of the tool be
made aware of, and responsible for, the following
maintenance steps:
LUBRICATION
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 in the tool head are protected with a
thin coat of high quality machine oil. Do not oil
excessively. This tool was engineered for
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY MONTH
OR
Figure 7B
5,000 CRIMPS)
Figure 7A
durability, but like any fine piece of equipment, it needs cleaning and lubrication for a maximum service life of
trouble-free crimping. The use of light oil, such as 30 weight automotive oil, every 5,000 crimps or monthly,
will significantly enhance the tool life and ensure a stable calibration. See Figure 7A or 7B for lubrication
points.
4. Store the tool in a clean and dry area when not in use.
Miscrimps or Jams for Crimp Hand Tools Only (See Figure 10)
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 rotating the small slotted screw marked with an arrow. See Figure 10.
Warranty
This tool kit is for electrical terminal crimping purposes only. This tool kit 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
Doc No: ATS-6382324HM Release Date: 01-15-14
Revision: A Revision Date: 01-15-14
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Hand Crimp Tool for CTX280 SWS Receptacle Terminals
days. Should such a defect occur, we will repair or exchange the tool kit free of charge. This repair or exchange
will not be applicable to altered, misused, or damaged tools.
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.
CAUTION: Repetitive use of this tool should be avoided.
Certification
Molex does not certify or re-certify commercial grade 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.
% When the hand tool is no longer capable of achieving minimum pull force, it should be taken out of service and
replaced.
% This tool is very difficult to disassemble and reassemble. Customer repair is not recommended.
Doc No: ATS-6382324HM Release Date: 01-15-14
Revision: A Revision Date: 01-15-14
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Hand Crimp Tool for CTX280 SWS Receptacle Terminals
The chart below shows all applications for this Tool Kit.
Tool Kit
Order No.
Tool
Order no.
Tool
Description
Power Head
Order No.
N/A
Adapter
Description
N/A
Figure
No.
63810-1050 Hand Crimp Frame (Short)
63810-1000 Hand Crimp Frame (Long)
63816-0200 Battery Power Tool (110 V) 63816-0300 Power Crimp Head
63816-0250 Battery Power Tool (220 V) 63816-0300 Power Crimp Head
8
8
9
9
N/A
N/A
63823-2470
Applications for the Tool Kit
Hand Crimp Tool
Battery Powered Tool
POWER
CRIMP
HEAD
TOOLING KIT
TOOLING KIT
BATTERY
POWERED
TOOL
LOCKING PINS
HAND CRIMP
FRAME LONG
AND SHORT
Figure 8
Figure 9
WARNING: NEVER operate service, install tool kits, or adjust the Power Crimp Head without proper
instruction and without first reading and understanding the instructions in the proper Manual or
Specification Sheet. See Chart above for the correct Manual or Specification Sheet.
WARNING: NEVER install tooling or service this tool while it is into any power source. Make sure the
power is turned off.
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.
Doc No: ATS-6382324HM Release Date: 01-15-14
Revision: A Revision Date: 01-15-14
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Hand Crimp Tool for CTX280 SWS Receptacle Terminals
HAND TOOL PARTS LIST
Item Number Order Number
Description
Hand Crimp Frame (Long)
Tool Kit with Locator
Locator (only)
Quantity
1
2
3
63810-1000
63823-2470
63823-2475
1
1
REF
M4 X 8mm
LONG BHCS
1
1
RATCHET
RELEASE SCREW
2
3
WITH TOOL KIT
LOCATOR ONLY
M4 X 10mm
LONG BHCS
Figure 10
M4 X 18mm
LONG BHCS
2
Doc No: ATS-6382324HM Release Date: 01-15-14
Revision: A Revision Date: 01-15-14
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Hand Crimp Tool for CTX280 SWS Receptacle Terminals
POWER HEAD PARTS LIST
Item Order No Engineering No.
Description
Power Crimp Head
Tool Kit
Quantity
63816-0300
63823-2470
63816-0300
63823-2470
1
1
1
2
2
1
1
M4 by 8 Long
BHCS
M4 by 18 Long
BHCS
M4 by 10 Long
BHCS
Figure 11
2
Visit our Web site at http://www.molex.com
Doc No: ATS-6382324HM Release Date: 01-15-14
Revision: A Revision Date: 01-15-14
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