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
BEND UP
BELL MOUTH
BRUSH
INSULATION
CRIMP
TWISTING
STRIP
LENGTH
CONDUCTOR
CRIMP
BEND
DOWN
SEAM
ROLLING
C/L
TERMINAL
LOCATION
CUT-OFF
TAB
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
BATTERY
POWER
CRIMP
ADAPTER
Air Powered Tool
LOCKING
PINS
MODULAR
CRIMP
HEAD
LOCKING
PINS
LOCKING
PINS
MODULAR
CRIMP HEAD
AIR POWER
CRIMP
ADAPTER
LOCKING PINS
HAND CRIMP
FRAME LONG
OR SHORT
BATTERY
POWERED
TOOL
AIR
POWER
TOOL
LOCKING
PINS
Figure 1
Figure 2
Figure 3
CONDITIONS:
After crimping, the crimp profiles should measure the following (See Notes).
Wire Size
AWG
14
12
10
14
12
10
14
12
10
14
12
10
mm
2
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
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
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
X
X
X
X
X
X
X
X
X
B
Terminal Series No.
1900
X
1901
42546
42547
Doc No: ATS-638111170
Revision: A
Release Date: 03-25-10
Revision Date: 03-25-10
UNCONTROLLED COPY
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
Figure 5
Doc No: ATS-638111170
Revision: A
Release Date: 03-25-10
Revision Date: 03-25-10
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
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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
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