modularcrimpheadforhcs125pinandsocketcrimp terminal docno:ats638111170 releasedate:032510 uncontrolledcopy page1of5 revision:a revisiondate:032510 terminal location insulation crimp brush strip length bellmouth cri crimp bend down bendup rolling conductor crimp twisting cutoff tab seam c/l c/l modularcrimphead specificationsheet orderno.638111170 features quickchangemodularcrimpheadiseasilyinstalled intopowercrimpadapter crimpheadisinterchangeablewiththeairorbatte rypoweractuators alsoinstalledintohandcrimpframeswithoutthea dapters aprecisionuserfriendlyterminallocatorwiresto pholdsterminalsinthepropercrimpingposition airorbatterypoweredcrimptoolshelpreducefati gueanddiscomfortfromrepetitivemanualcrimping scope products :3.18mm(.125")diameterhcs125pinandsocketcr impterminals,1014awg. terminalorderno. wiresize insulationdiameter st riplength terminal seriesno. loosepiece reel awg mm2 mm in. mm in. 1900 18122602 18122601 1014 5.252.00 3.564.5 7 .140.180 4.065.59 .160.220 1901 18121602 18121601 1014 5.252.00 3.564.5 7 .140.180 4.065.59 .160.220 42546 18121607 1014 5.252.00 3.564.57 .140.1 80 4.065.59 .160.220 42547 18121604 18121603 1014 5.252.00 3.564. 57 .140.180 4.065.59 .160.220 followthecutofftabspecificationsonapplicator specificationsheets. theseterminalscannotberemovedfromthereelby manualcutting. anapplicatormustbeusedortheterminalswillno tfunctionproperly. definitionofterms terminalistobecentrallylocatedbetweenthetwo (2)cutofftabedgesbyonehalfofthetotalcut offtab tolerance. thisillustrationisagenericterminalrepresentat ionandnotanexactimageofanyterminallistedi nthescope.
modularcrimpheadforhcs125pinandsocketcrimp terminal docno:ats638111170 releasedate:032510 uncontrolledcopy page2of5 revision:a revisiondate:032510 modular crimp head battery power crimp adapter locking pins lockingpins battery powered tool air power tool modular crimphead locking pins locking pins air power crimp adapter thechartbelowshowsallapplicationsforthismod ularcrimphead. modularcrimphead orderno. tool orderno. tool description adapter orderno. adapter description figure no. 638160000 handcrimpframe(short) n/a n/a 1 638160050 handcrimpframe(long) n/a n/a 1 638160200 batterypowertool 638160600 batterypowercrimpadapter 2 638111170 638160100 airpowertool 638160700 airpowercrimpadapter 3 applicationsforthemodularcrimphead handcrimptool batterypoweredtool airpoweredto ol figure1 figure2 figure3 conditions: aftercrimping,thecrimpprofilesshouldmeasuret hefollowing(seenotes). conductorcrimp wiresize height(ref) width(ref) pullforceminimum profile terminalseriesno. awg mm 2 mm in. mm in. n lb. a b 14 2.00 1.902.00 .075.079 3.91 .154 222.4 50.00 x 12 3.30 2.082.18 .082.086 3.91 .154 311.4 70.00 x 1900 10 5.25 2.242.34 .088.092 4.01 .158 355.9 80.00 x 14 2.00 1.902.00 .075.079 3.91 .154 222.4 50.00 x 12 3.30 2.082.18 .082.086 3.91 .154 311.4 70.00 x 1901 10 5.25 2.242.34 .088.092 4.01 .158 355.9 80.00 x 14 2.00 1.902.00 .075.079 3.91 .154 222.4 50.00 x 12 3.30 2.082.18 .082.086 3.91 .154 311.4 70.00 x 42546 10 5.25 2.242.34 .088.092 4.01 .158 355.9 80.00 x 14 2.00 1.902.00 .075.079 3.91 .154 222.4 50.00 x 12 3.30 2.082.18 .082.086 3.91 .154 311.4 70.00 x 42547 10 5.25 2.242.34 .088.092 4.01 .158 355.9 80.00 x modular crimp head locking pins handcrimp framelong orshort
modularcrimpheadforhcs125pinandsocketcrimp terminal docno:ats638111170 releasedate:032510 uncontrolledcopy page3of5 revision:a revisiondate:032510 figure3 warning : never operate,service,install,oradjustthismodularc rimpheadwithoutproperinstruction andwithoutfirstreadingandunderstandingtheins tructionsinthepropermanualorspecificationshe et. seechartaboveforthecorrectmanualorspecifica tionsheet. warning : never installtoolingorservicethistoolwhileitisin toanypowersource.disconnectthe powerbyunpluggingorturnofftheactuatorfromi tspowersource. caution: keepfingersawayfromthecrimpingareawhenopera tingthistool.itmaycausesevereinjury. caution: wearsafetyglasseswhenoperatingorservingthis tool. operation themodularcrimpheadcanbeinstalledintovariou sapplications.refertothechartontheprevious page andseefigures1through3. crimpingterminals 1. placetheterminalintothecorrectdieprofile(a orb)untiltheterminalstoppedbythelocator. 2. placeaprestripedwireintotheterminalandalig nthewirewiththeconductorandinsulationgrips visually.seefigure4and5. 3. cyclethetool. 4. carefullyremovethecrimpedterminal. figure5 conductor grips wire locator terminal insulation grips terminal prestrippedwire figure4
modularcrimpheadforhcs125pinandsocketcrimp terminal docno:ats638111170 releasedate:032510 uncontrolledcopy page4of5 revision:a revisiondate:032510 maintenance itisrecommendedthateachoperatorofthetoolbe madeawareof,andresponsiblefor,thefollowing maintenancesteps: 1. removedust,moisture,andothercontaminantswith acleanbrush,orsoft,lintfreecloth. 2. donotuseanyabrasivematerialsthatcoulddamage thetool. 3. makecertainallpins;pivotpointsandbearingsur facesareprotectedwithathincoatofhighqualit ymachine oil.donotoilexcessively.thetoolwasenginee redfordurabilitybutlikeanyotherequipmentit needs cleaningandlubricationforamaximumservicelife oftroublefreecrimping.lightoil(suchas30w eight automotiveoil)usedattheoilpoints,every5,000 crimpsor3months,willsignificantlyenhancethe toollife. 4. wipeexcessoilfromthetool,particularlyfromcr impingarea.oiltransferredfromthecrimpingare aonto certainterminationsmayaffecttheelectricalchar acteristicsofanapplication. 5. storethetoolinacleananddrylocationwhennot inuse. warranty thistoolisforelectricalterminalcrimpingpurpo sesonly.thistoolismadeofthebestqualityma terials.allvital componentsarelonglifetested.alltoolsarewar rantedtobefreeofmanufacturingdefectsforape riodof30 days.shouldsuchadefectoccur,wewillrepairo rexchangethetoolfreeofcharge.thisrepairor exchangewill notbeapplicabletoaltered,misused,ordamagedt ools. notes: 1. thistoolshouldonlybeusedfortheterminalsand wiregaugesspecifiedonthissheet. 2. thistoolisnotadjustableforcrimpheight;howev ercrimpforceisadjustable(seeinstructionsabov e). variationsintools,terminals,wirestrandingand insulationtypesmayaffectcrimpheight. 3. thistoolisintendedforstandardconductorsizes. itmaynotgiveagoodinsulationcrimpsupportf orall insulationsizes. 4. molexdoesnotrepairhandtools.(seewarrantyabo ve)thereplacementpartslistedaretheonlyparts availableforrepair.ifthecrimptoolingisdama gedorworn,anewtoolmustbepurchased. 5. pullforceshouldbeusedasthefinalcriteriafor anacceptablecrimp.pullforceismeasuredwith no influencefromtheinsulationcrimp.theinsulatio nshouldbestrippedlong(1/2in.)sotheinsulati ongrips ontheterminaldonotgripthewireinsulationor theconductor.refertomolexqualitycrimping handbook638000029foradditionalinformationonc rimpingandcrimptesting. 6. molexdoesnotcertifycrimptools. caution :molexcrimpspecificationsarevalidonlywhenu sedwithmolexterminalsandtooling.
modularcrimpheadforhcs125pinandsocketcrimp terminal docno:ats638111170 releasedate:032510 uncontrolledcopy page5of5 revision:a revisiondate:032510 partslist item ordernumber description quantity 1 636000520 crimpingspring 2 2 638111175 locator 1 americasheadquarters lisle,illinois60532u.s.a. 180078molex amerinfo@molex.com fareastnorthheadquarters yamato,kanagawa,japan 81462652324 feninfo@molex.com fareastsouthheadquarters jurong,singapore 6562686868 fesinfo@molex.com europeanheadquarters munich,germany 49894130920 eurinfo@molex.com corporateheadquarters 2222wellingtonct. lisle,il60532u.s.a. 6309694550 fax:6309691352 visitourwebsiteathttp://www.molex.com 2 1 figure6 m4x12mm longbhcs
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