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Hydraulic Dieless Crimping Tool
Description
Operation
Maintenance
Doc No. TM-638161700 Release Date: 03-21-14
Revision: D
Hydraulic Dieless Crimping Tool
With Swivel Bench Adapter and Terminal Locator
Operation Manual
Order No. 63816-1700
For Insulated and Non-Insulated Terminal and Splices
Revision Date: 05-10-17
UNCONTROLLED COPY
Page 1 of 29
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Summary of Contents for molex 63816-1700
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Page 1: Hydraulic Dieless Crimping Tool
Hydraulic Dieless Crimping Tool Hydraulic Dieless Crimping Tool With Swivel Bench Adapter and Terminal Locator Operation Manual Order No. 63816-1700 For Insulated and Non-Insulated Terminal and Splices Description Operation Maintenance UNCONTROLLED COPY Doc No. TM-638161700 Release Date: 03-21-14 Page 1 of 29... -
Page 2: Table Of Contents
Contents Hydraulic Dieless Crimping Tool............................1 Safety Warnings and Information ............................3 Section 1 ....................................6 General Description ................................6 Principal Mechanical Parts of the 63816-1700 Dieless Crimping Tool ................7 1.1. Description ................................7 1.2. Features ................................8 1.3. -
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 Hydraulic Dieless Crimping Tool WARNING WARNING Do not use compressed air to clean Never use this tool without guards or safety devices this equipment. that are intended to prevent hands from remaining The forces created by compressed in the die space. air can force debris into the tool.
- Page 5 Phone: +1-402-458-TOOL (8665) E-Mail: applicationtooling@molex.com Website: www.molex.com/applicationtooling Molex is a registered trademark of Molex, LLC in the United States of America and may be registered in other countries; all other trademarks listed herein belong to their respective owners. UNCONTROLLED COPY Doc No.
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Page 6: Section 1
Hydraulic Dieless Crimping Tool Section 1 General Description 1.1. Description 1.2. Features 1.3. Technical Specifications 1.4. Delivery Check 1.5. Tools UNCONTROLLED COPY Doc No. TM-638161700 Release Date: 03-21-14 Page 6 of 29 Revision: D Revision Date: 05-10-17... -
Page 7: Principal Mechanical Parts Of The 63816-1700 Dieless Crimping Tool
(See Figure 1-1) The Molex Dieless Crimping Tool is a combination Air and Hydraulic crimping system which utilizes four crimp “nibs” (3 moving and one stationary). The three movable nibs close against the terminal, which nests on the fourth nib, creating crimp indentations from the top, bottom and both sides, resulting in a four sided (quad) crimp. -
Page 8: Features
63916-1711 Hydraulic Hose Assembly 63816-1720 Air / Hydraulic Pump Power Unit with hoses 19286-0049 Filter regulator with gauge 19286-0103 Air Hose Assembly TM-63816-1700 Instruction Manual 1.5. Tools The following tools are recommended for setup and adjustments. Metric standard hex wrench set... -
Page 9: Section 2
Hydraulic Dieless Crimping Tool Section 2 Setup and Adjustments 2.1. Setup 2.2. Adjustments 2.3. Alternative Pump Settings UNCONTROLLED COPY Doc No. TM-638161700 Release Date: 03-21-14 Page 9 of 29 Revision: D Revision Date: 05-10-17... -
Page 10: Setup
Hydraulic Dieless Crimping Tool 2.1 Set-Up Caution: Always disconnect the air pressure until the system is ready to operate. The principal mechanical parts of the 63816-1700 Dieless Crimping Tool are illustrated in Section 5 Assembly Drawings. Air Supply Hook-Up AIR SUPPLY... -
Page 11: Adjustments
12,400 PSI *The SPX Power Team model PA9 air / hydraulic pump is currently shipped with the 63816-1700 tool. This pump has a 100:1 oil / air pressure ratio at the outlet hose with a 10,000 max. safety, regardless of air input. The pressure ratio at the crimp dies is 124:1 (6.2 ton max.) -
Page 12: Section 3
Hydraulic Dieless Crimping Tool Section 3 Terminal Specifications and Crimping Operation Scope Terminal Specifications Chart Crimping Terminals Adjusting the Pump Release Mechanism UNCONTROLLED COPY Doc No. TM-638161700 Release Date: 03-21-14 Page 12 of 29 Revision: D Revision Date: 05-10-17... -
Page 13: Scope
The following is a partial list of the product part numbers and their specifications that this tool is designed to run. We will be adding to this list and an up to date copy is available on www.molex.com. 3.2 Terminal Chart Wire Size: 8 AWG 8.50mm²... - Page 14 Hydraulic Dieless Crimping Tool Wire Size: 8 AWG 8.50mm² Wire Size: 8 AWG 8.50mm² Insulation Diameter Insulation Diameter Terminal Terminal Wire Strip Length Terminal Terminal Wire Strip Length Maximum Maximum Eng No. (REF) Eng No. (REF) 19067-0039 D-956-10 .438 11.11 .350 8.89 19221-0212...
- Page 15 Hydraulic Dieless Crimping Tool Wire Size: 6 AWG 16.50mm² Wire Size: 4 AWG 25.00mm² Insulation Diameter Insulation Diameter Terminal Terminal Wire Strip Length Terminal Terminal Wire Strip Length Maximum Maximum Eng No. (REF) Eng No. (REF) 19193-0219 E-357-56 .468 11.88 19071-0231 F-666-10X .531...
- Page 16 Hydraulic Dieless Crimping Tool Wire Size: 2 AWG 35.00mm² Wire Size: 2 AWG 35.00mm² Insulation Diameter Insulation Diameter Terminal Terminal Wire Strip Length Terminal Terminal Wire Strip Length Maximum Maximum Eng No. (REF) Eng No. (REF) 19063-0114 G-777-38 .578 14.68 .525 13.33 19202-0057...
- Page 17 Hydraulic Dieless Crimping Tool Wire Size: 1/0 AWG 50.00mm² Wire Size: 2/0 AWG 70.00mm² Insulation Diameter Insulation Diameter Terminal Terminal Wire Strip Length Terminal Terminal Wire Strip Length Maximum Maximum Eng No. (REF) Eng No. (REF) 19193-0330 H-381-14 .765 19.43 19193-0350 J-387-12 .781...
- Page 18 Hydraulic Dieless Crimping Tool Wire Size: 4/0 AWG 120.00mm² Wire Size: 300 MCM AWG 152.00mm² Insulation Diameter Insulation Diameter Terminal Terminal Wire Strip Length Terminal Terminal Wire Strip Length Maximum Maximum Eng No. (REF) Eng No. (REF) 19215-0050 L-379 .750 19.05 19221-0307 HDCL-300382-CC...
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Page 19: Crimping Terminals
Hydraulic Dieless Crimping Tool 3.3 Crimping Terminals INDENTOR Before crimping, set the recommended air pressure gauge CENTER BARREL to obtain the proper crimp . See Section 2.2 (Adjustments). BETWEEN NIBS WIRE STOP 1. Adjust wire stop to position terminal barrel centered on the Indentor nibs. -
Page 20: Adjusting The Pump Release Mechanism
Hydraulic Dieless Crimping Tool 3.4 Adjusting the Pump Release Mechanism (See Figure 3-5) ADJUSTING FOOT PEDAL PLATE Loosen the Adjusting Screw. AIR INLET ADJUSTING Verify that the Adjusting Plate is free. STEM SCREW Depress the Air Inlet Stem with the Foot Pedal. -
Page 21: Section 4
Hydraulic Dieless Crimping Tool Section 4 Maintenance Lubrication Bleeding Air From the System Inspecting the Hydraulic Fluid Level Draining and Flushing the Reservoir Refilling the Bladder Periodic Cleaning Spare Parts Perishable Parts Storage UNCONTROLLED COPY Doc No. TM-638161700 Release Date: 03-21-14 Page 21 of 29 Revision: D Revision Date: 05-10-17... -
Page 22: Lubrication
Hydraulic Dieless Crimping Tool Lubrication WARNING: Any repair or servicing, which requires dismantling the pump must be performed in a dirt- free environment by a qualified technician. CAUTION: Always disconnect the air supply before all maintenance If the pump is operated on a continuous duty cycle for extended periods, the manufacturer recommends an automatic air line oiler be installed in the air inlet as close to the pumping unit as possible. -
Page 23: Periodic Cleaning
An example of a maintenance chart is shown below. Copy and use this chart to track the maintenance of your 63816-1700 Dieless Crimping Tool or use this as a template to create your own schedule or use your company’s standard chart, if applicable. -
Page 24: Spare Parts
4.9 Storage When storing the 63816-1700 assembly, disconnect the air supply and store in a dry location. If the pump is disconnected from the dieless crimping Tool, reinstall the dust cap on the cylinder inlet. When transporting, reinstall the red-vented cap on the pump reservoir. -
Page 25: Section 5
Hydraulic Dieless Crimping Tool Section 5 Parts Lists and Assembly Drawings Troubleshooting UNCONTROLLED COPY Doc No. TM-638161700 Release Date: 03-21-14 Page 25 of 29 Revision: D Revision Date: 05-10-17... -
Page 26: Main Parts List And Assembly Drawing
Hydraulic Dieless Crimping Tool 5.1 Main Parts List and Assembly Drawing 63816-1700 Main Assembly - Figure 5-1 Item Order No. Description 63816-1710 Crimp Head Assembly 63816-1711 Hydraulic Hose Assembly – 10 ft. 63816-1720 Air / Hydraulic Pump Power Unit 19286-0049... -
Page 27: Repair Parts
Hydraulic Dieless Crimping Tool 5.2 Repair Parts The following is a list of spare and perishable parts that are available: 63816-1710 Repair Parts - Figure 5-2 Item Order No. Description 63816-1712 Hydraulic Cylinder 1 Ref (Repair Part) 63816-1713 Main Seal for Item 1 1 Ref (Repair Part) 63816-1714 Retract Spring for Item 1... -
Page 28: Troubleshooting
Phone: +1-402-458-TOOL (8665) E-Mail: applicationtooling@molex.com Website: www.molex.com/applicationtooling Molex is a registered trademark of Molex, LLC in the United States of America and may be registered in other countries; all other trademarks listed herein belong to their respective owners. UNCONTROLLED COPY Doc No. - Page 29 For more information use the Crimping Testing and Inspection Handbook for Industrial (Closed Barrel products). There is no charge for this book, which can be found on the Molex website (www.molex.com) or contact your local Molex sales engineer. UNCONTROLLED COPY Doc No.
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