Molex 207129 Series User manual

Hand Crimp Tool for HCS-125 Pin and Socket Crimp Terminal

Doc No: ATS-6381111H Release Date: 07-31-01 UNCONTROLLED COPY Page 1 of 5

Revision: G Revision Date: 06-22-10







TERMINAL

LOCATION

INSULATION

CRIMP

BRUSH

STRIP

LENGTH

BELL MOUTH

CRIMP HEIGHT

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP

TWISTING

CUT-OFF

TAB

SEAM

C/L

Application Toolin

Specification Sheet

Modular Crimp Head

Order No. 63811-1170

Hand Crimp Tool

Order No. 63811-1100

FEATURES

% 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

% odular 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 (110 V) or 63816-0250 (220 V),

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 Series No.

Terminal Order No. Wire Size Insulation Diameter Strip Len th

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





 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.

TYPE 4A

Hand Crimp Tool for HCS-125 Pin and Socket Crimp Terminal

Doc No: ATS-6381111H Release Date: 07-31-01 UNCONTROLLED COPY Page 2 of 5

Revision: G Revision Date: 06-22-10

Fi ure 2

CONDUCTOR

GRIPS

WIRE

LOCATOR

TERMINAL

INSULATION

GRIPS

WIRE

CONDUCTOR

PUNCH

TERMINAL

WIRE STOP

BLADE

Fi ure 1

CRIMP SPECIFICATION

After crimping, the crimp profiles should measure the following (see notes on page 4).

Terminal Series No. Wire Size Conductor Crimp Pull Force Minimum Profile

Hei ht (Ref) Width (Ref)

AWG

mm2 mm In. mm In. N Lb. A

1900

14 2.00 1.90-2.00 .075-.079 3.91 .154 222.4 50.00 X

12 3.30 2.08-2.18 .082-.086 3.91 .154 311.4 70.00 X

10 5.25 2.24-2.34 .088-.092 4.01 .158 355.9 80.00 X

1901

14 2.00 1.90-2.00 .075-.079 3.91 .154 222.4 50.00 X

12 3.30 2.08-2.18 .082-.086 3.91 .154 311.4 70.00 X

10 5.25 2.24-2.34 .088-.092 4.01 .158 355.9 80.00 X

42546

14 2.00 1.90-2.00 .075-.079 3.91 .154 222.4 50.00 X

12 3.30 2.08-2.18 .082-.086 3.91 .154 311.4 70.00 X

10 5.25 2.24-2.34 .088-.092 4.01 .158 355.9 80.00 X

42547

14 2.00 1.90-2.00 .075-.079 3.91 .154 222.4 50.00 X

12 3.30 2.08-2.18 .082-.086 3.91 .154 311.4 70.00 X

10 5.25 2.24-2.34 .088-.092 4.01 .158 355.9 80.00 X

OPERATION

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.

Crimpin Terminals

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 and 3.

4. Close the tool until the ratchet releases.

5. Carefully remove the crimped terminal.

Note: The tamper proof ratchet action will not release the tool until it has been fully closed.

Hand Crimp Tool for HCS-125 Pin and Socket Crimp Terminal

Doc No: ATS-6381111H Release Date: 07-31-01 UNCONTROLLED COPY Page 3 of 5

Revision: G Revision Date: 06-22-10

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.

3. ake 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 6.

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. anually 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 olex terminals specified for crimping with this tool.

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. olex 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.

Hand Crimp Tool for HCS-125 Pin and Socket Crimp Terminal

Doc No: ATS-6381111H Release Date: 07-31-01 UNCONTROLLED COPY Page 4 of 5

Revision: G Revision Date: 06-22-10

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

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 olex Quality Crimping

Handbook 63800-0029 for additional information on crimping and crimp testing.

6. olex does not certify crimp hand tools.

CAUTION: olex crimp specifications are valid only when used with olex terminals and tooling.

Applications for the Modular Crimp Head

WARNING: NEVER operate, service, install, or adjust this odular Crimp Head without proper instruction

and without first reading and understanding the instructions in the proper anual or Specification Sheet.

See Chart below for the correct anual 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.

The chart below shows all applications for this odular Crimp Head.

Modular Crimp Head

Order No.

Tool

Order no.

Tool

Description

Adapter

Order No.

Adapter

Description

Fi ure

No.

63811-1170

63816-0000

Hand Crimp Frame (Short) N/A N/A 3

63816-0050

Hand Crimp Frame (Long) N/A N/A 3

63816-0200

Battery Power Tool (110 V)

63816-0600

Battery Power Crimp Adapter

63816-0250

Battery Power Tool (220 V)

63816-0600

Battery Power Crimp Adapter

63816-0100

Air Power Tool 63816-0700

Air Power Crimp Adapter 5

Applications for the Modular Crimp Head

Hand Crimp Tool Battery Powered Tool Air Powered Tool

Fi ure 3 Fi ure 4 Fi ure 5

MODULAR

CRIMP

HEAD

LOCKING

PINS

HAND CRIMP

FRAME LONG

OR SHORT

Hand Crimp Tool for HCS-125 Pin and Socket Crimp Terminal

Doc No: ATS-6381111H Release Date: 07-31-01 UNCONTROLLED COPY Page 5 of 5

Revision: G Revision Date: 06-22-10

RATCHET

RELEASE LEVER

HANDLE

SPRING

CRIMPING

SPRING (2)

Fi ure 6

M4 X 12mm

LONG BHCS

PARTS LIST

Hand Crimp Tool 63811-1100

Item

Order Number

Description Quantity

1 63811-1170 odular 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

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