hand crimp tool for sabre male flat blade crimp ter minals doc no: ats-6382331hm release date: 06-25-10 uncontrolled copy page 1 of 7 revision: a revision date: 06-25-10 modular crimp head order no. 63823-3170 application tooling specification sheet hand crimp tool order no. 63823-3100 features % a full cycle ratcheting hand tool ensures complete crimps % ergonomically designed soft handles % precisely designed crimping profiles with simple co ntact positioning % easy handling due to outstanding force ratio % modular crimp head is removable and can be use in t he air powered tool order no.63816-0100, accompanied by air powered crimp adapter (order no. 63816-0700). % can also be used in the battery powered tool order no.63816-0200 (110 v) or 63816-0250 (220 v) accompanied by battery powered crimp adapter (order no. 63816-0600). scope products : sabre male flat blade crimp terminals, (2) 18 awg (ul1015), and (2) 20 awg (ul1015) wire stacked vertically. insulation diameter wire size and type ipc/whma-a620 terminal strip length terminal series no. terminal order no. awg mm2 type mm in. mm in. mm in. (2) 18 (2) 0.80 ul1015 2.85 .112 2.85 .112 43178 43178-2001 43178-2002 43178-6001 43178-6002 (2) 20 (2) 0.50 ul1015 2.54 .100 2.54 .100 3.96-5.54 .156-.218 to achieve optimum ipc-a620 insulation crimps, use this insulation od range. overall insulation od specification for terminal. customer to cut off terminal from reel: 0.50mm (.01 9) maximum cut-off tab. type 4a
hand crimp tool for sabre male flat blade crimp ter minals doc no: ats-6382331hm release date: 06-25-10 uncontrolled copy page 2 of 7 revision: a revision date: 06-25-10 insulation crimp brush strip length bell mouth conductor crimp height bend down bend up rolling conductor crimp twisting cut-off tab seam wires side by side no yes wires vertically stacked wires vertically stacked terminal wires side by side terminal definition of terms wire feeding orientation this hand tool was developed for (2) 18 awg ul 1015 or (2) 20 awg ul 1015 wires in a vertically stacked orientation. see the following illustrations below .
hand crimp tool for sabre male flat blade crimp ter minals doc no: ats-6382331hm release date: 06-25-10 uncontrolled copy page 3 of 7 revision: a revision date: 06-25-10 wire insulation punch terminal wire stop blade figure 1 crimp specification bell mouth conductor brush max. terminal series no. mm in. mm in. 43178 0.25-1.00 .010-.039 1.50 .059 bend up bend down twist roll terminal series no. degree degree 43178 3 3 4 8 seam seam shall not be open and no wire allowed out of the crimping area after crimping, the conductor profile should measur e the following. conductor crimp wire size height width pull force minimum profile terminal series no. awg mm 2 mm in. mm in. n lb. 2x18 2x20 18 (2) 0.80 (2) 1.75-1.85 .069-.073 3.40-3.50 .134- .138 88.9 20.0 x 43178 20 (2) 0.50 (2) 1.65-1.75 .065-.069 3.40-3.50 .134- .138 57.9 13.0 x insulation crimp wire size height (ref) width terminal series no. awg mm 2 mm in. mm in. 18 (2) 0.80 (2) 4.75-4.95 .187-.195 3.60-3.80 .142- .150 43178 20 (2) 0.50 (2) 4.60-4.80 .181-.189 3.60-3.80 .142- .150 pull force should be measured with no influence fro m the insulation crimp. the above specifications are guidelines to an optim um crimp. 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. place the terminal into the correct die profile unt il the terminal stopped by the locator. 2. bring the wire stop blade down, make sure the wire stop located behind the conductor grip. 3. place a pre-striped wire into the terminal until th e end of wire touching the wire stop. see figure 2. 4. close the tool until the ratchet releases, the tool handles will then spring open. 5. carefully remove the crimped terminal. note: the tamper proof ratchet action will not release t he tool until it has been fully closed.
hand crimp tool for sabre male flat blade crimp ter minals doc no: ats-6382331hm release date: 06-25-10 uncontrolled copy page 4 of 7 revision: a revision date: 06-25-10 maintenance it is recommended that each operator of the tool be made aware of, and responsible for, the following mainte nance 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 sur faces are protected with a thin coat of high quality machine oil. do not oil excessively. the tool was engineered for d urability but like any other equipment it needs cleaning and lubrication for a maximum service life of trouble f ree 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 c rimping area. oil transferred from the crimping area onto certain terminations may affect the electrical char acteristics of an application. 5. when tool is not in use, keep the handles closed to prevent objects from becoming lodged in the crimpi ng dies, and store the tool in a clean, dry area. miscrimps or jams should this tool ever become stuck or jammed in a p artially closed position, do not force the handles open or closed . the tool will open easily by lifting the ratchet release lever. see figure 6. warranty this tool is for electrical terminal crimping purpo ses only. this tool is made of the best quality ma terials. all vital components are long life tested. all tools are war ranted to be free of manufacturing defects for a pe riod of 30 days. should such a defect occur, we will repair o r exchange the tool free of charge. this repair or exchange will not be applicable to altered, misused, or damaged t ools. this tool is designed for hand use only. an y clamping, fixturing, or use of handle extensions voids this w arranty. caution: repetitive use of this tool should be avoided. cautions: 1. manually powered hand tools are intended for low vo lume 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. figure 2 wires terminal locator insulation punch insulation anvil wire stop blade conductor anvil conductor punch
hand crimp tool for sabre male flat blade crimp ter minals doc no: ats-6382331hm release date: 06-25-10 uncontrolled copy page 5 of 7 revision: a revision date: 06-25-10 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, howev er crimp force is adjustable (see instructions abov e). 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 a good insulation crimp support f or all insulation sizes. 4. molex does not repair hand tools (see warranty abov e) the replacement parts listed are the only parts available for repair. if the handles or crimp tool ing is damaged or worn, a new tool must be purchase d. 5. pull force should be used as the final criteria for an acceptable crimp. pull force is measured with no influence from the insulation crimp. the insulatio n should be stripped long (1/2 in.) so the insulati on 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 c rimping and crimp testing. 6. molex does not certify crimp hand tools. caution : molex crimp specifications are valid only when u sed with molex terminals and tooling.
hand crimp tool for sabre male flat blade crimp ter minals doc no: ats-6382331hm release date: 06-25-10 uncontrolled copy page 6 of 7 revision: a revision date: 06-25-10 modular crimp head battery power crimp adapter locking pins locking pins battery powered tool air power tool modular crimp head locking pins locking pins air power crimp adapter applications for the modular crimp head warning : never operate, service, install, or adjust this modular c rimp head without proper instruction and without first reading and understanding the ins tructions in the proper manual or specification she et. see chart below for the correct manual or specifica tion sheet. warning : never install tooling or service this tool while it is in to any power source. disconnect the power by unplugging or turn off the actuator from i ts power source. caution: keep fingers away from the crimping area when opera ting this tool. it may cause severe injury. caution: wear safety glasses when operating or serving this tool. the chart below shows all applications for this mod ular crimp head. modular crimp head order no. tool order no. tool description adapter order no. adapter description figure no. 63816-0000 hand crimp frame (short) n/a n/a 3 63816-0050 hand crimp frame (long) n/a n/a 3 63816-0200 battery power tool (110 v) 63816-0600 battery power crimp adapter 4 63816-0250 battery power tool (220 v) 63816-0600 battery power crimp adapter 4 63823-3170 63816-0100 air power tool 63816-0700 air power crimp adapter 5 applications for the modular crimp head hand crimp tool battery powered tool air powered to ol figure 3 figure 4 figure 5 modular crimp head locking pins hand crimp frame long or short
hand crimp tool for sabre male flat blade crimp ter minals doc no: ats-6382331hm release date: 06-25-10 uncontrolled copy page 7 of 7 revision: a revision date: 06-25-10 ratchet release lever handle spring crimping spring (2) 3 6 4 figure 6 m4 x 14mm long bhcs 2 5 1 parts list hand crimp tool 63823-3100 item order number description quantity 1 63823-3170 modular crimp head 1 (ref) 2 63816-0050 hand crimp frame (long) 1 (ref) 3 63823-3175 locator 1 4 63816-0001 locking pin 2 5 63600-0525 handle spring 1 6 63600-0520 crimping spring 2 http://www.molex.com
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