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Summary of Contents for molex CS 150
- Page 1 CS 150 Battery Crimping Tool BATTERY POWERED CRIMPING TOOL Instruction Manual Order No. 63816-0200 ΠΠDescription ΠOperation Maintenance UNCONTROLLED COPY Doc No: ATS-638160200 Release Date: 12-06-07 Page 1 of 21 Revision: A Revision Date: 12-06-07...
- Page 2 CS 150 Battery Crimping Tool Table of Contents SECTION Safety Warnings and Information General Description Setup and Adjustments Crimping Dies Go-No go Preventive Maintenance Troubleshooting UNCONTROLLED COPY Doc No: ATS-638160200 Release Date: 12-06-07 Page 2 of 21 Revision: A Revision Date: 12-06-07...
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Page 3: Safety Alert Symbol
CS 150 Battery Crimping Tool Read and understand all of the instructions and safety information in this Manual before operating or servicing this tool. Keep this manual available when using this tool Replacement manuals are available upon request at no charge at www.molex.com. - Page 4 Do not attempt to open the battery. It contains no user-serviceable parts. and property damage. Failure to observe these precautions may result in injury or property damage. For Service, Contact Your Local Molex Sales Office Molex Application Tooling Group 2200 Wellington Court...
- Page 5 CS 150 Battery Crimping Tool Section 2 General Description Description Features Technical Specifications Delivery Check Tools UNCONTROLLED COPY Doc No: ATS-638160200 Release Date: 12-06-07 Page 5 of 21 Revision: A Revision Date: 12-06-07...
- Page 6 (NiCad 9.6V) BATTERY Description The Molex Battery Crimping Tool is designed to crimp 8 to 4/0 AWG insulated and uninsulated terminals and splices. This tool has an automatic retractable system which returns the crimping adapter along with the crimping dies to the starting position when the maximum force is reached. It is equipped with a special brake that will stop the forward motion of the crimping dies when the trigger is released.
- Page 7 75dB (A) in a distance of 1.0m Vibrations <2.5m/s Delivery Check Carefully remove the CS 150 Battery Crimping Tool from its shipping container and determine that the following items are included in the package. á á CS 150 Battery Crimping Tool with battery á...
- Page 8 CS 150 Battery Crimping Tool Section 3 Set-Up and Adjustments 3.1. Setup 3.2. Operation 3.3. Installation of Tool Kits Á UNCONTROLLED COPY Doc No: ATS-638160200 Release Date: 12-06-07 Page 8 of 21 Revision: A Revision Date: 12-06-07...
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Page 9: Operation
CS 150 Battery Crimping Tool 3.1 Set-Up CRIMPING HEAD WITH Before starting any work on electrical applications make sure there are no TOOLING live cables or parts in the immediate area of the user. WARNING LOCKING LATCH Remove the battery from the crimping tool before installing and removing dies in the crimp head. - Page 10 CS 150 Battery Crimping Tool The crimping operation can be interrupted at any time during the cycle by releasing the trigger. 4. The crimping cycle is complete when the dies are completely closed and the maximum crimping force is reached. The dies will automatically release and will go back to their original position.
- Page 11 CS 150 Battery Crimping Tool CAUTION Œ Œ Do not allow anything to contact the battery’s terminals. Do not immerse the battery in liquid. Liquid may create a short circuit and damage the battery. Œ If the battery is immersed, contact your service center for proper handling.
- Page 12 CS 150 Battery Crimping Tool Section 4 Terminal Specifications and Crimping Operation Scope Terminal Specifications Chart UNCONTROLLED COPY Doc No: ATS-638160200 Release Date: 12-06-07 Page 12 of 21 Revision: A Revision Date: 12-06-07...
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Page 13: Crimping Terminals
CS 150 Battery Crimping Tool SCOPE This tool is designed to crimp various Molex terminals and splices using our offering of crimping heads. Testing Mechanical The tensile test, or pull test, is a means of evaluating the mechanical properties of the crimped connections. - Page 14 CS 150 Battery Crimping Tool Section 5 Preventive Maintenance Periodic Cleaning Storage Battery and Charging Unit Disposal Warranty UNCONTROLLED COPY Doc No: ATS-638160200 Release Date: 12-06-07 Page 14 of 21 Revision: A Revision Date: 12-06-07...
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Page 15: Periodic Cleaning
This tool is basically maintenance free, only the bolt joints at the crimping head have to be oiled regularly. Before use: 1. Inspect dies for wear or damage such as cracks, gouges, or chips. 2. Inspect the tool for damage or leaks. If damage is detected, return the tool to a Molex representative for inspection. After use: 1. -
Page 16: Preventive Maintenance Chart
(2) bolts in crimping head Use SAE 10W Hydraulic oil Schedule should be adjusted up or down depending on usage. Molex recommends that a log of preventive maintenance be kept with the tool. 5.2 Storage In order to protect the tool against damages, this tool should be cleaned carefully after every use. It should then be placed into the carrying case along with the charging unit, crimp heads and the instruction manual and stored in a dry location. - Page 17 CS 150 Battery Crimping Tool The charging unit is run with a nominal voltage of 110V and a frequency of 50-60Hz . New batteries must be charged before use. To remove the battery from the crimping tool push down on the battery lock and pull out.
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Page 18: Warranty
This tool is designed for hand use only. Any clamping, fixturing, or use of handle extensions voids this warranty. After one year Molex recommends the crimping tool be returned to a Molex representative for inspection. Only the heads of the crimping tool are permitted to be changed by the operator. - Page 19 CS 150 Battery Crimping Tool Section 6 6.1. Parts List and Assembly Drawing 6.2. Troubleshooting UNCONTROLLED COPY Doc No: ATS-638160200 Release Date: 12-06-07 Page 19 of 21 Revision: A Revision Date: 12-06-07...
- Page 20 CS 150 Battery Crimping Tool Parts List and Assembly Drawings Item Order No Description Quantity 63816-0200 Battery Crimp Tool CS 150 63816-0201 Battery Powered Tool Head (without tooling) CSE30 63816-0202 Battery Unit CS 150 Figure 6-1 UNCONTROLLED COPY Doc No: ATS-638160200...
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Page 21: Troubleshooting
CS 150 Battery Crimping Tool 6.2 Troubleshooting Make sure the battery is charged before toubleshooting this tool. ΠSymptom Cause Solution ΠDirt, contaminants, etc., Clean the crimping tool. in ram area of tool. ΠTool is Clean contacts with pencil eraser or Battery unit contacts corroded.
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