Hand Crimp Tool for Sabre Female Flat Blade Crimp Terminals Application Tooling Specification Sheet Modular Crimp Head Order No. 63823-2870 TYPE 4A Hand Crimp Tool Order No. 63823-2800 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 Modular Crimp Head is removable and can be use in the 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 Female Flat Blade Crimp Terminals, 18-20 AWG, UL1056 and SPT-3 wires. Wire Size and Type Insulation Diameter Strip Length AWG mm² Type mm In. mm In. 18 0.80 UL1056 4.27 Max .168 Max 43375-3001 20 0.50 UL1056 3.98 Min .157 Min 3.96-5.54 .156-.218 18 0.80 SPT-3 4.57 Max .180 Max Insulation crimp to meet IPC/WHMA-A-620 Class 2 compliance. Note: Terminal will accommodate the UL1056 and SPT-3 wires. For UL1015 wires use Hand Tool 63823-2700. SPT-3 wire is only available in 18 AWG. Customer to cut off terminal from reel: 0.30mm (.012”) maximum Cut-off Tab. Terminal Series No. 43375 Doc No: ATS-6382328HM Revision: A Terminal Order No. Release Date: 08-24-10 Revision Date: 08-24-10 UNCONTROLLED COPY Page 1 of 6 Hand Crimp Tool for Sabre Female Flat Blade Crimp Terminals DEFINITION OF TERMS STRIP LENGTH CONDUCTOR CRIMP HEIGHT BRUSH BELL MOUTH CUT-OFF TAB BEND UP INSULATION CRIMP TWISTING ROLLING CONDUCTOR CRIMP BEND DOWN SEAM CRIMP SPECIFICATION Terminal Series No. 43375 Terminal Series No. Bell mouth mm In. 0.20-0.50 .008-.020 Bend up Bend down 3 Degree 3 Seam Twist Roll Degree 43375 Conductor Brush Max. mm In. 0.76 .030 4 8 Seam shall not be open and no wire allowed out of the crimping area After crimping, the conductor profile should measure the following. Wire Size Terminal Series No. 43375 AWG mm2 18 0.80 20 0.50 Conductor Crimp Height Width mm In. mm In. 1.16-1.26 .046-.050 2.00-2.10 .079-.083 1.10-1.20 .043-.047 2.00-2.10 .079-.083 Terminal Series No. 43375 Wire Size AWG mm2 18 0.80 20 0.50 Pull Force Minimum N 89.0 57.9 Lb. 20.0 13.0 Profile 18 AWG 20 AWG X X Insulation Crimp Height (Max) Width mm In. mm In. 4.20 Max .165 Max 4.80-5.00 .189-.197 3.90 Max .154 Max 4.80-5.00 .189-.197 Note: SPT-3 wire is only available in 18 AWG. Pull Force should be measured with no influence from the insulation crimp. The above specifications are guidelines to an optimum crimp. Doc No: ATS-6382328HM Revision: A Release Date: 08-24-10 Revision Date: 08-24-10 UNCONTROLLED COPY Page 2 of 6 Hand Crimp Tool for Sabre Female Flat Blade Crimp Terminals WIRE STOP BLADE OPERATION TERMINAL INSULATION PUNCH 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 until 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 the end of wire 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. Figure 1 Note: The tamper proof ratchet action will not release the tool until it has been fully closed. CONDUCTOR PUNCH Maintenance It is recommended that each operator of the tool be made aware of, and responsible for, the following maintenance steps: WIRE STOP BLADE INSULATION PUNCH 1. Remove dust, moisture, and other contaminants WIRE with a clean brush, or soft, lint free cloth. LOCATOR 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 INSULATION TERMINAL equipment it needs cleaning and lubrication for a ANVIL 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. CONDUCTOR 4. Wipe excess oil from hand tool, particularly from Figure 2 ANVIL 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 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 6. Doc No: ATS-6382328HM Revision: A Release Date: 08-24-10 Revision Date: 08-24-10 UNCONTROLLED COPY Page 3 of 6 Hand Crimp Tool for Sabre Female Flat Blade Crimp Terminals 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, 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. 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. 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; however crimp force is adjustable (See instructions above). 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 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 is damaged or worn, a new tool must be purchased. 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 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-6382328HM Revision: A Release Date: 08-24-10 Revision Date: 08-24-10 UNCONTROLLED COPY Page 4 of 6 Hand Crimp Tool for Sabre Female Flat Blade Crimp Terminals Applications for the Modular Crimp Head WARNING: NEVER operate, service, install, or adjust this Modular Crimp Head without proper instruction and without first reading and understanding the instructions in the proper Manual or Specification Sheet. See Chart below for the correct Manual or Specification Sheet. WARNING: NEVER install tooling or service this tool while it is into any power source. Disconnect the power by unplugging or turn off the Actuator from its power source. 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. The chart below shows all applications for this Modular Crimp Head. Modular Crimp Head Order No. 63823-2870 Tool Tool Adapter Adapter Figure Order no. Description Order No. Description No. N/A N/A 3 63816-0000 Hand Crimp Frame (Short) 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 63816-0100 Air Power Tool 63816-0700 Air Power Crimp Adapter 5 Hand Crimp Tool Applications for the Modular Crimp Head Battery Powered Tool MODULAR CRIMP HEAD LOCKING PINS MODULAR CRIMP HEAD LOCKING PINS HAND CRIMP FRAME LONG OR SHORT Doc No: ATS-6382328HM Revision: A LOCKING PINS AIR POWER CRIMP ADAPTER BATTERY POWERED TOOL LOCKING PINS AIR POWER TOOL Figure 4 Release Date: 08-24-10 Revision Date: 08-24-10 MODULAR CRIMP HEAD BATTERY POWER CRIMP ADAPTER LOCKING PINS Figure 3 Air Powered Tool UNCONTROLLED COPY Figure 5 Page 5 of 6 Hand Crimp Tool for Sabre Female Flat Blade Crimp Terminals PARTS LIST Hand Crimp Tool 63823-2800 Item Order Number Description Quantity 1 63823-2870 Modular Crimp Head 1 (Ref) 2 63816-0050 Hand Crimp Frame (Long) 1 (Ref) 3 63823-2875 Locator 1 4 63816-0001 Locking Pin 2 5 63600-0525 Handle Spring 1 6 63600-0520 Crimping Spring 2 5 HANDLE SPRING 2 M4 X 14mm LONG BHCS RATCHET RELEASE LEVER 3 4 1 6 CRIMPING SPRING (2) Figure 6 http://www.molex.com Doc No: ATS-6382328HM Revision: A Release Date: 08-24-10 Revision Date: 08-24-10 UNCONTROLLED COPY Page 6 of 6