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Hand Crimp Tool For CTX150 SWS Receptacle Terminals

Doc No: ATS-6 82 4700 Release Date: 08-26-1 UNCONTROLLED COPY Page 1 of 7

Revision: A Revision Date: 08-26-1

CONDUCTOR

BRUSH

STRIP LENGTH

SEAM

CONDUCTOR

CRIMP

CUT

OFF

TAB

BELL MOUTH

BEND UP

TWISTING

ROLLING

BEND

DOWN

WIRE

SEAL

0.05

0.40 (REF)

SEAL POSITION

TYPE 4D

HAND CRIMP

TOOL

Appli ation Tooling

Spe ifi ation Sheet Order No. 63823-4700

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

 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 1.50 mm2.

Terminal

Series No.

Terminal Order No.

Wire Size

Insulation Diameter

Strip Length







Reel

Wire T

ype

mm²

In.

502 07

008

T -ZHID 1.50 mm2 2.10-2.25 .08 -.089 4.50-5.00 .177-.197

502 07

108

502 07

4806

4806- 00 4806- 008

T -ZHID 1.50 mm2 2.10-2.25 .08 -.089 4.50-5.00 .177-.197

4806

108

4806

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

DEFINITION OF TERMS

Hand Crimp Tool For CTX150 SWS Receptacle Terminals

Doc No: ATS-6 82 4700 Release Date: 08-26-1 UNCONTROLLED COPY Page 2 of 7

Revision: A Revision Date: 08-26-1

WIRE

INSULATION SEAL

0.05

0.40

eferen e

SEAL POSTION ON WIRE

CONDITIONS:

After crimping, the conductor profiles should measure the following.

Terminal

Series No.

Bell mouth

Condu tor

Brush Bend up Bend down

Twist Roll Seam

Seam shall not be

open and no wire allowed

out of the crimping area

In.

Degree Max.

502 07

0.20-0.55

.008-.022

0.20-1.20

.008-.047

1 1 2

4806

Terminal

Series No.

Wire Size

Condu tor

Insulation

Pull For e

Minimum

Crimp Height

Crimp Width

Max. Crimp Height Crimp Width

Wire Type

mm²

In.

Lb.

502 07

ZHID

1.50 mm2

1. 0

1.40

.051

.055

2.20

.087

. 4

.44

.1 1

.1 5

.40

.126

.1 4

155

4.9

4806

ZHID

1.50 mm2

1. 0

1.40

.051

.055

2.20

.087

. 4

.44

.1 1

.1 5

.20

.40

.126

.1 4

155

4.9

Terminal Series No.

Wire Size

Profile

Single Wire Seal

Wire Type

mm²

1.50 mm2

Order No.

Color

Seal Al

lowed Wire Ø

502 07

ZHID

1.50 mm2

See Note

4806

ZHID

1.50 mm2





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.

. See Product Application Specification AS-502 07-002 for applicable Seal number, Color and Seal Allowed

Wire Diameter.

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

SQUEEZE

HANDLES

TOGETHER

HANDLE WILL

SPRING OPEN

Figure 1

LOCATOR

IN DOWN

POSTION

PUSH ON THE

LOCATOR

BUTTON

Figure 2

Hand Crimp Tool For CTX150 SWS Receptacle Terminals

Doc No: ATS-6 82 4700 Release Date: 08-26-1 UNCONTROLLED COPY Page of 7

Revision: A Revision Date: 08-26-1

RELEASE

LOCATOR

BUTTON

TERMINAL

Figure 3

LOCATOR

PUSHED THRU

TOOLING

TERMINAL

LOCATOR

BUTTON

PUSHED IN

LOCATOR

Figure 4

TERMINAL

WIRE AGAINST

THE

WIRE STOP

WIRE AND

SEAL POSITON

WIRE STOP

TERMINAL

WIRE AND

SEAL

tool. Do not crimp hardened objects as damage can occur to the tool frame and/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.

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, push the locator button

on the back of the hand tool to bring the locator forward through the tooling. See Figure 2.

. 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 .

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.

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.

Note: The tamper proof ratchet action will not release the tool until it has been fully closed.

8. Remove the crimped terminal from the terminal locator by pulling on the wire.

9. Visually inspect the crimped terminal for proper crimp location.

Hand Crimp Tool For CTX150 SWS Receptacle Terminals

Doc No: ATS-6 82 4700 Release Date: 08-26-1 UNCONTROLLED COPY Page 4 of 7

Revision: A Revision Date: 08-26-1

Figure

PUSH ON

HANDLE

JAWS OPEN

PULL OPEN

TOOLING

M3 BHCS

MAT

UP MARKS

FRONT

BACK

Figure

MAKE SURE

CENTER OF LOCATOR

IS IN THE

DOWN POSITION

Figure

SQUEEZE

HERE

SQUEEZE

HERE

LOCATOR

Figure

TOP HOOKS

TOP SLOTS OF

HANDTOOL

LOWER TABS

Lo ator Repla ement

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 5A with your thumb and index finger. The lower tabs of the

locator should disengage from the hand tool.

. Lift and pull away from the hand tool. The top locator hooks should slip out of the top slots easily. See

Figure 5A.

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 5B.

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.

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:

Hand Crimp Tool For CTX150 SWS Receptacle Terminals

Doc No: ATS-6 82 4700 Release Date: 08-26-1 UNCONTROLLED COPY Page 5 of 7

Revision: A Revision Date: 08-26-1

Figure 10

SQUEEZE

THE LINK IN

THE HANDLE

HOLD THE HAND

TOOL IN POSITION

SETTING

WHEEL

RATCHET

RELEASE LEVER

1. The locator must be removed before reversing the tooling.

2. Remove the M BHCS which is holding the upper tooling.

. Flip the upper tooling to the opposite side and replace the M 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 Figure 6 and 7.

4. Do the same thing with the lower tooling and tighten the M screws. Be sure

the small markings line up.

5. Reinstall the locator by following the Instructions in the locator replacement

section.

Maintenan e

It is recommended that each operator of the tool be made aware of, and

responsible for, the following maintenance steps: See Figure 8.

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.

Mis rimps 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 9.

How to Adjust Tool Preload

(See 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:

LUBRICATION POINTS

(BOTH SIDES) LIGHT OIL

(EVERY 3 MONTHS OR

5,000 CRIMPS)

Figure 8

RATCHET RELEASE

LEVER

Figure 9

Hand Crimp Tool For CTX150 SWS Receptacle Terminals

Doc No: ATS-6 82 4700 Release Date: 08-26-1 UNCONTROLLED COPY Page 6 of 7

Revision: A Revision Date: 08-26-1

1. Hold the hand tool in the palm of your hand as shown in Figure 10. 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 counter-clockwise (CCW) to increase handle force. The numbers will display higher.

To decrease handle force rotate the setting wheel clockwise (CW).

. 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 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: 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.

. Wear eye protection at all times.

4. Use only the Molex terminals specified for crimping with this tool.

Certifi ation

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. 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 CTX150 SWS Receptacle Terminals

Doc No: ATS-6 82 4700 Release Date: 08-26-1 UNCONTROLLED COPY Page 7 of 7

Revision: A Revision Date: 08-26-1

RATCHET

RELEASE LEVER

Figure

PARTS LIST

Item Number

Order Num

ber

Des ription

Quantity

REF

6 8

Hand Crimp Tool

Figure 1

6 8

Locator Assembly

6 810

0104

Spring, Return

6 810

0105

Spring, Ratchet

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

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