Modular Crimp Head for HCS-125 Pin and Socket Crimp Terminal Modular Crimp Head Specification Sheet Order No. 63811-1170 FEATURES Quick change Modular Crimp Head is easily installed into Power Crimp Adapter Crimp head is interchangeable with the Air or Battery Power Actuators Also installed into Hand Crimp Frames without the adapters A precision user-friendly terminal locator wire stop holds terminals in the proper crimping position Air or battery powered crimp tools help reduce fatigue and discomfort from repetitive manual crimping SCOPE Products: 3.18mm (.125") Diameter HCS-125 Pin and Socket Crimp Terminals, 10-14 AWG. Terminal Series No. 1900 1901 42546 42547 Terminal Order No. Wire Size Insulation Diameter Strip Length AWG mm² mm In. mm In. Loose Piece ●Reel 18-12-2602 18-12-2601 10-14 5.25-2.00 3.56-4.57 .140-.180 4.06-5.59 .160-.220 18-12-1602 18-12-1601 10-14 5.25-2.00 3.56-4.57 .140-.180 4.06-5.59 .160-.220 18-12-1607 10-14 5.25-2.00 3.56-4.57 .140-.180 4.06-5.59 .160-.220 18-12-1604 18-12-1603 10-14 5.25-2.00 3.56-4.57 .140-.180 4.06-5.59 .160-.220 ● Follow the Cut-Off Tab specifications on Applicator specification sheets. These Terminals cannot be removed from the reel by manual cutting. An applicator must be used or the terminals will not function properly. DEFINITION OF TERMS C/L BEND UP BELL MOUTH BRUSH TERMINAL LOCATION ROLLING SEAM INSULATION CRIMP TWISTING CUT-OFF TAB BEND DOWN STRIP LENGTH CONDUCTOR CRIMP C/L CRI CRIMP Terminal is to be centrally located between the two (2) cut-off tab edges by one half of the total cut-off tab tolerance. This illustration is a generic terminal representation and not an exact image of any terminal listed in the scope. Doc No: ATS-638111170 Revision: A Release Date: 03-25-10 Revision Date: 03-25-10 UNCONTROLLED COPY Page 1 of 5 Modular Crimp Head for HCS-125 Pin and Socket Crimp Terminal The chart below shows all applications for this Modular Crimp Head. Modular Crimp Head Order No. 63811-1170 Tool Tool Adapter Adapter Figure Order no. Description Order No. Description No. 63816-0000 Hand Crimp Frame (Short) N/A N/A 1 63816-0050 Hand Crimp Frame (Long) N/A N/A 1 63816-0200 Battery Power Tool 63816-0600 Battery Power Crimp Adapter 2 63816-0100 Air Power Tool 63816-0700 Air Power Crimp Adapter 3 Applications for the Modular Crimp Head Hand Crimp Tool Battery Powered Tool MODULAR CRIMP HEAD LOCKING PINS MODULAR CRIMP HEAD LOCKING PINS LOCKING PINS MODULAR CRIMP HEAD AIR POWER CRIMP ADAPTER BATTERY POWER CRIMP ADAPTER LOCKING PINS HAND CRIMP FRAME LONG OR SHORT BATTERY POWERED TOOL Figure 1 Air Powered Tool LOCKING PINS AIR POWER TOOL Figure 2 Figure 3 CONDITIONS: After crimping, the crimp profiles should measure the following (See Notes). Terminal Series No. 1900 1901 42546 42547 Doc No: ATS-638111170 Revision: A Wire Size AWG 14 12 10 14 12 10 14 12 10 14 12 10 mm2 2.00 3.30 5.25 2.00 3.30 5.25 2.00 3.30 5.25 2.00 3.30 5.25 Conductor Crimp Height (Ref) Width (Ref) mm In. mm In. 1.90-2.00 .075-.079 3.91 .154 2.08-2.18 .082-.086 3.91 .154 2.24-2.34 .088-.092 4.01 .158 1.90-2.00 .075-.079 3.91 .154 2.08-2.18 .082-.086 3.91 .154 2.24-2.34 .088-.092 4.01 .158 1.90-2.00 .075-.079 3.91 .154 2.08-2.18 .082-.086 3.91 .154 2.24-2.34 .088-.092 4.01 .158 1.90-2.00 .075-.079 3.91 .154 2.08-2.18 .082-.086 3.91 .154 2.24-2.34 .088-.092 4.01 .158 Release Date: 03-25-10 Revision Date: 03-25-10 Pull Force Minimum N 222.4 311.4 355.9 222.4 311.4 355.9 222.4 311.4 355.9 222.4 311.4 355.9 UNCONTROLLED COPY Lb. 50.00 70.00 80.00 50.00 70.00 80.00 50.00 70.00 80.00 50.00 70.00 80.00 Profile A X X B X X X X X X X X X X Page 2 of 5 Modular Crimp Head for HCS-125 Pin and Socket Crimp Terminal 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 above 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. OPERATION The Modular Crimp Head can be installed into various applications. Refer to the chart on the previous page and see Figures 1 through 3. Crimping Terminals 1. Place the terminal into the correct die profile (A or B) until the terminal stopped by the locator. 2. Place a pre-striped wire into the terminal and align the wire with the conductor and insulation grips visually. See Figure 4 and 5. 3. Cycle the tool. Figure 3 CONDUCTOR 4. Carefully remove the crimped terminal. GRIPS PRE-STRIPPED WIRE LOCATOR INSULATION GRIPS TERMINAL WIRE TERMINAL Figure 4 Doc No: ATS-638111170 Revision: A Release Date: 03-25-10 Revision Date: 03-25-10 Figure 5 UNCONTROLLED COPY Page 3 of 5 Modular Crimp Head for HCS-125 Pin and Socket Crimp Terminal 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 other equipment it needs cleaning and lubrication for a 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 the tool, particularly from crimping area. Oil transferred from the crimping area onto certain terminations may affect the electrical characteristics of an application. 5. Store the tool in a clean and dry location when not in use. 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. 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 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 tools. CAUTION: Molex crimp specifications are valid only when used with Molex terminals and tooling. Doc No: ATS-638111170 Revision: A Release Date: 03-25-10 Revision Date: 03-25-10 UNCONTROLLED COPY Page 4 of 5 Modular Crimp Head for HCS-125 Pin and Socket Crimp Terminal PARTS LIST Item Order Number Description Quantity 1 63600-0520 Crimping Spring 2 2 63811-1175 Locator 1 M4 X 12mm LONG BHCS 2 Figure 6 1 Americas Headquarters Lisle, Illinois 60532 U.S.A. 1-800-78MOLEX [email protected] Far East North Headquarters Yamato, Kanagawa, Japan 81-462-65-2324 [email protected] Far East South Headquarters Jurong, Singapore 65-6-268-6868 [email protected] European Headquarters Munich, Germany 49-89-413092-0 [email protected] Corporate Headquarters 2222 Wellington Ct. Lisle, IL 60532 U.S.A. 630-969-4550 Fax: 630-969-1352 Visit our Web site at http://www.molex.com Doc No: ATS-638111170 Revision: A Release Date: 03-25-10 Revision Date: 03-25-10 UNCONTROLLED COPY Page 5 of 5