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Battery Powered Crimping Tool
Description
Operation
Maintenance
Doc No: TM-638160200
Revision: D
This datasheet has been downloaded from
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: 05-20-11
UNCONTROLLED COPY
http://www.digchip.com
Page 1 of 23
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Summary of Contents for molex 63816-0200
- Page 1 Battery Powered Crimping Tool BATTERY POWERED CRIMPING TOOL Operation Manual Order No. 63816-0200 (110 V) Order No. 63816-0250 (220 V) Description Operation Maintenance UNCONTROLLED COPY Doc No: TM-638160200 Release Date: 12-06-07 Page 1 of 23 Revision: D Revision Date: 05-20-11 This datasheet has been downloaded from http://www.digchip.com...
- Page 2 Battery Powered Crimping Tool Table of Contents SECTION Safety Warnings and Information General Description Set-up and Adjustments Terminal Specifications and Crimping Operation Preventive Maintenance Parts List, Assembly Drawing and Troubleshooting” UNCONTROLLED COPY Doc No: TM-638160200 Release Date: 12-06-07 Page 2 of 23 Revision: D Revision Date: 05-20-11...
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Page 3: Safety Warnings And Information
Keep this manual available when using this tool. Replacement manuals are available upon request 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 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...
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Page 5: General Description
Battery Powered Crimping Tool Section 2 General Description Description Features Technical Specifications Delivery Check UNCONTROLLED COPY Doc No: TM-638160200 Release Date: 12-06-07 Page 5 of 23 Revision: D Revision Date: 05-20-11... - Page 6 (NiCad 9.6V) BATTERY Description The Molex Battery Powered Tool is designed to crimp terminals with the use of interchangeable crimp die kits. 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 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 with battery 63816-0210 Battery Charger Carrying Case...
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Page 8: Setup And Adjustments
Battery Powered Crimping Tool Section 3 Set-Up and Adjustments 3.1. Set-up 3.2. Operation 3.3. Preventive Instructions UNCONTROLLED COPY Doc No: TM-638160200 Release Date: 12-06-07 Page 8 of 23 Revision: D Revision Date: 05-20-11... - Page 9 Battery Powered Crimping Tool 3.1 Set-Up Figure 3-1 Replacing Power or Modular Crimp Heads Type AT Type 4A TYPE 4A TYPE AT MODULAR CRIMP MODULAR CRIMP HEAD HEAD WITH TOOLING WITH TOOLING LOCKING PINS (2) SLOTTED 63816-0600 SCREWS (2) ADAPTER 63816-0900 ADAPTER LOCKING...
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Page 10: Operation
Battery Powered Crimping Tool WARNING Remove the battery from the crimping tool before installing and removing dies in the crimp head. 1. Select the appropriate modular crimp head or power crimp head with the proper tooling kit inserted for the application needed. - Page 11 Battery Powered Crimping Tool 3. Hold the trigger down again until the crimping tool achieves pressure relief, which is accompanied by an audible “pop”. The crimping operation can be interrupted at any time during the cycle by releasing the trigger. 4.
- Page 12 Battery Powered Crimping Tool CAUTION 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. If the battery is immersed, contact your service center for proper handling. Do not place the battery into a pocket, tool pouch, or tool box with conductive objects.
- Page 13 Battery Powered Crimping Tool Section 4 Terminal Specifications and Crimping Operation Scope Crimping terminals UNCONTROLLED COPY Doc No: TM-638160200 Release Date: 12-06-07 Page 13 of 23 Revision: D Revision Date: 05-20-11...
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Page 14: Crimping Terminals
Battery Powered 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 15: Preventive Maintenance
Battery Powered Crimping Tool Section 5 Preventive Maintenance Periodic Cleaning Storage Battery and Charging Unit Disposal Warranty UNCONTROLLED COPY Doc No: TM-638160200 Release Date: 12-06-07 Page 15 of 23 Revision: D Revision Date: 05-20-11... -
Page 16: 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 17: 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, modular crimp heads and the instruction manual and stored in a dry location. - Page 18 Battery Powered Crimping Tool The charging unit is run with a nominal voltage of 110V or 220V (for Europe) 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 19: 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 20 Battery Powered Crimping Tool Section 6 Parts List, Asseby Drawings and Troubleshooting 6.1. Parts List and Assembly Drawing 6.2. Troubleshooting UNCONTROLLED COPY Doc No: TM-638160200 Release Date: 12-06-07 Page 20 of 23 Revision: D Revision Date: 05-20-11...
- Page 21 The following Modular Crimp Heads and Battery Powerd 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 6-1 and 6-2.
- Page 22 Battery Powered Crimping Tool Figure 6-2 Modular Crimp Head Type 4A Type AT 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...
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Page 23: Troubleshooting
Battery unit contacts corroded. inoperative. contact cleaner Battery unit contacts damaged. Reform the contacts. Tool parts worn or damaged. Contact a Molex representative. Dies stop Battery charge is low. Charge or replace battery unit. during operation. LED glows for Battery charge is low.
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