Hand Crimp Tool for CTX50 (Unsealed) Receptacle Terminals
Order No. 63828-2000
Application Tooling Specification
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
Selected crimping die is always centered in the tool for maximum crimp accuracy
Type 4G
SCOPE
Products:
CTX50 Unsealed Receptacle Terminals
Terminal Terminal Order
No.
Series No.
560023-0444
560023-0445
560023-0421
560023-0423
560023-0448
560023-0450
560023-0548
560023-0550
Wire Type
Type
FLCUSNO3RY
CHFUS
FLR2XAZ3H
FLR13Y-A
A3Z
Wire Size
mm²
0.13
0.22
Insulation Diameter
mm
0.75-1.05
0.95-1.20
In.
.029-.041
.037-.047
Strip Length
mm (Ref.)
3.6
2.9
In. (Ref.)
.142
.114
560023
0.35
1.10-1.40
.043-.055
3.1
.122
Doc. No: ATS-638282000 Release Date: 11-15-17
Revision: A
Revision Date: 11-15-17
UNCONTROLLED COPY
Page 1 of 6
Hand Crimp Tool for CTX50 (Unsealed) Receptacle Terminals
DEFINITION OF TERMS
BEND UP
CONDUCTOR
CRIMP
STRIP
LENGTH
INSUL CRIMP
BELL
MOUTH
ROLLING
SEAM
TWISTING
BEND
DOWN
BRUSH
CUT-OFF
TAB
CRIMP HEIGHT
CRIMP SPECIFICATIONS
Terminal
560023-0444
560023-0445
560023-0421
560023-0423
560023-0448
560023-0450
560023-0548
560023-0550
Bell Mouth (Rear Only)
mm
In.
0.12-0.32
0.40-0.60
.005-.013
.016-.024
*Conductor
Brush
mm
In.
0.55 Max
0.55 Max
.021 Max
.021 Max
Bend Up Bend Down
Degree (Max)
1
1
1
1
Twist
Roll
Degree (Max)
2
2
N/A
N/A
0.65-0.75
.026-.030
0.55 Max
.021 Max
1
1
2
N/A
*Brush
is not to extend above the conductor crimp transition area.
After crimping, the crimp profiles must measure the following (see notes on page 5):
Terminal
560023-0444
560023-0445
560023-0421
560023-0423
560023-0448
560023-0450
560023-0458
560023-0550
Wire
Size
mm
2
0.13
Conductor
Crimp Height
Crimp Width
mm
In.
mm
In.
0.50-0.56 .019-.022 0.80-0.86 .031-.034
Insulation
Crimp Height
Crimp Width
mm
In.
mm
In.
1.15-1.25
.045-.049 1.05-1.15
.041-.045
Pull Force
Tool Position
Minimum
N
0.13
0.35 0.22
50
X
0.22
0.66-0.72 .026-.028 1.01-1.07 .040-.042
1.20-1.30
.047-.051 1.10-1.20
.043-.047
40
X
0.35
0.65-0.69 .025-.027 1.01-1.07 .040-.042
1.48-1.58
.058-.062 1.30-1.40
.051-.055
50
X
Doc. No: ATS-638282000 Release Date: 11-15-17
Revision: A
Revision Date: 11-15-17
UNCONTROLLED COPY
Page 2 of 6
Hand Crimp Tool for CTX50 (Unsealed) Receptacle Terminals
OPERATION
Changing Crimp Dies
CAUTION:
Please pay attention to these instructions.
1. Swing out the contact locator. See Figure 1.
2. Pull up on the locking bolt, and hold it in the up position. See Figure 2.
3. Move the slide to the right or the left until the desired crimp nest is
identified in the window. See Figures 2 and 3.
4. Release the locking bolt and make sure it is locked into position (down).
•
CAUTION:
Always be sure that the locator is hinged open before
moving the slide to a new position.
CAUTION:
Only crimp the Molex terminals listed above with this tool. Do not crimp
hardened objects because damage can occur to the tool or die.
LOCATOR
Figure 1
LOCKING
BOLT
CRIMP NEST
IDENTIFICATION
WINDOW
LOCKING
BOLT
Figure 2
Figure 3
Tool 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.
WIRE STOP
HAND TOOL
OPEN
SWING
LOCATOR
OPEN
TERMINAL
ANVIL
Figure 4
TERMINAL
SEATED IN
LOCATOR
WIRE
Figure 5
Doc. No: ATS-638282000 Release Date: 11-15-17
Revision: A
Revision Date: 11-15-17
UNCONTROLLED COPY
Page 3 of 6
Hand Crimp Tool for CTX50 (Unsealed) Receptacle Terminals
Crimping Terminals
1. With the hand tool in the open position, pivot the
terminal locator open by pulling up on the locator
knob.
2. Push down on the wire stop release to raise the
wire stop. See Figure 6. Insert the terminal into
the profile until the terminal is fully seated and
stops.
3. Gently pivot the locator closed.
PUSH DOWN
WIRE STOP
RELEASE
WIRE STOP
LOCATOR
4. Slide the pre-stripped wire into the terminal;
make sure to aim the wire brush toward the tip
point on the wire stop. See Figure 5. Align the
wire so that it is parallel and sitting into the
terminal. Maintain a light and constant pressure
Figure 6
on the wire that is seated in the terminal at all
times. (Do not let go of the wire.) Be sure to hold the wire and terminal in place until the
terminal is fully crimped. See Figure 7.
5. Close the tool until the ratchet releases.
6. Push down on the wire stop release to raise
the wire stop.
7. Carefully remove the crimped terminal.
CONDUCTOR
PUNCH
WIRE STOP
LOCATOR
INSULATION
PUNCH
WIRE
Note:
To maintain a good brush control and a
consistent bell mouth, the crimping instructions
must be followed.
TERMINAL
Figure 7
CONDUCTOR
ANVIL
INSULATION
ANVIL
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 a 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 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 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.
Doc. No: ATS-638282000 Release Date: 11-15-17
Revision: A
Revision Date: 11-15-17
UNCONTROLLED COPY
Page 4 of 6
Hand Crimp Tool for CTX50 (Unsealed) Receptacle Terminals
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
8.
RATCHET
RELEASE LEVER
WARRANTY
Figure 8
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:
Repetitive use of this tool should be avoided.
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.
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. Variations in tools, terminals, wire stranding and
insulation types may affect crimp height.
3. This tool is intended for standard conductor sizes. It may not give 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 are damaged or worn, a new tool
must be purchased.
5. Pull force should be used as the final criterion 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 63800-0029 for additional information on crimping and crimp
testing.
6. Molex does not certify crimp hand tools.
CAUTION:
Molex crimp specifications are valid only when used with Molex terminals and tooling.
Doc. No: ATS-638282000 Release Date: 11-15-17
Revision: A
Revision Date: 11-15-17
UNCONTROLLED COPY
Page 5 of 6
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