0638112100

Hand Crimp Tool for “Sabre™ Crimp Terminals HAND CRIMP TOOL SPECIFICATION SHEET Order No. 63811-2100 FEATURES



TYPE 4C 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 This tool is IPC/WHMA-A-620 Class 2 and RoHS compliant SCOPE Products: Sabre™ Male Crimp Terminal 14-18 or Double 18 AWG wires placed vertically. Terminal Order No. Wire Size Insulation Diameter
Available in Reel form only AWG mm² mm in 3.03-4.57 .119-.180 43178-2001 43178-2002 14-18 2.00-0.80 43178-6001 43178-6002 (2) 18 (2) 0.80 (2) 2.79 Max. (2).110 Max.
Follow the Cut-Off Tab specifications on Applicator specification sheets. Terminal Series No. 43178 DEFINITION OF TERMS Strip Length mm in 3.96-5.54 .156-.218 3.96-5.54 .156-.218 STRIP LENGTH CONDUCTOR CRIMP HEIGHT BRUSH BELL MOUTH BEND UP ROLLING CUT-OFF TAB TWISTING INSULATION CRIMP CONDUCTOR CRIMP BEND DOWN SEAM Doc No. ATS-638112100 Revision: F Release Date: 12-26-00 Revision Date: 05-03-10 UNCONTROLLED COPY Page 1 of 6 Hand Crimp Tool for “Sabre™ Crimp Terminals CONDITIONS: After crimping, the crimp profiles should measure the following (see notes on page 3). Terminal Series No. AWG 14 16 18
(2) 18 43178 Punch Width (Ref) Conductor Crimp Height (Ref) Conductor Insulation mm2 mm In. mm In. mm In. 2.00 1.76-1.86 .069-.073 3.40 .134 4.80 .189 1.35 1.66-1.76 .065-.069 3.40 .134 4.80 .189 0.80 1.66-1.76 .065-.069 3.40 .134 4.80 .189 (2) 0.80 1.76-1.86 .069-.073 3.40 .134 4.80 .189
Wires should be placed vertically for double crimp. Wire Size Pull Force Minimum N Lb. 222.4 50.00 133.5 30.00 89.0 20.00 89.0 20.00 Profile A B X C X X X OPERATION CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects as damage can occur to the tool or die. 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 1. 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 2. TERMINAL SWING OPEN PUSH HERE TO OPEN WIRE STOP LOCATOR LOCATOR TERMINAL IN PLACE Figure 1 3. Press down on the wire stop on the locator as shown in Figure 2. 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. Doc No. ATS-638112100 Revision: F Release Date: 12-26-00 Revision Date: 05-03-10 UNCONTROLLED COPY Page 2 of 6 Hand Crimp Tool for “Sabre™ Crimp Terminals HANDLE OPEN WIRE AGAINST WIRE STOP TERMINAL WIRE IN TERMINAL JAWS PARTIALLY CLOSED LOCATOR CLOSED PUSH HERE TO OPEN WIRE STOP Figure 2 Figure 3 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 3 and 4. 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. CONDUCTOR PUNCH INSULATION PUNCH WIRES AGAINST LOCATOR STOP LOCATOR WIRE TERMINAL Note: Figure 4 CONDUCTOR ANVIL INSULATION ANVIL 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. Doc No. ATS-638112100 Revision: F Release Date: 12-26-00 Revision Date: 05-03-10 UNCONTROLLED COPY Page 3 of 6 Hand Crimp Tool for “Sabre™ Crimp Terminals 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. 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. See Figure.5. 4. Replace it with the proper locator by putting over the brass pivot shaft and snapping it into place. LIFT UP ON THE LOCATOR PRESS DOWN ON THE BRASS PIVOT SHAFT SWING LOCATOR OPEN Maintenance It is recommended that each operator of the tool be made aware of, and responsible for, the following maintenance steps: Figure 5 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 was engineered for durability but like any equipment it needs cleaning and lubrication for a maximum service life of trouble free crimping. Use light oil (30 weight automotive oil), at all the oil points, every 5,000 crimps or 3 months. This will significantly enhance the tool life. See Figure 6. 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. Miscrimps or Jams (See Figure 7) 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 7. LUBRICATION POINTS (BOTH SIDES) LIGHT OIL (EVERY 3 MONTHS OR 5,000 CRIMPS) 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 Figure 6 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. Doc No. ATS-638112100 Revision: F Release Date: 12-26-00 Revision Date: 05-03-10 UNCONTROLLED COPY Page 4 of 6 Hand Crimp Tool for “Sabre™ Crimp Terminals 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 prototyping 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 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-638112100 Revision: F Release Date: 12-26-00 Revision Date: 05-03-10 UNCONTROLLED COPY Page 5 of 6 Hand Crimp Tool for “Sabre™ Crimp Terminals PARTS LIST Item Number 1 2 3 Order Number 63810-1000 63811-2170 63811-5573 Description Frame Tool Kit with Locator Assembly Locator Base Quantity 1 1 1 M4 X 8mm LONG BHCS RATCHET RELEASE SCREW 3 2 1 M4 X 10mm LONG BHCS Figure 7 M4 X 18mm LONG BHCS 2 Americas Headquarters Lisle, Illinois 60532 U.S.A. 1-800-78MOLEX amerinfo@molex.com Far East North Headquarters Yamato, Kanagawa, Japan 81-462-65-2324 feninfo@molex.com Far East South Headquarters Jurong, Singapore 65-6-268-6868 fesinfo@molex.com European Headquarters Munich, Germany 49-89-413092-0 eurinfo@molex.com Corporate Headquarters 2222 Wellington Ct. Lisle, IL 60532 U.S.A. 630-969-4550 Fax: 630-969-1352 Visit our Web site at http://www.molex.com Doc No. ATS-638112100 Revision: F Release Date: 12-26-00 Revision Date: 05-03-10 UNCONTROLLED COPY Page 6 of 6