Hand Crimp Tool for Sabre Female Flat Blade Crimp Terminals

TYPE 4A
Application Tooling
Modular Crimp Head Specification Sheet Hand Crimp Tool
Order No. 63823-2870 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.

Terminal Wire Size and Type
Insulation Diameter Strip Length

Terminal Series No.
Order No. AWG mm² Type mm In. mm In.
18 0.80 UL1056 4.27 Max .168 Max
43375 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.

Doc No: ATS-6382328HM Release Date: 08-24-10 UNCONTROLLED COPY Page 1 of 6

Revision: A Revision Date: 08-24-10
Hand Crimp Tool for Sabre Female Flat Blade Crimp Terminals

DEFINITION OF TERMS STRIP LENGTH CONDUCTOR

BRUSH CRIMP HEIGHT

BELL MOUTH

CUT-OFF TAB
BEND UP INSULATION CRIMP
ROLLING TWISTING

CONDUCTOR CRIMP

BEND
DOWN SEAM

CRIMP SPECIFICATION
Bell mouth Conductor Brush Max.
Terminal Series No.
mm In. mm In.
43375 0.20-0.50 .008-.020 0.76 .030

Seam
Bend up Bend down Twist Roll
Terminal Series No.
Degree Degree Seam shall not be open
and no wire allowed out
43375 3 3 4 8 of the crimping area

After crimping, the conductor profile should measure the following.

Conductor Crimp
Wire Size Pull Force Minimum Profile
Terminal Series No. Height Width
AWG mm2 mm In. mm In. N Lb. 18 AWG 20 AWG
18 0.80 1.16-1.26 .046-.050 2.00-2.10 .079-.083 89.0 20.0 X
43375
20 0.50 1.10-1.20 .043-.047 2.00-2.10 .079-.083 57.9 13.0 X

Insulation Crimp
Wire Size
Terminal Series No. Height (Max) Width
AWG mm2 mm In. mm In.
18 0.80 4.20 Max .165 Max 4.80-5.00 .189-.197
43375
20 0.50 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 Release Date: 08-24-10 UNCONTROLLED COPY Page 2 of 6

Revision: A Revision Date: 08-24-10
Hand Crimp Tool for Sabre Female Flat Blade Crimp Terminals

WIRE STOP BLADE INSULATION

OPERATION PUNCH
TERMINAL
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 Figure 1
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.

Note: The tamper proof ratchet action will not release the tool until it has been fully closed.

CONDUCTOR
Maintenance PUNCH

It is recommended that each operator of the tool be

made aware of, and responsible for, the following WIRE STOP INSULATION
maintenance steps: BLADE PUNCH

1. Remove dust, moisture, and other contaminants

with a clean brush, or soft, lint free cloth. WIRE
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
equipment it needs cleaning and lubrication for a TERMINAL INSULATION
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.
4. Wipe excess oil from hand tool, particularly from CONDUCTOR 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 Release Date: 08-24-10 UNCONTROLLED COPY Page 3 of 6

Revision: A Revision Date: 08-24-10
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 Release Date: 08-24-10 UNCONTROLLED COPY Page 4 of 6

Revision: A Revision Date: 08-24-10
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 Tool Tool Adapter Adapter Figure

Order No. Order no. Description Order No. Description No.
63816-0000 Hand Crimp Frame (Short) N/A N/A 3
63816-0050 Hand Crimp Frame (Long) N/A N/A 3
63823-2870 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

Applications for the Modular Crimp Head

Hand Crimp Tool Battery Powered Tool Air Powered Tool

MODULAR
CRIMP LOCKING MODULAR
MODULAR LOCKING HEAD
LOCKING CRIMP PINS CRIMP HEAD
PINS
PINS HEAD
AIR POWER
BATTERY
CRIMP
POWER
ADAPTER
CRIMP
LOCKING PINS ADAPTER
AIR LOCKING
HAND CRIMP PINS
POWER
FRAME LONG
BATTERY TOOL
OR SHORT
POWERED
TOOL

Figure 3 Figure 4 Figure 5

Doc No: ATS-6382328HM Release Date: 08-24-10 UNCONTROLLED COPY Page 5 of 6

Revision: A Revision Date: 08-24-10
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

M4 X 14mm
LONG BHCS

RATCHET
RELEASE LEVER

4
1

6 CRIMPING
SPRING (2) Figure 6

http://www.molex.com

Doc No: ATS-6382328HM Release Date: 08-24-10 UNCONTROLLED COPY Page 6 of 6

Revision: A Revision Date: 08-24-10