molex 63811-7200 User manual

Tool Kit for Sabre™ Flat Blade Crimp Terminal
Doc No: ATS-6381172HM Release Date: 02-12-07 UNCONTROLLED COPY Page 1 of 7
Revision: D Revision Date: 06-30-23
INSULATION CRIMP
▲SEE NOTE
BRUSH
STRIP LENGTH
BELL MOUTH
CONDUCTOR
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
CUT-OFF TAB
SEAM
Order No.
63811-7200
Application Tooling
Specification Sheet
FEATURES
A full cycle ratcheting hand tool ensures complete crimps
Ergonomic soft grip handles for comfortable crimping
Right- and left-handed applications
Easy handling due to outstanding force ratio
A precision user-friendly terminal locator with wire stop that holds terminals in the proper crimping position
This tool is IPC/WHMA-A-620 compliant
Tooling can be installed in the 63816-1915 Power Crimp Head, which is installed into the 63816-0270 (110 V) or
63816-0280 (220 V) Battery Powered Tools and the 63816-1900 Electric Crimp Machine
This tool is RoHS compliant; however, RoHS compliance is not required
SCOPE
Products: Sabre™ Flat Blade Crimp Terminal, 14-18 AWG.
Terminal
Series No.
Terminal Order No.
Wire Size
Insulation Diameter
Strip Length
Available in Reel form only
AWG
mm²
mm
in
mm
in
43178
43178-1001
43178-1003
43178-5002
18
0.80
2.36-3.56
.093-.140
3.96-5.54
.156-.218
43178-1002
43178-5001
43178-5003
43374
43374-0001
14-18
2.00-0.80
2.36-3.56
.093-.140
3.96-5.54
.156-.218
43375
43375-0001
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-6381172HM Release Date: 02-12-07 UNCONTROLLED COPY Page 2 of 7
Revision: D Revision Date: 06-30-23
▲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 Height (Ref)
Crimp Width (Ref)
AWG
mm2
mm
In.
mm
In.
N
Lb.
A
B
C
43178
18
0.80
1.78-1.88
.070-.074
3.20
.126
88.9
20.0
X
43374
14
2.09
1.65-1.75
.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
43375
14
2.09
1.65-1.75
.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 Crimps, the following over-all wire insulation diameter ranges are recommended:
1. Profile A: 2.36-3.56mm (.093-.140 inch)
2. Profile B: 2.79-3.56mm (.110-.140 inch)
3. Profile C: 2.36-3.14mm (.093-.124 inch)
Tool Qualification Notes
1. (Ref) means that the dimension provided is approximate because of the wide range of wires, conductor
stranding, insulation diameter and insulation hardness.
2. An occasional conductor crimp height measurement should be performed, and it should be used as the final
criterion for an acceptable crimp. It must lie between the minimum and maximum crimp height specification.
Refer to Molex Quality Crimping Handbook 63800-0029 for additional information on crimping and crimp
testing.
3. In addition, an occasional pull force test may be performed. It must exceed the minimum pull force
specification. Pull force should be measured with no influence from the insulation crimp. To ensure this, strip
the wire long enough so the terminal insulation grips do not contact the wire insulation.
OVERLAP
INSULATION
CRIMP
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
WIRE

Tool Kit for Sabre™ Flat Blade Crimp Terminal
Doc No: ATS-6381172HM Release Date: 02-12-07 UNCONTROLLED COPY Page 3 of 7
Revision: D Revision Date: 06-30-23
ANVILS
POWER
CRIMP
HEAD
Figure 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
Figure 2
SWING OPEN
TERMINAL
PUSH HERE TO
OPEN WIRE STOP
LOCATOR
LOCATOR
TERMINAL IN PLACE
Figure 3
Notes
1. This tool should only be used for the terminals and wire gauges specified on this document.
2. Variations in tools, terminals, wire stranding and insulation types may affect crimp height.
3. This tool is intended for the conductor sizes specified on this document. It may not give good insulation crimp
support for insulation sizes outside of the specified range.
4. Molex does not repair hand tools. See warranty on page 5. The replacement parts listed are the only parts
available for repair. If the handles or crimp tooling become damaged or worn, a new tool must be purchased.
CAUTION: Crimp 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.
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.

Tool Kit for Sabre™ Flat Blade Crimp Terminal
Doc No: ATS-6381172HM Release Date: 02-12-07 UNCONTROLLED COPY Page 4 of 7
Revision: D Revision Date: 06-30-23
TERMINAL
Figure 6
WIRE IN TERMINAL
JAWS
PARTIALLY
CLOSED
WIRE AGAINST
WIRE STOP
HANDLE
OPEN
LOCATOR
CLOSED
Figure 5
PUSH HERE TO
OPEN WIRE STOP
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. 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.
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.
Figure 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-6381172HM Release Date: 02-12-07 UNCONTROLLED COPY Page 5 of 7
Revision: D Revision Date: 06-30-23
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.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 7A or 7B 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 Figure 11)
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 11.
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, Molex 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.
CAUTION: Molex crimp specifications are valid only when used with Molex terminals and tooling.
LUBRICATION
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY MONTH
OR
5,000 CRIMPS)
Figure 7A
Figure 7B

Tool Kit for Sabre™ Flat Blade Crimp Terminal
Doc No: ATS-6381172HM Release Date: 02-12-07 UNCONTROLLED COPY Page 6 of 7
Revision: D Revision Date: 06-30-23
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 or determine tool life:
1. When the hand tool is no longer capable of achieving minimum conductor crimp height, it should be taken out of
service and replaced.
2. The tool frame is very difficult to disassemble and reassemble. Customer repair is not recommended.
APPLICATIONS FOR THE POWER CRIMP HEAD
The chart below shows all applications for this Power Crimp Head:
Tool Order No.
Tool Description
Crimp Head
Order No.
Crimp Head
Description
Figure No.
63811-7200
Hand Crimp Tool
---
---
8
63816-0270
Battery Power Tool (110 V)
63816-1915
Power Crimp Head
9
63816-0280
Battery Power Tool (220 V)
63816-1915
Power Crimp Head
9
63816-1900
Electric Crimp Machine
63816-1915
Power Crimp Head
10
Crimp Tooling Applications
Hand Crimp Tool
Battery Powered Tool
Electric Crimp Machine
Figure 8
Figure 9
Figure 10
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.
HAND CRIMP
FRAME
TOOL KIT
POWER
CRIMP
HEAD
LOCKING PINS
BATTERY
POWERED
TOOL
TOOL KIT
ELECTRIC CRIMP
MACHINE
POWER CRIMP
HEAD
LOCATOR
LOCATOR

Tool Kit for Sabre™ Flat Blade Crimp Terminal
Doc No: ATS-6381172HM Release Date: 02-12-07 UNCONTROLLED COPY Page 7 of 7
Revision: D Revision Date: 06-30-23
HAND TOOL PARTS LIST
Item Number
Order Number
Description
Quantity
REF
63811-7200
Hand Crimp Tool
Figure 11
1
---
Hand Crimp Frame
1
2
---
Tool Kit
1
3
63811-5573
Locator Base
1
4
63811-7275
Locator
1
Application Tooling Support
E-Mail: [email protected]
Website: www.molex.com/applicationtooling
Molex is a registered trademark of Molex, LLC in the United States of America and may be registered in other countries; all other
trademarks listed herein belong to their respective owners.
RATCHET
RELEASE SCREW
Figure 11
M4 X 8mm
LONG BHCS
2
1
3
M4 X 18mm
LONG BHCS
M4 X 10mm
LONG BHCS
4
LOCATOR