0638111100

Hand Crimp Tool for HCS-125 Pin and Socket Crimp Terminal Hand Crimp Tool Specification Sheet Order No. 63811-1100 FEATURES % % % % % % TYPE 4A 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, accompanied by Battery Powered Crimp Adapter (Order No. 63816-0600). SCOPE Products: 3.18mm (.125") Diameter HCS-125 Pin and Socket Crimp Terminals, 10-14 AWG. Terminal Order No. Wire Size Insulation Diameter Strip 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 3.56-4.57 .140-.180 4.06-5.59 .160-.220 1901 18-12-1602 18-12-1601 10-14 5.25-2.00 3.56-4.57 .140-.180 4.06-5.59 .160-.220 42546 18-12-1607 10-14 5.25-2.00 3.56-4.57 .140-.180 4.06-5.59 .160-.220 42547 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 CUT-OFF TAB TWISTING BEND DOWN STRIP LENGTH CONDUCTOR CRIMP CRIMP HEIGHT C/L 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-638111100 Revision: F Release Date: 07-31-01 Revision Date: 03-31-10 UNCONTROLLED COPY Page 1 of 5 Hand Crimp Tool for HCS-125 Pin and Socket Crimp Terminal CONDITIONS: After crimping, the crimp profiles should measure the following (see notes on page 4). Terminal Series No. Wire Size AWG 14 12 10 14 12 10 14 12 10 14 12 10 1900 1901 42546 42547 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 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 B X X X X X X X X X X OPERATION PRE-STRIPPED WIRE 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 TERMINAL CONDUCTOR GRIPS Figure 1 LOCATOR INSULATION GRIPS WIRE TERMINAL 1. Place the terminal into the correct die profile (A or B) until the terminal stopped by the locator. 2. Partially close the tool until the terminal is held in place. 3. Place a pre-striped wire into the terminal and align the wire with the conductor and insulation grips visually. See Figure 2. 4. Close the tool until the ratchet releases. 5. Carefully remove the crimped terminal. Figure 2 Note: The tamper proof ratchet action will not release the tool until it has been fully closed. Doc No: ATS-638111100 Revision: F Release Date: 07-31-01 Revision Date: 03-31-10 UNCONTROLLED COPY Page 2 of 5 Hand Crimp Tool 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 hand tool, particularly from 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 3. 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. Doc No: ATS-638111100 Revision: F Release Date: 07-31-01 Revision Date: 03-31-10 UNCONTROLLED COPY Page 3 of 5 Hand Crimp Tool for HCS-125 Pin and Socket Crimp Terminal 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-638111100 Revision: F Release Date: 07-31-01 Revision Date: 03-31-10 UNCONTROLLED COPY Page 4 of 5 Hand Crimp Tool for HCS-125 Pin and Socket Crimp Terminal PARTS LIST Item Order Number Description Quantity 1 63811-1170 Modular Crimp Head 1 (ref) 2 63816-0050 Hand Crimp Frame (Long) 1 (ref) 3 63811-1175 Locator 1 4 63816-0001 Locking Pin 2 5 63600-0525 Handle Spring 1 6 63600-0520 Crimping Spring 2 5 HANDLE SPRING 2 M4 X 12mm LONG BHCS RATCHET RELEASE LEVER 3 1 4 6 CRIMPING SPRING (2) Figure 3 Americas Headquarters Lisle, Illinois 60532 U.S.A. 1-800-78MOLEX amerinfo@molex.com Far East North Headquarters Yamato, Kanagawa, Japan 81-462-65-2324 feninfo@molex.com Far East South Headquarters Jurong, Singapore 65-6-268-6868 fesinfo@molex.com European Headquarters Munich, Germany 49-89-413092-0 eurinfo@molex.com 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-638111100 Revision: F Release Date: 07-31-01 Revision Date: 03-31-10 UNCONTROLLED COPY Page 5 of 5