molex 43178 Series User manual

Hand Crimp Tool for “Sabre™ Crimp Terminals
Doc No. ATS-6381121 Release Date: 12-26- UNCONTROLLED COPY Page 1 of 6
Revision: F Revision Date: 5- 3-1
INSULATION CRIMP
BRUSH
STRIP LENGTH
BELL MOUTH
CONDUCTOR
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR CRIMP
TWISTING
CUT-OFF TAB
SEAM
HAND CRIMP TOOL
SPECIFICATION SHEET
Order No. 63811- 100
FEATURES
 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-62 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 Strip Length
Terminal Series No. Available in Reel form only AWG mm² mm in mm in
14-18 2. - .8 3. 3-4.57 .119-.18 3.96-5.54 .156-.218
43178 43178-2 1
43178-6 1
43178-2 2
43178-6 2 (2) 18 (2) .8 (2) 2.79 Max. (2).11 Max. 3.96-5.54 .156-.218
Follow the Cut-Off Tab specifications on Applicator specification sheets.
DEFINITION OF TERMS
TYPE 4C

Hand Crimp Tool for “Sabre™ Crimp Terminals
Doc No. ATS-6381121 Release Date: 12-26- UNCONTROLLED COPY Page 2 of 6
Revision: F Revision Date: 5- 3-1
SWING OPEN
TERMINAL
PUSH HERE TO
OPEN WIRE STOP
LOCATOR
LOCATOR TERMINAL IN PLACE
Figure 1
CONDITIONS:
After crimping, the crimp profiles should measure the following (see notes on page 3).
Punch Width (Ref)
Wire Size Conductor Crimp
Height (Ref) Conductor Insulation
Pull Force
Minimum Profile
Terminal Series No.
AWG mm mm In. mm In. mm In. N Lb. A B C
14 2. 1.76-1.86 . 69-. 73 3.4 .134 4.8 .189 222.4 5 . X
16 1.35 1.66-1.76 . 65-. 69 3.4 .134 4.8 .189 133.5 3 . X
18 .8 1.66-1.76 . 65-. 69 3.4 .134 4.8 .189 89. 2 . X
43178
(2) 18 (2) .8 1.76-1.86 . 69-. 73 3.4 .134 4.8 .189 89. 2 . X
 Wires should be placed vertically for double crimp.
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.
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.

Hand Crimp Tool for “Sabre™ Crimp Terminals
Doc No. ATS-6381121 Release Date: 12-26- UNCONTROLLED COPY Page 3 of 6
Revision: F Revision Date: 5- 3-1
Figure 3
WIRE IN TERMINAL
JAWS
PARTIALLY
CLOSED
WIRE AGAINST
WIRE STOP
Figure 4
WIRE
INSULATION
PUNCH
CONDUCTOR
ANVIL
LOCATOR
INSULATION
ANVIL
WIRES AGAINST
LOCATOR STOP
CONDUCTOR
PUNCH
TERMINAL
TERMINAL
HANDLE
OPEN
LOCATOR
CLOSED
Figure
PUSH HERE TO
OPEN WIRE STOP
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.
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.

Hand Crimp Tool for “Sabre™ Crimp Terminals
Doc No. ATS-6381121 Release Date: 12-26- UNCONTROLLED COPY Page 4 of 6
Revision: F Revision Date: 5- 3-1
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.
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 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 (3 weight automotive oil), at
all the oil points, every 5, 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.
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 3 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.
SWING
LOCATOR
OPEN
PRESS DOWN
ON THE BRASS
PIVOT SHAFT
LIFT UP ON
THE LOCATOR
Figure 5
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figure 6

Hand Crimp Tool for “Sabre™ Crimp Terminals
Doc No. ATS-6381121 Release Date: 12-26- UNCONTROLLED COPY Page 5 of 6
Revision: F Revision Date: 5- 3-1
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. ”) 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.

Hand Crimp Tool for “Sabre™ Crimp Terminals
Doc No. ATS-6381121 Release Date: 12-26- UNCONTROLLED COPY Page 6 of 6
Revision: F Revision Date: 5- 3-1
RATCHET
RELEASE SCREW
Figure 7
M4 X 8mm
LONG BHCS
1
3
M4 X 18mm
LONG BHCS
M4 X 10mm
LONG BHCS
PARTS LIST
Item Number Order Number Description Quantity
1 6381 -1 Frame 1
2 63811-217 Tool Kit with Locator Assembly 1
3 63811-5573 Locator Base 1
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