Molex 63811-7200 Bedienungsanleitung

Tool Kit for Sabre™ Flat Blade Crimp Terminal

Doc No: ATS-6381172HM Release Date: 02-12-07 UNCONTROLLED COPY Page 1 of 7

Revision: D Revision Date: 06-30-23

INSULATION CRIMP

▲SEE NOTE

BRUSH

STRIP LENGTH

BELL MOUTH

CONDUCTOR

CRIMP HEIGHT

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP

TWISTING

CUT-OFF TAB

SEAM

Order No.

63811-7200

Application Tooling

Specification Sheet

FEATURES

A full cycle ratcheting hand tool ensures complete crimps

Ergonomic soft grip handles for comfortable crimping

Right- and left-handed applications

Easy handling due to outstanding force ratio

A precision user-friendly terminal locator with wire stop that holds terminals in the proper crimping position

This tool is IPC/WHMA-A-620 compliant

Tooling can be installed in the 63816-1915 Power Crimp Head, which is installed into the 63816-0270 (110 V) or

63816-0280 (220 V) Battery Powered Tools and the 63816-1900 Electric Crimp Machine

This tool is RoHS compliant; however, RoHS compliance is not required

SCOPE

Products: Sabre™ Flat Blade Crimp Terminal, 14-18 AWG.

Terminal

Series No.

Terminal Order No.

Wire Size

Insulation Diameter

Strip Length

Available in Reel form only

AWG

mm²

43178

43178-1001

43178-1003

43178-5002

0.80

2.36-3.56

.093-.140

3.96-5.54

.156-.218

43178-1002

43178-5001

43178-5003

43374

43374-0001

14-18

2.00-0.80

2.36-3.56

.093-.140

3.96-5.54

.156-.218

43375

43375-0001

14-18

2.00-0.80

2.36-3.56

.093-.140

3.96-5.54

.156-.218

Customer to cut off terminal from reel: 0.30mm (.012”) maximum Cut-Off Tab.

See Conditions on Page 2.

DEFINITION OF TERMS

TYPE 4C

Tool Kit for Sabre™ Flat Blade Crimp Terminal

Doc No: ATS-6381172HM Release Date: 02-12-07 UNCONTROLLED COPY Page 2 of 7

Revision: D Revision Date: 06-30-23

▲Insulation Crimp Note:

Due to the terminal’s insulation grip design

and/or insulation diameter range, this tool

uses “overlap” form geometry in the

insulation punch. This produces an overlap

insulation crimp (A620 –compliant). While

the insulation punch profile may appear

“lopsided”, this is a normal condition for this

tool. See figure to the right. (Some tools with

multiple crimp pockets may not have the

“overlap” profile on all pockets).

CONDITIONS:

After crimping, the conductor profiles should

measure the following (See notes below).

Terminal Series No.

Wire Size

Conductor

Pull Force

Minimum

Profile

Crimp Height (Ref)

Crimp Width (Ref)

AWG

mm2

In.

Lb.

43178

0.80

1.78-1.88

.070-.074

3.20

.126

88.9

20.0

43374

2.09

1.65-1.75

.065-.069

2.50

.098

222.4

50.0

1.33

1.38-1.48

.054-.058

2.50

.098

133.4

30.0

0.82

1.35-1.43

.053-.056

2.50

.098

88.9

20.0

43375

2.09

1.65-1.75

.065-.069

2.50

.098

222.4

50.0

1.33

1.38-1.48

.054-.058

2.50

.098

133.4

30.0

0.82

1.35-1.43

.053-.056

2.50

.098

88.9

20.0

To Achieve IPC-A-620 Crimps, the following over-all wire insulation diameter ranges are recommended:

1. Profile A: 2.36-3.56mm (.093-.140 inch)

2. Profile B: 2.79-3.56mm (.110-.140 inch)

3. Profile C: 2.36-3.14mm (.093-.124 inch)

Tool Qualification Notes

1. (Ref) means that the dimension provided is approximate because of the wide range of wires, conductor

stranding, insulation diameter and insulation hardness.

2. An occasional conductor crimp height measurement should be performed, and it should be used as the final

criterion for an acceptable crimp. It must lie between the minimum and maximum crimp height specification.

Refer to Molex Quality Crimping Handbook 63800-0029 for additional information on crimping and crimp

testing.

3. In addition, an occasional pull force test may be performed. It must exceed the minimum pull force

specification. Pull force should be measured with no influence from the insulation crimp. To ensure this, strip

the wire long enough so the terminal insulation grips do not contact the wire insulation.

OVERLAP

INSULATION

CRIMP

OVERLAP FORM GEOMETRY

ANVIL

PUNCH

WIRE

Tool Kit for Sabre™ Flat Blade Crimp Terminal

Doc No: ATS-6381172HM Release Date: 02-12-07 UNCONTROLLED COPY Page 3 of 7

Revision: D Revision Date: 06-30-23

ANVILS

POWER

CRIMP

HEAD

Figure 1

PUNCHES

M4 X 10 LONG

BHCS

M4 X 18 LONG

BHCS

SWING

LOCATOR

OPEN

PRESS DOWN

ON THE BRASS

PIVOT SHAFT

LIFT UP ON

THE LOCATOR

Figure 2

SWING OPEN

TERMINAL

PUSH HERE TO

OPEN WIRE STOP

LOCATOR

TERMINAL IN PLACE

Figure 3

Notes

1. This tool should only be used for the terminals and wire gauges specified on this document.

2. Variations in tools, terminals, wire stranding and insulation types may affect crimp height.

3. This tool is intended for the conductor sizes specified on this document. It may not give good insulation crimp

support for insulation sizes outside of the specified range.

4. Molex does not repair hand tools. See warranty on page 5. The replacement parts listed are the only parts

available for repair. If the handles or crimp tooling become damaged or worn, a new tool must be purchased.

CAUTION: Crimp 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:

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.

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.

To remove the locator

1. Open the crimp hand tool.

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.

Tool Kit for Sabre™ Flat Blade Crimp Terminal

Doc No: ATS-6381172HM Release Date: 02-12-07 UNCONTROLLED COPY Page 4 of 7

Revision: D Revision Date: 06-30-23

TERMINAL

Figure 6

WIRE IN TERMINAL

JAWS

PARTIALLY

CLOSED

WIRE AGAINST

WIRE STOP

HANDLE

OPEN

LOCATOR

CLOSED

Figure 5

PUSH HERE TO

OPEN WIRE STOP

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.

Crimping Terminals

1. Select the desired terminal listed in the preceding

charts.

2. Swing the terminal locator away from the crimp tool

shown in Figure 3. Some terminals with large

insulation grips may interfere with the crimp tooling

when swinging the locator into position. The terminal

must then be loaded into the locator in the closed

crimp position. See Figure 4.

3. Press down on the wire stop on the locator as shown

in Figure 5. Insert the proper terminal into the proper

nest opening. Make sure when choosing the nest

opening, it will correspond with the A, B, or C profile

on the hand tool. See Figure 4.

4. Return the locator to its original position.

5. Insert the proper wire over the terminal. Gently touch the wire stop with the end of the wire.

See Figure 5 and 6.

6. Compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.

Release handles to open the jaws.

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

7. Remove the crimped terminal from the terminal locator by pressing down on the wire stop and gently pulling on

the wire. The terminal locator can be in either position.

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

Figure 4

WIRE

INSULATION

PUNCH

CONDUCTOR ANVIL

LOCATOR

INSULATION

ANVIL

WIRES AGAINST

LOCATOR STOP

CONDUCTOR

PUNCH

TERMINAL

Tool Kit for Sabre™ Flat Blade Crimp Terminal

Doc No: ATS-6381172HM Release Date: 02-12-07 UNCONTROLLED COPY Page 5 of 7

Revision: D Revision Date: 06-30-23

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. The terminal locator can be

in either position.

3. Visually inspect the crimped terminal

for proper crimp location.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 in the tool head are

protected with a thin coat of high quality machine oil. Do not oil excessively. This tool was engineered for

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 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 rotating the small slotted screw marked with an arrow. See Figure 11.

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: Repetitive use of this tool should be avoided.

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: Molex crimp specifications are valid only when used with Molex terminals and tooling.

LUBRICATION

POINTS

(BOTH SIDES)

LIGHT OIL

(EVERY MONTH

5,000 CRIMPS)

Figure 7A

Figure 7B

Tool Kit for Sabre™ Flat Blade Crimp Terminal

Doc No: ATS-6381172HM Release Date: 02-12-07 UNCONTROLLED COPY Page 6 of 7

Revision: D Revision Date: 06-30-23

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 or determine tool life:

1. When the hand tool is no longer capable of achieving minimum conductor crimp height, it should be taken out of

service and replaced.

2. The tool frame is very difficult to disassemble and reassemble. Customer repair is not recommended.

APPLICATIONS FOR THE POWER CRIMP HEAD

The chart below shows all applications for this Power Crimp Head:

Tool Order No.

Tool Description

Crimp Head

Order No.

Crimp Head

Description

Figure No.

63811-7200

Hand Crimp Tool

---

63816-0270

Battery Power Tool (110 V)

63816-1915

Power Crimp Head

63816-0280

Battery Power Tool (220 V)

63816-1915

Power Crimp Head

63816-1900

Electric Crimp Machine

63816-1915

Power Crimp Head

Crimp Tooling Applications

Hand Crimp Tool

Battery Powered Tool

Electric Crimp Machine

Figure 8

Figure 9

Figure 10

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.

HAND CRIMP

FRAME

TOOL KIT

POWER

CRIMP

HEAD

LOCKING PINS

BATTERY

POWERED

TOOL

TOOL KIT

ELECTRIC CRIMP

MACHINE

POWER CRIMP

HEAD

LOCATOR

Tool Kit for Sabre™ Flat Blade Crimp Terminal

Doc No: ATS-6381172HM Release Date: 02-12-07 UNCONTROLLED COPY Page 7 of 7

Revision: D Revision Date: 06-30-23

HAND TOOL PARTS LIST

Item Number

Order Number

Description

Quantity

REF

63811-7200

Hand Crimp Tool

Figure 11

---

Hand Crimp Frame

---

Tool Kit

63811-5573

Locator Base

63811-7275

Locator

Application Tooling Support

E-Mail: [email protected]

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.

RATCHET

RELEASE SCREW

Figure 11

M4 X 8mm

LONG BHCS

M4 X 18mm

LONG BHCS

M4 X 10mm

LONG BHCS

LOCATOR

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