molex HCS-125 Series User manual

Modular Crimp Head for HCS-125 Pin and Socket Crimp Terminal
Doc No: ATS-6 8111170 Release Date: 0 -25-10 UNCONTROLLED COPY Page 1 of 5
Revision: A Revision Date: 0 -25-10


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TERMINAL
LOCATION
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
BELL MOUTH
CRI
CRIMP
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
CUT-OFF
TAB
SEAM
C/L
C/L
Modular Crim Head
S ecification 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: .18mm (.125") Diameter HCS-125 Pin and Socket Crimp Terminals, 10-14 AWG.
Terminal Order No. Wire Size Insulation Diameter Stri Length Terminal
Series No. Loose Piece ●Reel AWG mm² mm In. mm In.
1900 18-12-2602 18-12-2601 10-14 5.25-2.00 .56-4.57 .140-.180 4.06-5.59 .160-.220
1901 18-12-1602 18-12-1601 10-14 5.25-2.00 .56-4.57 .140-.180 4.06-5.59 .160-.220
42546 18-12-1607 10-14 5.25-2.00 .56-4.57 .140-.180 4.06-5.59 .160-.220
42547 18-12-1604 18-12-160 10-14 5.25-2.00 .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
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 Terminal is to be centrally located between the two (2) cut-off tab edges by one half of the total cut-off tab
tolerance.
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This illustration is a generic terminal representation and not an exact image of any terminal listed in the scope.

Modular Crimp Head for HCS-125 Pin and Socket Crimp Terminal
Doc No: ATS-6 8111170 Release Date: 0 -25-10 UNCONTROLLED COPY Page 2 of 5
Revision: A Revision Date: 0 -25-10
MODULAR
CRIMP
HEAD
BATTERY
POWER
CRIMP
ADAPTER
LOCKING
PINS
LOCKING PINS
BATTERY
POWERED
TOOL
AIR
POWER
TOOL
MODULAR
CRIMP HEAD
LOCKING
PINS
LOCKING
PINS
AIR
POWER
CRIMP
ADAPTER
The chart below shows all applications for this Modular Crimp Head.
Modular Crim Head
Order No.
Tool
Order no.
Tool
Descri tion
Ada ter
Order No.
Ada ter
Descri tion
Figure
No.
6 816-0000 Hand Crimp Frame (Short) N/A N/A 1
6 816-0050 Hand Crimp Frame (Long) N/A N/A 1
6 816-0200 Battery Power Tool 6 816-0600 Battery Power Crimp Adapter 2
6 811-1170
6 816-0100 Air Power Tool 6 816-0700 Air Power Crimp Adapter
A lications for the Modular Crim Head
Hand Crim Tool Battery Powered Tool Air Powered Tool
Figure 1 Figure 2 Figure 3
CONDITIONS:
After crimping, the crimp profiles should measure the following (See Notes).
Conductor Crim
Wire Size Height (Ref) Width (Ref) Pull Force Minimum Profile
Terminal Series No.
AWG mm2 mm In. mm In. N Lb. A B
14 2.00 1.90-2.00 .075-.079 .91 .154 222.4 50.00 X
12 . 0 2.08-2.18 .082-.086 .91 .154 11.4 70.00 X
1900
10 5.25 2.24-2. 4 .088-.092 4.01 .158 55.9 80.00 X
14 2.00 1.90-2.00 .075-.079 .91 .154 222.4 50.00 X
12 . 0 2.08-2.18 .082-.086 .91 .154 11.4 70.00 X
1901
10 5.25 2.24-2. 4 .088-.092 4.01 .158 55.9 80.00 X
14 2.00 1.90-2.00 .075-.079 .91 .154 222.4 50.00 X
12 . 0 2.08-2.18 .082-.086 .91 .154 11.4 70.00 X
42546
10 5.25 2.24-2. 4 .088-.092 4.01 .158 55.9 80.00 X
14 2.00 1.90-2.00 .075-.079 .91 .154 222.4 50.00 X
12 . 0 2.08-2.18 .082-.086 .91 .154 11.4 70.00 X
42547
10 5.25 2.24-2. 4 .088-.092 4.01 .158 55.9 80.00 X
MODULAR
CRIMP
HEAD
LOCKING
PINS
HAND CRIMP
FRAME LONG
OR SHORT

Modular Crimp Head for HCS-125 Pin and Socket Crimp Terminal
Doc No: ATS-6 8111170 Release Date: 0 -25-10 UNCONTROLLED COPY Page of 5
Revision: A Revision Date: 0 -25-10
Figure 3
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 .
Crim ing 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.
. Cycle the tool.
4. Carefully remove the crimped terminal.
Figure 5
CONDUCTOR
GRIPS
WIRE
LOCATOR
TERMINAL
INSULATION
GRIPS
TERMINAL
PRE-STRIPPED WIRE
Figure 4

Modular Crimp Head for HCS-125 Pin and Socket Crimp Terminal
Doc No: ATS-6 8111170 Release Date: 0 -25-10 UNCONTROLLED COPY Page 4 of 5
Revision: A Revision Date: 0 -25-10
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.
. 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 0 weight
automotive oil) used at the oil points, every 5,000 crimps or 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 0
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.
. 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 6 800-0029 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.

Modular Crimp Head for HCS-125 Pin and Socket Crimp Terminal
Doc No: ATS-6 8111170 Release Date: 0 -25-10 UNCONTROLLED COPY Page 5 of 5
Revision: A Revision Date: 0 -25-10
PARTS LIST
Item Order Number Descri tion Quantity
1 6 600-0520 Crimping Spring 2
2 6 811-1175 Locator 1
Americas Headquarters
Lisle, Illinois 605 2 U.S.A.
1-800-78MOLEX
[email protected]
Far East North Headquarters
Yamato, Kanagawa, Japan
81-462-65-2 24
[email protected]
Far East South Headquarters
Jurong, Singapore
65-6-268-6868
[email protected]
Euro ean Headquarters
Munich, Germany
49-89-41 092-0
[email protected]
Cor orate Headquarters
2222 Wellington Ct.
Lisle, IL 605 2 U.S.A.
6 0-969-4550
Fax: [phone]
Visit our Web site at htt ://www.molex.com
2
1
Figure 6
M4 X 12mm
LONG BHCS