molex 207129 Series User manual

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)
3. 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
OR
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 9
63816-0250 Battery Power Tool (220 V) 63816-0300 Power Crimp Head 9
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
2
1
3
M4 X 18mm
LONG BHCS
M4 X 10mm
LONG BHCS
2
4
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
1
2
2
M4 by 8 Lon
BHCS
M4 by 18 Lon
BHCS
M4 by 10 Lon
BHCS
1
POWER HEAD PARTS LIST
Item Order No En ineerin No. Description Quantity
1
63816-0300 63816-0300 Power Crimp Head 1
2
63811- 2 0 63811- 2 0 Tool Kit 1
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