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molex 63816-0200 Operation Manual

Battery powered crimping tool
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Battery Powered Crimping Tool

Order No: TM-638160200
Revision: E
BATTERY POWERED CRIMPING TOOL
Operation Manual
Order No. 63816-0200 (110 V)
Order No. 63816-0250 (220 V)
Release Date: 12.06-07
Revision Date: 06-07-12
UNCONTROLLED COPY
Page 1 of 33

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Summary of Contents for molex 63816-0200

  • Page 1: Battery Powered Crimping Tool

    Battery Powered Crimping Tool BATTERY POWERED CRIMPING TOOL Operation Manual Order No. 63816-0200 (110 V) Order No. 63816-0250 (220 V) UNCONTROLLED COPY Order No: TM-638160200 Release Date: 12.06-07 Page 1 of 33 Revision: E Revision Date: 06-07-12...

  • Page 2: Table Of Contents

    Battery Powered Crimping Tool Table of Contents BATTERY POWERED CRIMPING TOOL ........................1 Safety Warnings and Information ............................. 3 SECTION 1 ..................................7 Description ....................................7 1.1. Features ..................................7 1.2. Technical Specifications .............................. 8 Delivery Check ................................8 SECTION 2 ..................................9 Power Crimp Heads and Adapters...............................

  • Page 3: Safety Warnings And Information

    Keep this manual available when using this tool. Replacement manuals are available for download at no charge at www.molex.com. SAFETY ALERT SYMBOL This symbol is used to call your attention to hazards or unsafe practices which could result in an injury or property damage.
  • Page 4 Never perform any service or maintenance other than as described in this manual. Never modify, alter or misuse the equipment Molex crimp specifications are valid only when used with Molex terminals, applicators and tooling. Failure to observe this precaution may result in injury and property damage.
  • Page 5 Call Toll Free 1-800-786-6539 (US) 1-630-969-4550 (Global). This assistance is limited to the operation and set-up of a customer’s Molex tool. Questions with regard to Molex connector products or how to identify the proper tooling and/ or tooling documentation should be directed to your local Molex personnel or Customer Service Representative.
  • Page 6 Battery Powered Crimping Tool Table of Contents SECTIONS General Description Power Crimp Heads and Adapters Set-up and Adjustments Terminal Specifications and Crimping Operation Preventive Maintenance Parts List, Assembly Drawing, and Troubleshooting UNCONTROLLED COPY Order No: TM-638160200 Release Date: 12.06-07 Page 6 of 33 Revision: E Revision Date: 06-07-12...

  • Page 7: Section 1

    Battery Powered Crimping Tool SECTION 1 Principal Mechanical Parts of the 63816-0200 (110 V) and the 63816-0250 (220 V) Battery Powered Tool. Battery charger not shown LOCKING PINS (2) CRIMPING HEAD ADAPTER RETRACTOR SLIDE TRIGGER UNLOCKING SWITCH RECHARGEABLE Figure 1-1 (NiCad 9.6V) BATTERY...

  • Page 8: Technical Specifications

    75dB (A) in a distance of 1.0m Vibrations <2.5m/s Delivery Check Carefully remove the Battery Powered Tool from its shipping container and determine that the following items are included in the package. For the 63816-0200 (110 V): 63816-0200 Battery Crimping Tool 63816-0202 Battery Unit (2) 63816-0210...

  • Page 9: Section 2

    Battery Powered Crimping Tool SECTION 2 Power Crimp Heads and Adapters Comparison Chart - Hand and Power Tools 63816-0600 Power Crimp Adapter for Type 4A Hand Crimp Tools 63816-0300 Power Crimp Head for Type 2C and 4C Hand Crimp Tools 63816-0800 Power Crimp Head for Type 4D Hand Crimp Tools 63816-0900 Adapter for Type AT Air Crimp Tools (with 64005-0000 Head for Type RHT Hand Crimp Tools)

  • Page 10: Comparison Chart - Hand And Power Crimp Tools

    Head Head Adapter + Adapter 63816-0200 Battery Powered Crimp Tool • NOTE: Un-tooled AT heads are not available separately. Customers can install RHT Tooling into one of their existing AT heads. Caution must be taken as the markings on the AT head will not match the tooling from an RHT tool for a different terminal.

  • Page 11: 63816-0600 Power Crimp Adapter For Type 4A Hand Crimp Tools

    ADAPTER Figure 2-1 Installation of Type 4A Power Crimp Adapter to Battery Powered Crimping Tool To install the 63816-0600 Power Crimp Adapter onto the 63816-0200 Battery Powered Tool, refer to Section 3, “Set-Up and Adjustments”. Operation 1. Load the terminal as described in the Operation section of the specification sheet for the tool.
  • Page 12 Battery Powered Crimping Tool Maintenance It is recommended that each operator of the tool be made aware of, and responsible for, the following maintenance steps: 1. This tool was engineered for durability, but like any fine piece of equipment, it needs cleaning and lubrication for a maximum service life of trouble-free crimping 2.

  • Page 13: 63816-0300 Power Crimp Head For Type 2C And 4C Hand Crimp Tools

    WARNING: Never place fingers into the tooling nest. Power Crimp Head Installation onto Battery Powered Crimping Tool To install the 63816-0300 Power Crimp Head onto the 63816-0200 Battery Powered Crimping Tool, refer to Section 3, “Set- Up and Adjustments”. UNCONTROLLED COPY Order No: TM-638160200 Release Date: 12.06-07...
  • Page 14 Battery Powered Crimping Tool Operation 1. Load the terminal as described in the Operation section of the specification sheet for the tool. 2. Cycle the Battery Powered Tool to crimp the terminal to the wire. Hold the trigger until the tool completes the cycle. 3.

  • Page 15: 63816-0800 Power Crimp Head For Type 4D Hand Crimp Tools

    SCOPE The 63816-0800 Power Crimp Head was created for use with Type 4D Crimp Dies and Locator when used with the Battery Powered Tool (Order No. 63816-0200). Installation for Type 4D Crimp Tooling Installation into Power Crimp Head First, remove the crimp tooling from the Type 4D Hand Crimp Tool. To do this, see the instruction sheet included with the hand crimp tool.
  • Page 16 6. Completely close the crimp dies until they are touching, and then securely tighten the M3 BHCS. Power Crimp Head Installation onto Battery Powered Crimping Tool KNURLED KNOB To install the 63813-0800 Power Crimp Head onto the 63816-0200 Battery Powered Tool, refer to Section 3, “Set-Up and Adjustments”. LOCKING Adjustments...
  • Page 17 Battery Powered Crimping Tool Operation 1. To load a terminal and position the wire in the terminal in the Power Crimp Head, follow the loading procedure as explained in the Hand Crimp Tool Specification sheet. 2. Crimp the terminal by squeezing the trigger on the side of the battery actuator until the tool cycles and returns and the jaws open.

  • Page 18: 63816-0900 Power Adapter For Type At Air Crimp Heads

    The 63816-0900 Power Adapter was created to adapt the 64005 and 64007 series Type AT Crimp Heads for use in the 63816-0200 Battery Powered Tool. The addition, customers who have Type RHT hand crimp tools along with a Type AT Crimp Head, can load the RHT dies...
  • Page 19 Battery Powered Crimping Tool Installation of Power Crimp Head with Power Adapter to the Battery Powered Crimping Tool To install the 63816-0900 Power Adapter onto the 63816-0200 Battery Powered Tool, refer to Section 4, “Set-Up and Adjustments”. Operation LUBRICATION 1. To load a terminal and position the wire in the terminal in the Power Crimp Head,...

  • Page 20: Section 3

    Battery Powered Crimping Tool SECTION 3 Set-Up and Adjustments 3.1. Set-up 3.2. Operation 3.3. Preventive Instructions UNCONTROLLED COPY Order No: TM-638160200 Release Date: 12.06-07 Page 20 of 33 Revision: E Revision Date: 06-07-12...

  • Page 21: Set-Up

    Battery Powered Crimping Tool 3.1 Set-Up Figure 3-1 Replacing Power or Modular Crimp Heads 63806-0900 (Type AT) 63816-0600 (Type 4A) TYPE 4A TYPE 4A TYPE AT MODULAR CRIMP HEAD TYPE AT WITH TOOLING MODULAR CRIMP LOCKING HEAD PINS (2) SLOTTED 63816-0600 SCREWS (2) ADAPTER...

  • Page 22: Operation

    Battery Powered Crimping Tool Warning: Remove the battery from the crimping tool before installing and removing dies in the crimp head Select the appropriate modular crimp head or power crimp head with the proper tooling kit inserted for the application needed.

  • Page 23: Preventive Instructions

    Battery Powered Crimping Tool Warning: An incomplete crimp can cause a fire. Use proper die, connector, and cable combinations. Improper combinations can result in an incomplete crimp. The relief valve will sound to indicate a completed crimp. If you do not hear the sound of the relief valve, the crimp is not complete.

  • Page 24: Section 4

    Battery Powered Crimping Tool SECTION 4 General Terminal Specifications and Crimping Operation 4.1. Scope 4.2. Crimping terminals UNCONTROLLED COPY Order No: TM-638160200 Release Date: 12.06-07 Page 24 of 33 Revision: E Revision Date: 06-07-12...

  • Page 25: Scope

    These documents are called the Application Tooling Specification (ATS) Sheets. These come with complete Hand Tools / Module Crimp Heads. If another copy is needed search on the www.Molex.com for the hand tool order number desired. In the section Specification & Other Documents click on the Application Tooling Specification (PDF) (ATS-EN).

  • Page 26: Section 5

    Battery Powered Crimping Tool SECTION 5 Preventive Maintenance 5.1. Periodic Cleaning 5.2. Storage 5.3. Battery and Charging Unit 5.4. Disposal 5.5. Warranty UNCONTROLLED COPY Order No: TM-638160200 Release Date: 12.06-07 Page 26 of 33 Revision: E Revision Date: 06-07-12...

  • Page 27: Periodic Cleaning

    Before use: Inspect dies for wear or damage such as cracks, gouges, or chips. Inspect the tool for damage or leaks. If damage is detected, return the tool to a Molex representative for inspection. After use: Wipe all tool surfaces clean with a damp cloth and mild detergent. Excessive dirt and grit can contribute to the premature wear of the tool’s internal mechanical parts.

  • Page 28: Battery And Charging Unit

    Battery Powered Crimping Tool 5.2 Battery and Charging Unit WARNING: Do not dispose of the battery in a fire. It will vent fumes and may explode. Failure to observe this warning could result in severe injury from harmful fumes or burns from flying debris CAUTION: Do not store the battery at more than 60 °C (140 °F).

  • Page 29: Disposal

    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 30: Section 6

    Battery Powered Crimping Tool SECTION 6 Parts List, Assembly Drawings, and Troubleshooting 6.1. Parts List and Assembly Drawing 6.2. Troubleshooting UNCONTROLLED COPY Order No: TM-638160200 Release Date: 12.06-07 Page 30 of 33 Revision: E Revision Date: 06-07-12...

  • Page 31: Parts List And Assembly Drawings

    The following Modular Crimp Heads and Battery Powered Crimp Adapters are sold separately and are not included with the 63816-0200 (110 V) or the 63816-0250 (220 V) Battery Powered Tool. The chart below shows all applications for the Battery Powered Tool. See Figure 6-2 and 6-3.
  • Page 32 Battery Powered Crimping Tool Figure 6-2 Modular Crimp Head TYPE AT TYPE 4A MODULAR MODULAR CRIMP HEAD CRIMP HEAD WITH TOOLING LOCKING WITH TOOLING PINS (2) SLOTTED SCREWS (2) 63816-0600 63816-0900 ADAPTER ADAPTER LOCKING PINS (2) LOCKING PINS (2) BATTERY BATTERY POWERED TOOL POWERED TOOL...

  • Page 33: Troubleshooting

    Battery charge is low. during operation. LED glows for Battery charge is low. Charge or replace battery unit. 20 seconds. Visit our Web site at http://www.molex.com UNCONTROLLED COPY Order No: TM-638160200 Release Date: 12.06-07 Page 33 of 33 Revision: E...

This manual is also suitable for:

63816-0250

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