Molex 207129 Series Manuale utente

Tool Kit for Sabre™ Flat Blade Crimp Terminal

Doc No: ATS-63811 2HM Release Date: 02-12-0 UNCONTROLLED COPY Page 1 of 8

Revision: C Revision Date: 09-09-10

INSULATION CRIMP

▲SEE NOTE

BRUSH

STRIP LENGTH

BELL MOUTH

CONDUCTOR

CRIMP HEIGHT

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP

TWISTING

CUT-OFF TAB

SEAM

Application Toolin

Specification Sheet

Tool Kit

Order No. 63811-7270

Hand Crimp Tool

Order No. 63811-7200

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

 Tool kits are easily installed into the Hand Crimp Tool or the 63816-0300 Power Crimp Head which is installed

into the 63816-0200 (110 V) or the 63816-0250 (220 V) Battery Powered Tool.

 Many different Tool kits can be used with a single Battery Powered Tool.

 This tool is IPC/WHMA-A-620 Class 2 and RoHS compliant.

SCOPE

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

Terminal

Series No.

Terminal Order No. Wire Size 



Insulation Diameter Strip Len th





Available in Reel form only AWG mm² mm in mm in

431 8 431 8-1001 431 8-1003 431 8-5002 18 0.80 2.36-3.56 .093-.140 3.96-5.54 .156-.218

431 8-1002 431 8-5001 431 8-5003

433 4 433 4-0001 14-18 2.00-0.80 2.36-3.56 .093-.140 3.96-5.54 .156-.218

433 5 433 5-0001 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-63811 2HM Release Date: 02-12-0 UNCONTROLLED COPY Page 2 of 8

Revision: C Revision Date: 09-09-10

▲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 Hei ht (Ref) Crimp Width (Ref)

AWG

mm2 mm In. mm In. N Lb. A B C

431 8 18 0.80 1. 8-1.88 .0 0-.0 4 3.20 .126 88.9 20.0 X

433 4

14 2.09 1.65-1. 5 .065-.069 2.50 .098 222.4 50.0 X

16 1.33 1.38-1.48 .054-.058 2.50 .098 133.4 30.0 X

18 0.82 1.35-1.43 .053-.056 2.50 .098 88.9 20.0 X

433 5

14 2.09 1.65-1. 5 .065-.069 2.50 .098 222.4 50.0 X

16 1.33 1.38-1.48 .054-.058 2.50 .098 133.4 30.0 X

18 0.82 1.35-1.43 .053-.056 2.50 .098 88.9 20.0 X

 To Achieve IPC-A-620 Class 2 Crimps, the followin over-all wire insulation diameter ran es are recommended:

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

2. Profile B: 2. 9-3.56mm (.110-.140 inch)

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

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.

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, 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.

CAUTION: Install 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.

OVERLAP

INSULATION

CRIMP

OVERLAP FORM GEOMETRY

ANVIL

PUNCH

WIRE

Tool Kit for Sabre™ Flat Blade Crimp Terminal

Doc No: ATS-63811 2HM Release Date: 02-12-0 UNCONTROLLED COPY Page 3 of 8

Revision: C Revision Date: 09-09-10

ANVILS

POWER

CRIMP

HEAD

Fi ure 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

Fi ure 2

SWING OPEN

TERMINAL

PUSH HERE TO

OPEN WIRE STOP

LOCATOR

LOCATOR TERMINAL IN PLACE

Fi ure 3

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.

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.

Tool Kit for Sabre™ Flat Blade Crimp Terminal

Doc No: ATS-63811 2HM Release Date: 02-12-0 UNCONTROLLED COPY Page 4 of 8

Revision: C Revision Date: 09-09-10

TERMINAL

Fi ure 6

WIRE IN TERMINAL

JAWS

PARTIALLY

CLOSED

WIRE AGAINST

WIRE STOP

HANDLE

OPEN

LOCATOR

CLOSED

Fi ure 5

PUSH HERE TO

OPEN WIRE STOP

Crimpin 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.

. 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.

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.

Fi ure 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-63811 2HM Release Date: 02-12-0 UNCONTROLLED COPY Page 5 of 8

Revision: C Revision Date: 09-09-10

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 A or B 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 Fi ure 10)

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 10.

Warranty

This tool kit is for electrical terminal crimping purposes only. This tool kit 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, we will repair or exchange the tool kit free of charge. This repair or exchange

will not be applicable to altered, misused, or damaged tools.

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.

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 commercial grade hand tools but rather supplies the following guidelines for

customers to re-certify hand tools.

LUBRICATION

POINTS

(BOTH SIDES)

LIGHT OIL

(EVERY MONTH

5,000 CRIMPS)

Fi ure 7A

Fi ure 7B

Tool Kit for Sabre™ Flat Blade Crimp Terminal

Doc No: ATS-63811 2HM Release Date: 02-12-0 UNCONTROLLED COPY Page 6 of 8

Revision: C Revision Date: 09-09-10

% This tool is qualified to pull force only. To re-certify, crimp a terminal to a wire, which has been stripped

12. mm (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.

The chart below shows all applications for this Tool Kit.

Tool Kit

Order No.

Tool

Order no.

Tool

Description

Power Head

Order No.

Adapter

Description

Fi ure

No.

63811- 2 0

63810-1050

Hand Crimp Frame (Short) N/A N/A 8

63810-1000

Hand Crimp Frame (Long) N/A N/A 8

63816-0200

Battery Power Tool (110 V)

63816-0300 Power Crimp Head

63816-0250

Battery Power Tool (220 V)

63816-0300 Power Crimp Head

Applications for the Tool Kit

Hand Crimp Tool Battery Powered Tool

Fi ure 8 Fi ure 9

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.

POWER

CRIMP

HEAD

LOCKING PINS

BATTERY

POWERED

TOOL

TOOLING KIT

HAND CRIMP

FRAME LONG

AND SHORT

TOOLING KIT

Tool Kit for Sabre™ Flat Blade Crimp Terminal

Doc No: ATS-63811 2HM Release Date: 02-12-0 UNCONTROLLED COPY Page of 8

Revision: C Revision Date: 09-09-10

RATCHET

RELEASE SCREW

Fi ure 10

M4 X 8mm

LONG BHCS

M4 X 18mm

LONG BHCS

M4 X 10mm

LONG BHCS

WITH TOOL KIT

LOCATOR ONLY

HAND TOOL PARTS LIST

Item Number Order Number Description Quantity

1 63810-1000 Hand Crimp Frame (Long) 1

2 63811- 2 0 Tool Kit with Locator 1

3 63811-55 3 Locator Base 1

4 63811- 2 5 Locator (only) REF

Tool Kit for Sabre™ Flat Blade Crimp Terminal

Doc No: ATS-63811 2HM Release Date: 02-12-0 UNCONTROLLED COPY Page 8 of 8

Revision: C Revision Date: 09-09-10

Fi ure 11

M4 by 8 Lon

BHCS

M4 by 18 Lon

BHCS

M4 by 10 Lon

BHCS

POWER HEAD PARTS LIST

Item Order No En ineerin No. Description Quantity

63816-0300 63816-0300 Power Crimp Head 1

63811- 2 0 63811- 2 0 Tool Kit 1

http://www.molex.com

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