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battery powered crimping tool order no: tm-638160200 release date: 12.06-07 uncontrolled copy page 1 of 33 revision: e revision date: 06-07-12 battery powered crimping tool operation manual order no. 63816-0200 (110 v) order no. 63816-0250 (220 v)
battery powered crimping tool order no: tm-638160200 release date: 12.06-07 uncontrolled copy page 2 of 33 revision: e revision date: 06-07-12 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 1.3 delivery check .................................... ................................................... ................................................... ................... 8 section 2 ......................................... ................................................... ................................................... ....................... 9 power crimp heads and adapters..................... ................................................... ................................................... .................... 9 2.1 comparison chart - hand and power crimp tools...... ................................................... ........................................... 10 2.2 63816-0600 power crimp adapter for type 4a hand cri mp tools .......................................... ................................. 11 2.3 63816-0300 power crimp head for type 2c and 4c hand crimp tools ...................................... ............................ 13 2.4 63816-0800 power crimp head for type 4d hand crimp tools ............................................. .................................. 15 2.5 63816-0900 power adapter for type at air crimp head s ................................................. ....................................... 18 section 3 ......................................... ................................................... ................................................... ..................... 20 set-up and adjustments ............................ ................................................... ................................................... .......................... 20 3.1 set-up ............................................ ................................................... ................................................... ...................... 21 3.2 operation ......................................... ................................................... ................................................... .................... 22 3.3 preventive instructions ........................... ................................................... ................................................... ............. 23 section 4 ......................................... ................................................... ................................................... ..................... 24 general terminal specifications and crimping operat ion ............................................... ................................................... ....... 24 4.1 scope ............................................. ................................................... ................................................... ...................... 25 4.2 crimping terminals ................................ ................................................... ................................................... .............. 25 section 5 ......................................... ................................................... ................................................... ..................... 26 preventive maintenance ............................ ................................................... ................................................... .......................... 26 5.1 periodic cleaning ................................. ................................................... ................................................... ................ 27 5.2 battery and charging unit.......................... ................................................... ................................................... .......... 28 5.3 disposal .......................................... ................................................... ................................................... ..................... 29 5.4 warranty .......................................... ................................................... ................................................... .................... 29 section 6 ......................................... ................................................... ................................................... ..................... 30 parts list, assembly drawings, and troubleshooting ................................................... ................................................... .......... 30 6.1 parts list and assembly drawings .................. ................................................... ................................................... .... 31 6.2 troubleshooting .................................. ................................................... ................................................... ................ 33
battery powered crimping tool order no: tm-638160200 release date: 12.06-07 uncontrolled copy page 3 of 33 revision: e revision date: 06-07-12 safety warnings and information read and understand all of the instructions and safety information in t his manual before operating or servicing this tool. keep this manual available when using this tool. replacement manuals are available for download at n o charge at www.molex.com. safety alert symbol this symbol is used to call your attention to hazar ds or unsafe practices which could result in an inj ury or property damage. the signal word, defined below , indicates the severity of the hazard. the messag e after the signal word provides information for prev enting or avoiding the hazard. danger danger: indicates an imminently hazardous situation which, if not avoided, could result in death or serious in jury. warning warning: indicates a potentially hazardous situation which, if not avoided, could result in death or serious in jury. caution caution: indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate inj ury. caution may also be used to alert against unsafe practices associated with events that could lead to personal injury. warning warning always wear proper eye protection when operating or servicing this tool. failure to wear eye protection could result in serious eye injury from flying debris or hydraulic oil . always wear proper ear protection when operating or servicing this tool. warning warning never wear clothing or jewelery that is loose or that could potentially get caught in this tool. failure to observe this warning could result in severe injury or death. electric shock hazard: this tool is not insulated. when using this unit n ear energized electrical lines, use proper personal protective equipment. failure to observe this warning could result in severe injury or death warning warning never operate, service, install, or adjust this tool without proper instruction and without first reading and understanding the instructions in this manual and all applicable manuals. pinch points: keep hands away from the crimping head when crimping. failure to observe this warning could result in severe injury or death.
battery powered crimping tool order no: tm-638160200 release date: 12.06-07 uncontrolled copy page 4 of 33 revision: e revision date: 06-07-12 warning warning do not use solvents or flammable liquids to clean the crimping tool. solvents or flammable liquids could ignite and cause serious injury or property damage. do not use compressed air to clean this tool. the forces created by compressed air can force debris into the tool. failure to observe these precautions may result in injury or property damage. warning 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 inspect tool and dies before use. replace any worn or damaged parts. a damaged or improperly assembled tool can break and strike someone nearby. failure to observe this warning could result in severe injury or death. caution do not operate the tool without the dies. damage t o the ram or crimping head can result. do not operate with the crimping head open. damage to the ram or seals can result. this tool is not designed for continuous use. afte r 100 crimping cycles, allow the crimping tool to c ool down for 15 minutes. do not place the tool in a vise. the crimping tool is designed for hand-held operation only. this tool may be used in damp or wet environments; however, we recommend air-drying the tool before us e if it becomes soaked. use this tool for the manufacturers intended purpo se only. failure to observe these precautions may result in injury or property damage caution do not allow anything to contact the batterys term inals. do not immerse the battery in liquid. liquid may c reate a short circuit and damage the battery. if the battery is immersed, contact your service ce nter for proper handling. do not place the battery into a pocket, tool pouch, or tool box with conductive objects. conductive objects may create a short circuit and d amage the battery. do not place a battery on moist ground or grass. m oisture may create a short circuit and damage the b attery. failure to observe these precautions may result in injury or property damage. ca ution do not store the battery at more than 60 c (140 f ). damage to the battery can result. do not use another manufacturers charger. other m anufacturers chargers may overcharge and damage th e battery. do not attempt to open the battery. it contains no user-serviceable parts. failure to observe these precautions may result in injury or property damage. caution never perform any service or maintenance other than as de scribed 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 in jury and property damage.
battery powered crimping tool order no: tm-638160200 release date: 12.06-07 uncontrolled copy page 5 of 33 revision: e revision date: 06-07-12 tooling technical assistance molex offers tooling technical assistance for custo mers who may need some guidance for tooling adjustm ents. this support can be obtained by calling either of the two number s listed below and asking for the molex tooling gro up. 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 customers molex tool. questions with reg ard to molex connector products or how to identify the proper tooling and/ or tooling documentation should be directed to you r local molex personnel or customer service representative. when calling for service on this tool, a copy of th e tooling manual and specific application tooling specification (ats) sheet should be present and a person that is familiar wit h this tool should be present. be sure the followi ng information is supplied: 1. customer name 2. customer address 3. person to contact such as (name, title, e-mail, and telephone number 4. power tool order number (lease number also if appli cable) 5. serial number (lease number also if applicable) 6. molex connector product order number 7. urgency of request 8. nature of problem molex application tooling group 2200 wellington court lisle, il 60532, usa tel: +1 (630) 969-4550 fax:+1 (630) 505-0049 visit our web site at http://www.molex.com
battery powered crimping tool order no: tm-638160200 release date: 12.06-07 uncontrolled copy page 6 of 33 revision: e revision date: 06-07-12 table of contents sections 1. general description 2. power crimp heads and adapters 3. set-up and adjustments 4. terminal specifications and crimping operation 5. preventive maintenance 6. parts list, assembly drawing, and troubleshooting
battery powered crimping tool order no: tm-638160200 release date: 12.06-07 uncontrolled copy page 7 of 33 revision: e revision date: 06-07-12 figure 1-1 locking pins (2) trigger crimping head adapter rechargeable (nicad 9.6v) battery unlocking switch retractor slide section 1 principal mechanical parts of the 63816-0200 (110 v ) and the 63816-0250 (220 v) battery powered tool. battery charger not shown . description the molex battery powered tool is designed to crimp terminals with the use of interchangeable modular crimp heads or power crimp heads, and tool kits. this tool has an automatic retractable system which returns the cri mping adapter along with the crimping dies to the starting position whe n the maximum force is reached. it is equipped wit h a special brake that will stop the forward motion of the crimping dies w hen the trigger is released. the crimping head can be rotated 360 for better access in difficult working situations. 1.1. features crimps a wide range of products with interchangeabl e modular crimp heads or power crimp heads, and too l kits, which reduce the overall cost and provide production flex ibility. modular crimp heads or power crimp head and dies ar e easily and quickly interchanged to reduce product ion down time. complete portable system that allows tool to be mov ed and stored easily.
battery powered crimping tool order no: tm-638160200 release date: 12.06-07 uncontrolled copy page 8 of 33 revision: e revision date: 06-07-12 1.2. technical specifications dimensions (with battery) length 292.1mm (11.50) width 76.2mm (3.00) depth 50.8mm (2.00) unpacked weight 1.50kg (3.31lbs) production rate 250 cycles per hour maximum, depending on operator skill and tool kit installed. battery voltage 9.6v capacity 1.3 ah charging time approximately 40 minutes, about 15 mi nutes with fast-charger crimps/battery-charge 150 at 10mm 2 operating parameters maximum force 15kn (1.7 tonne-force) cycle time 2.0 seconds stroke length 9.00mm (.354) ambient temperature -20 o c to +40 o c sound level 75db (a) in a distance of 1.0m vibrations <2.5m/s 2 1.3 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 battery charger carrying case tm-638160200 operation manual for the 63816-0250 (220 v): 63816-0250 battery crimping tool 63816-0202 battery unit (2) 63816-0260 battery charger carrying case tm-638160200 operation manual
battery powered crimping tool order no: tm-638160200 release date: 12.06-07 uncontrolled copy page 9 of 33 revision: e revision date: 06-07-12 section 2 power crimp heads and adapters 2.1 comparison chart - hand and power tools 2.2 63816-0600 power crimp adapter for type 4a hand crimp tools 2.3 63816-0300 power crimp head for type 2c and 4c hand crimp tools 2.4 63816-0800 power crimp head for type 4d hand cr imp tools 2.5 63816-0900 adapter for type at air crimp tools (with 64005-0000 head for type rht hand crimp tools) note : hand crimp tool type with a pictorial illustrat ion, is displayed on the upper right corner of the hand crimp tool specification sheet (ats) and in the following pages of this manual.
battery powered crimping tool order no: tm-638160200 release date: 12.06-07 uncontrolled copy page 10 of 33 revision: e revision date: 06-07-12 2.1 comparison chart - hand and power crimp tools scope modular crimp heads, power crimp head, adapters, an d dies are easily and quickly interchanged between the hand crimp tools and the battery powered tools. see chart bel ow. battery power crimp tool and adapters for hand crim p tools type 4a type 2c type 4c type 4d type at type rht see note 638160600 638160300 638160300 638160800 638160900 64005xx00 + 638160900 adapter head head head adapter at head + 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 hea d will not match the tooling from an rht tool for a different terminal. comparison chart battery power and crimp hand tools
battery powered crimping tool order no: tm-638160200 release date: 12.06-07 uncontrolled copy page 11 of 33 revision: e revision date: 06-07-12 63816 - 0001 locking pins (2) type 4a modular crimp head with tooling 63816 - 0600 adapter figure 2-1 2.2 63816-0600 power crimp adapter for type 4a hand crimp tools scope the 63816-0600 power crimp adapter was created for use with the type 4a modular crimp heads when used with the battery powered tool (order no. 63816-0200). installation of type 4a modular crimp heads onto po wer crimp adapter to mount the type 4a modular crimp heads to the 63816-0600 modul ar crimp adapter, slide the locking pins outward un til they stop. then place the crimp head in the upper s lot and align the holes with the pins. then, push i n the pins until they lock. see figure 2-1. installation of type 4a power crimp adapter to batt ery powered crimping tool to install the 63816-0600 power crimp adapter onto the 63816-0200 battery powered tool, refer to secti on 3 , set-up and adjustments . operation 1. load the terminal as described in the operation sec tion of the specification sheet for the tool. 2. cycle the battery powered tool to crimp the termina l to the wire. hold the trigger until the tool comp letes the cycle. 3. remove the crimped terminal from the terminal locat or by pressing down on the wire stop and gently pul ling on the wire. the terminal locator can be in either position. 4. visually inspect the crimped terminal for proper cr imp location. warning: never place fingers into the tooling nest. 63816-0600 power crimp adapter application tooling for type 4a hand crimp tools type 4a
battery powered crimping tool order no: tm-638160200 release date: 12.06-07 uncontrolled copy page 12 of 33 revision: e revision date: 06-07-12 figure 2 - 3 1 lubrication points (both sides) light oil (every month or 5,000 crimps) figure 2 - 2 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 a ny fine piece of equipment, it needs cleaning and l ubrication for a maximum service life of trouble-free crimping 2. remove dust, moisture and other contaminants with a clean brush, or soft, lint-free cloth. 3. do not use any abrasive materials that could damage the tool. 4. make certain all pins, pivot points and bearing sur faces in the tool head are protected with a thin coat of high quality machine oil. do not oil excessively. use light oil, such as sae 30 weight automotive oil , every 5,000 crimps or monthly, will significantly enhance the tool life a nd ensure a stable calibration. see figure 2-2 for lubrication points. 5. store the tool in a clean and dry area when not in use. warranty this tool is for electrical terminal crimping purpo ses only. this tool is made of the best quality materials. all vital components a re long life-tested. all tools are warranted free of manufacturing defects for a perio d of 30 days. should such a defect occur, we will repair or exchange the tool i f it cannot be repaired, free of charge. this repair or exchange will not be applic able to altered, misused, or damaged tools. parts list item order no. description quantity 1 6381 6 - 0 6 00 power crimp adapter 1
battery powered crimping tool order no: tm-638160200 release date: 12.06-07 uncontrolled copy page 13 of 33 revision: e revision date: 06-07-12 anvils power crimp head figure 2 - 4 punches m4 x 10 long bhcs m4 x 18 long bhcs 2.3 63816-0300 power crimp head for type 2c and 4c hand crimp tools scope the 63816-0300 power crimp head was created for use with the type 2c and 4c crimp dies and locator kits when used with the battery powered tool (order no. 63816-0200 ). installation of type 2c or 4c crimp tool kit instal lation into power crimp head 1. remove the crimp tool kit from the type 2c or 4c ha nd crimp tool. to do this, see the instruction she et included with the hand crimp tool. 2. to install the crimp tool kit into the power crimp head, follow the steps below: 1. insert the anvils into the bottom slots of the nest . the wire size markings face toward the front of the head, opposite from the locator pivot shaft. install the m4 x 10 l ong bhcs and tighten in place. 2. insert the punches into the top slots of the nest w ith wire size markings to the front. install the m 4 x 18 long bhcs and tighten in place. see figure 2-4. 3. position the locator with the hole over the brass p ivot shaft and snap it into place. see figure 2-5. 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 . 63816-0300 power crimp head application tooling type 2c type 4c hand crimp tools
battery powered crimping tool order no: tm-638160200 release date: 12.06-07 uncontrolled copy page 14 of 33 revision: e revision date: 06-07-12 2 figure 2 - 7 1 m4 x 8 long bhcs (ref) operation 1. load the terminal as described in the operation sec tion of the specification sheet for the tool. 2. cycle the battery powered tool to crimp the termina l to the wire. hold the trigger until the tool comp letes the cycle. 3. remove the crimped terminal from the terminal locat or by pressing down on the wire stop and gently pul ling on the wire. the terminal locator can be in either position. 4. visually inspect the crimped terminal for proper cr imp location. 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. make certain all pins, pivot points and bearing sur faces in the tool head are protected with a thin coat of high quality machine oil. do not oil excessively. this tool was engineered for durability, but like any fi ne piece of equipment, it needs cleaning and lubrication for a maximum service life of trouble-free crimping. use light oil, such as sae 30 weight automotive oil, ev ery 5,000 crimps or monthly, will significantly enhance the tool life and ensure a st able calibration. see figure 2-6 for lubrication points. 4. store the tool in a clean and dry area when not in use. warranty this tool is for electrical terminal crimping purpo ses only. this tool is made of the best quality ma terials. all vital components are long life-tested. all tools are warranted free of manufacturing defects for a period of 30 days. should such a defect occur, we will repair or exchange the tool if it ca nnot be repaired, free of charge. this repair or e xchange will not be applicable to altered, misused, or damaged tools. parts list item order no description quantity 1 63816 - 0300 power crimp head 1 2 63811 - 4773 universal locator mount 1 lubrication points (both sides) light oil (every month or 5,000 crimps) figure 2-6
battery powered crimping tool order no: tm-638160200 release date: 12.06-07 uncontrolled copy page 15 of 33 revision: e revision date: 06-07-12 2.4 63816-0800 power crimp head for type 4d hand cr imp 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 ha nd crimp tool. to do this, see the instruction shee t included with the hand crimp tool. to remove the locator from the power crimp head 1. open the power crimp head to remove the locator. 2. squeeze gently on the lower area of the locator ass embly, shown in figure 2-8 with your thumb and inde x finger. the lower tabs of the locator should disengage from the power crimp head. 3. lift and pull away from the power crimp head. the top locator hooks should slip out of the top slots easily. see figure 2-8. to install the locator in the power crimp head 1. install the locator assembly. 2. press the red insert down as far as it will go. see figure 2-9. 3. the locator goes on the opposite side from the dies with the wire gauge markings. 4. while holding onto the lower part of the locator wi th your thumb and index finger, insert the locator top hooks (2) into the power crimp head top slots. 5. rotate the locator down and press the lower tabs in to the two bottom slots of the head. to secure the locator into place, the lower tabs must snap into place on the head frame. removing the crimp dies from the power crimp head 1. open the power crimp head. 2. remove the two m3 bhcs. 3. remove the crimp dies as shown in figure 2-10. 4. make sure all of components removed from the power crimp head are reinstalled into the power crimp hea d in the same manner. 63816-0800 power crimp head application tooling type 4 d hand crimp tools top slot of the handtool top hooks top slot of the handtool lower tabs squeeze here squeeze here locator figure 2 - 8 make sur e center of locator is in the down position figure 2 - 9 type 4d
battery powered crimping tool order no: tm-638160200 release date: 12.06-07 uncontrolled copy page 16 of 33 revision: e revision date: 06-07-12 figure 2-10 m3 bhcs x 8 long e1 e2 i2 i1 power crimp head m3 bhcs x 14 long figure 2-11 match up markings wire gauge identifications showing front back installing the crimp dies in the power crimp head 1. select the desired type 4d crimping dies. 2. insert the anvils or dies (e1 and i1) into the bott om slots of the nest. install the m3 x 14 long bhc s and lightly tighten in place. note : the tool part number markings on the dies go inwa rd so they will not be visible when installed. 3. insert the punches or dies (e2 and i2) into the top slots of the nest. install the m3 x 8 long bhcs a nd lightly tighten in place. see figure 2-10 4. make sure the small markings on the individual dies match up and wire gauge identification (awg) marks should be facing out and aligned as shown in figure 2-11. 5. note : make sure the longer screw only goes into the low er dies. 6. completely close the crimp dies until they are touc hing, and then securely tighten the m3 bhcs. power crimp head installation onto battery powered crimping tool to install the 63813-0800 power crimp head onto the 63816-0200 battery powered tool, refer to section 3 , set-up and adjustments . adjustments the crimp height on the 63816-0800 power crimp head can be adjusted, if necessary. to do this, first measure the conductor crimp height of a crimped terminal and compare to the crimp specification lis ted in the product specification for that terminal. if an adjustment is required, follow the procedure, below: 1. loosen the locking set screw located just below the knurled knob at the top of the power crimp head. see figure 2-12. 2. if the crimp height is too loose, rotate the knob, a small amount, in the counter- clockwise direction. crimp another terminal and re- check the crimp height. 3. if the crimp height is too tight, turn the knob clo ckwise and follow the same procedure. 4. do this until the proper crimp height is achieved. 5. when the proper crimp height is achieved, lock the set screw. locking set screw figure 2 - 12 kn urled knob
battery powered crimping tool order no: tm-638160200 release date: 12.06-07 uncontrolled copy page 17 of 33 revision: e revision date: 06-07-12 2 2 figure 2 - 11 1 operation 1. to load a terminal and position the wire in the ter minal 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 . 3. remove the terminal from the locator and inspect th e crimp for proper quality. warning: never place fingers into the tooling nest. maintenance it is recommended that each operator of the tool be made aware of, and responsible for, the following maintenance steps: this tool was engineered for durability, but like a ny fine piece of equipment, it needs cleaning and lubrication for a maximum servic e life of trouble-free crimping remove dust, moisture and other contaminants with a clean brush, or soft, lint- free cloth. do not use any abrasive materials that could damage the tool. use light oil, such as sae 30 weight automotive oil , every 5,000 crimps, or monthly, will significantly enhance the tool life a nd ensure a stable calibration. make certain all sliding surfaces in the tool head are protected with a thin coat of high quality mach ine oil. see figure 2-13 for lubrication points. do not oil excessively and wipe excess oil from the tool frame when complete. store the tool in a clean and dry area when not in use. warranty this tool is for electrical terminal crimping purpo ses only. this tool is made of the best quality ma terials. all vital components are long life-tested. all tools are warranted free of manufacturing defects for a period of 30 days. should such a defect occur, we will repair or exchange the tool if it ca nnot be repaired, free of charge. this repair or e xchange will not be applicable to altered, misused, or damaged tools. parts list item order no description quantity 1 63816 - 0800 power crimp head (for style 4d crimp tools) 1 2 63816 - 0801 return spring 2 lubrication points (both sides) light oil (every month or 5,000 crimps) figure 2-13
battery powered crimping tool order no: tm-638160200 release date: 12.06-07 uncontrolled copy page 18 of 33 revision: e revision date: 06-07-12 2.5 63816-0900 power adapter for type at air crimp head s (with 64005-0000 head for type rht hand crimp tools ) scope the 63816-0900 power adapter was created to adapt the 64005 and 64 007 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 and locator into the at crimp head and then in the battery powered tool installation type at air crimp head installation into at power adapte r install the at air crimp head onto the at power ada pter as shown in figure 2-15. type rht crimp tool kit into at head and at power a dapter (one at crimp head required) remove the crimp tooling kit from the type rht hand crimp tool. to do this, see the instruction sheet included with the hand crimp tool. 1. install the rht tooling kit with locator, into the at power crimp head. see figures 2-14. 2. then install the crimp head onto the at power adapt er. this is a typical type rht crimp tooling kit ar rangement in at head. see figure 2-15. for specific tooling, see the specification sheet t hat is included with the rht tool. warning: never place fingers into the tooling nest. 63816-0900 power adapter application tooling type rht type at hand crimp tools and air crimp heads at crimp head adapter figure 2-15 at crimp head slotted screw (2) figure 2 - 1 4 at head rht crimp tooling kit
battery powered crimping tool order no: tm-638160200 release date: 12.06-07 uncontrolled copy page 19 of 33 revision: e revision date: 06-07-12 2 figure 2 - 17 1 installation of power crimp head with power adapter to the battery powered crimping tool to install the 63816-0900 power adapter onto the 63 816-0200 battery powered tool, refer to section 4, set-up and adjustments. operation 1. to load a terminal and position the wire in the ter minal in the power crimp head, follow the loading procedure as explained in the at crimp head (or rht hand crimp tool) instruction 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. 3. remove the terminal from the locator and inspect th e crimp for proper quality. maintenance it is recommended that each operator of the tool be made aware of, and responsible for, the following maintenance steps: 6. this tool was engineered for durability, but like a ny fine piece of equipment, it needs cleaning and lubrication for a maximum service life of trouble-free crimping 7. remove dust, moisture and other contaminants with a clean brush, or soft, lint-free cloth. 8. do not use any abrasive materials that could damage the tool. 9. make certain all pins, pivot points and bearing sur faces in the tool head are protected with a thin co at of high quality machine oil. do not oil excessively. use light oil, such as sae 30 weight automotive oil, every 5, 000 crimps or monthly, will significantly enhance the tool life a nd ensure a stable calibration. see figure 2-16 for lubrication points. 10. store the tool in a clean and dry area when not in use. warranty this tool is for electrical terminal crimping purpo ses only. this tool is made of the best quality ma terials. all vital components are long life-tested. all tools are warranted free of manufacturing defects for a period of 30 days. should such a defect occur, we will repair or exchange the tool if it ca nnot be repaired, free of charge. this repair or e xchange will not be applicable to altered, misused, or damaged tools. parts list item order no. description quantity 1 63816 - 0900 power crimp adapter 1 2 19279 - 0161 slotted screw 2 lubrication points (both sides) light oil (every month or 5,000 crimps) figure 2 - 16
battery powered crimping tool order no: tm-638160200 release date: 12.06-07 uncontrolled copy page 20 of 33 revision: e revision date: 06-07-12 section 3 set-up and adjustments 3.1. set-up 3.2. operation 3.3. preventive instructions
battery powered crimping tool order no: tm-638160200 release date: 12.06-07 uncontrolled copy page 21 of 33 revision: e revision date: 06-07-12 3.1 set-up figure 3 - 1 replacing power or modular crimp heads 63806 - 0900 (type a t) 63816 - 0600 (type 4a) 63816 - 0300 (type 2c or 4c) 63816 - 0800 (type 4d) before starting any work on electrical applications , make sure there are no live cables or parts in th e immediate area of the user. type 2c or 4c locking pins (2) type 2c or 4 c power crimp head no tooling shown battery powered tool yoke crimp head adapter locking latch retract slide type at modular crimp head slotted screws (2) battery powered tool 63816 - 0900 adapter locking pins (2) retract slide yoke type at type 4a retract slide locking pins (2) battery powered tool type 4a modular crimp head with tooling 63816 - 0600 adapter locking pins (2) yoke type 4d battery powered tool type 4 d power crimp head no tooling shown crimp head adapter locking pins (2) retract slide yoke
battery powered crimping tool order no: tm-638160200 release date: 12.06-07 uncontrolled copy page 22 of 33 revision: e revision date: 06-07-12 type 4a modular crimp head with locator hold trigger down type 4a power crimp adapter figure 3-2 with locator terminal and wire in place hold trigger down terminal and wire in place type 2c and 4c power crimp head with locator warning : remove the battery from the crimping tool before in stalling 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. the modular crimp head with the battery po wered crimp adapter or the power crimp head are sol d separately. 2. remove the locking pins (2) from the battery powere d crimp yoke. 3. place the modular crimp head into the yoke and push down until it engages into the slot of the adapter . the power crimp heads do not require a separate power crimp adapter . 4. replace the locking pins (2) making sure the modula r crimp head or the power crimp head are secure. t he locking pins can be inserted from either side of the yoke. see figur e 3-1. warning: electric shock hazard : this tool is not insulated. when using this unit n ear energized electrical lines, use proper personal protective equipment. failure to observe this warning could result in sev ere injury or death warning: wear eye protection when operating or servicing thi s tool. failure to wear eye protection could result in seri ous eye injury from flying debris or hydraulic oil. 3.2 operation 1. insert the proper terminal or connector into the to oling nest and push on the trigger in the handle ju st enough so the dies contact the terminal or connector securely. releas e the trigger. this allows the operator to make ad justments to the connector before the final termination. see figure 3-2. 2. insert the wire or cable into the terminal. push o n the wire or cable to assure it is fully seated in the terminal. 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 ti me during the cycle by releasing the trigger. 4. the crimping cycle is complete when the dies are co mpletely closed and the maximum crimping force is r eached. the dies will automatically release and will go back to their original position. note: in case of an error or emergency, the ram can be r etracted before the crimping cycle is complete. to do this push the retractor slide towards the battery. see figur e 3-1.
battery powered crimping tool order no: tm-638160200 release date: 12.06-07 uncontrolled copy page 23 of 33 revision: e revision date: 06-07-12 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. failure to observe these warnings co uld result in severe injury or death. 3.3 preventive instructions 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 sev ere injury from harmful fumes or burns from flying debris warning: inspect tool and dies before use. replace any worn or damaged parts. a damaged or improperly assembled tool can break and strike someone nearby. failure to observe this warning could result in s evere injury or death. caution: do not operate the tool without the dies. damage t o the ram or crimping head can result. do not operate with the crimping head open. damage to the ram or seals can result. this tool is not designed for continuous use. afte r 100 crimping cycles, allow the crimping tool to c ool down for 15 minutes. do not place the tool in a vise. the crimping tool is designed for hand-held operation only. this tool may be used in damp or wet environments; however, we recommend air-drying the tool before us e if it becomes soaked. use this tool for the manufacturers intended purpo se only. failure to observe these precautions may result in injury or property damage. caution: do not allow anything to contact the batterys term inals. do not immerse the battery in liquid. liquid may c reate a short circuit and damage the battery. if the battery is immersed, contact your service ce nter for proper handling. do not place the battery into a pocket, tool pouch, or tool box with conductive objects. conductive objects may create a short circuit and d amage the battery. do not place a battery on moist ground or grass. m oisture may create a short circuit and damage the b attery. failure to observe these precautions may result in injury or property damage. avoid dropping this tool. extreme shock may damage the internal mechanism and result in malfunction o f the tool.
battery powered crimping tool order no: tm-638160200 release date: 12.06-07 uncontrolled copy page 24 of 33 revision: e revision date: 06-07-12 section 4 general terminal specifications and crimping operat ion 4.1. scope 4.2. crimping terminals
battery powered crimping tool order no: tm-638160200 release date: 12.06-07 uncontrolled copy page 25 of 33 revision: e revision date: 06-07-12 4.1 scope this tool is designed to crimp various molex termin als and splices using our offering of crimping head s. testing mechanical the tensile test, or pull test, is a means of evalu ating the mechanical properties of the crimped conn ections. the following charts show the ul specifications for various wire sizes. the tensile strength is shown in pound-forc e, which indicates the minimum acceptable force to break or separate the t erminal from the conductor. wire size (awg) tooling color code *ul C 486a **ul C 486c ***mil - t - 7928 22 8 8 20 13 10 18 20 10 16 30 15 14 50 25 12 70 35 10 80 40 8 red 90 45 225 6 blue 100 50 300 4 yellow 140 - 400 2 red 180 - 550 1 blue 200 - 650 1/0 blue 250 - 700 2/0 yellow 300 - 750 3/0 red 350 - 825 4/0 blue 450 - 875 *ul C 486a C terminals (copper conductors only) **ul C 486c C butt slices and parallel slices (over 6 awg use 486a values) ***mil-t-7928 - military approved terminals only as listed 4.2 crimping terminals specifications and instructions for crimping are in cluded with the individual hand tool / modular crim p heads. 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).
battery powered crimping tool order no: tm-638160200 release date: 12.06-07 uncontrolled copy page 26 of 33 revision: e revision date: 06-07-12 section 5 preventive maintenance 5.1. periodic cleaning 5.2. storage 5.3. battery and charging unit 5.4. disposal 5.5. warranty
battery powered crimping tool order no: tm-638160200 release date: 12.06-07 uncontrolled copy page 27 of 33 revision: e revision date: 06-07-12 5.1 periodic cleaning always clean tool after use and keep moving parts c lear of dirt and debris. this tool is basically maintenance free, only the b olt joints at the crimping head have to be oiled re gularly. before use: inspect dies for wear or damage such as cracks, gou ges, or chips. inspect the tool for damage or leaks. if damage is detected, return the tool to a molex representativ e for inspection. after use: wipe all tool surfaces clean with a damp cloth and mild detergent. excessive dirt and grit can contrib ute to the premature wear of the tools internal mechanical parts. if t his tool becomes dirty with excessive debris it may jam and become damaged during operation. fully retract the ram. place the tool in the carry ing case. store in a cool, dry place. charge the battery. warning: do not use compressed air to clean this tool. the forces cre ated by compressed air can force debris into the tool. failure to observe these precaution s may result in injury or property damage. warning: do not use solvents or flammable liquids to clean the crimping tool. solvents or flammable liquids could ignite and cause serious injury or property d amage. monthly: thoroughly clean all surfaces. a routine should be established to keep the tool as free from dirt as possible. an example of a maintenance chart is shown below. copy and use this chart to track the maintenance of this crimping tool or use this as a template to create your own schedule or use your companys standard chart, if applicable . preventive maintenance chart check sheet month year _________ week daily use days of the week solution mon tue wed thu fri sat sun 1 2 3 4 cleaning daily after use lubrication (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.
battery powered crimping tool order no: tm-638160200 release date: 12.06-07 uncontrolled copy page 28 of 33 revision: e revision date: 06-07-12 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 sev ere injury from harmful fumes or burns from flying debris caution: do not store the battery at more than 60 c (140 f ). damage to the battery can result. do not use another manufacturers charger. other m anufacturers chargers may overcharge and damage th e battery. do not attempt to open the battery. it contains no user-serviceable parts. failure to observe these precautions may result in injury or property damage. caution: do not allow anything to contact the batterys term inals. do not immerse the battery in liquid. liquid may c reate a short circuit and damage the battery. if the battery is immersed, contact your service ce nter for proper handling. do not place the battery into a pocket, tool pouch, or tool box with conductive objects. conductive objects may create a short circuit and d amage the battery. do not place a battery on moist ground or grass. m oisture may create a short circuit and damage the b attery. failure to observe these precautions may result in injury or property damage. the charging unit is run with a nominal voltage of 110v or 220v (for europe) and a frequency of 50-60h z . new batteries must be charged before use. to remove the battery from the crimping tool push down on the battery loc k and pull out. see figure 5-1. to charge the battery plug in the char ging unit into a power source and slide the battery upside down into the charging unit. the normal charging time is about 4 0 minutes. the charging level of the battery cartr idge can be checked by the right led (multicolor) of the charging unit. color left led (red) right led (multicolor) red charging unit is ready to operate. battery defect red flashing charging battery is out of order. new or unused batterys voltage capacity is insufficient. battery too hot or too cold. remove the battery. safety components possibly defected. green --- charging cycle stared. green flashing --- battery fully charged. charging unit switches auto matically into a maintaining level. battery can stay in charge for an indefinite time w ithout being damaged. yellow --- battery is at least 90% charged. charging can be t erminated. --- unit not powered if the right led does not light up, the circuit of the battery is disconnected or the battery is incorrectly polar ized. notes: if the standard capacity of the battery is not achi eved, it does not mean that the battery is faulty. the full capacity of the battery can be achieved after 3 charging/dischargin g cycles. 1. if there is a noticeable decrease in speed of the c rimping tool the battery should be recharged. char ge the battery at room temperature between 10c-40c (50f-104f). 2. the battery should be charged before storing.
battery powered crimping tool order no: tm-638160200 release date: 12.06-07 uncontrolled copy page 29 of 33 revision: e revision date: 06-07-12 cautions: 1. charging a battery which has been used recently or in the sun or a long period of time the right led m ight flash red (battery temperature) greater than 65c (149f). i n this case let the battery cool down and try again . 2. charging the battery at low temperatures under 5c (41f) is not possible. the battery temperature mu st be warmed up before starting the battery cycle again. 3. do not expose the charging unit to rain or snow. 4. do not charge the battery in or around explosive ma terials or gases. 5. do not use any other (dry or car) battery with the charging unit or the crimping tool. 6. do not use the cord as a handle to carry the batter y unit. 7. do not pull the cord out of a wall socket with forc e. 8. do not pull the plug of the charging unit until aft er the battery has been charged. 9. do not insert foreign objects into the ducts of the charging unit. 10. do not disassemble the charging unit. 11. do not place the battery in your pocket or a tool b ox, if there are conductive materials such as coins, keys, tools or other metal lic parts, they may cause injury or property damage. 5.3 disposal when this tool is no longer operating properly the different components of this tool will need to be disposed of separately. 1. the battery must be disposed of according to the re chargeable battery recycling corporation (rbrc) in the usa, or other a pplicable guidelines in other countries. 2. the remaining parts of this tool must be disposed o f according to the domestic environmental standards or the environment al protection agency (epa) in the usa, or other applicable guidelines in other countries. 3. because of possible environmental damage, we recomm end disposal of the tool by a professional company. do not dispose of this tool in your residential or commercial waste, as it would be hazardous to the e nvironment. 5.4 warranty all tools are warranted to be free of manufacturing defects for a period of 30 days. should such a de fect occur, we will repair or exchange the tool free of charge. this repair o r exchange will not be applicable to altered, misus ed, or damaged tools. this tool is designed for hand use only. any clamp ing, fixturing, or use of handle extensions voids t his warranty. after one year molex recommends the crimping tool be returned to a molex representative for inspection. only th e heads of the crimping tool are permitted to be changed by the op erator. do not damage the seals of this tool. if seals are damaged the warranty is void. caution : molex crimp specifications are valid only when us ed with molex terminals and tooling. push down on battery lock figure 5 - 1 battery unit
battery powered crimping tool order no: tm-638160200 release date: 12.06-07 uncontrolled copy page 30 of 33 revision: e revision date: 06-07-12 section 6 parts list, assembly drawings, and troubleshooting 6.1. parts list and assembly drawing 6.2. troubleshooting
battery powered crimping tool order no: tm-638160200 release date: 12.06-07 uncontrolled copy page 31 of 33 revision: e revision date: 06-07-12 3 figure 6 - 1 item no. 4 not shown 1 2 6.1 parts list and assembly drawings item order no description quantity 1 63816 - 0200 or 63816 - 0250 battery powered tool (110 v) or battery powered tool (220 v) 1 2 63816 - 0001 modular crimp head locking pins 2 3 63816 - 0202 batt ery unit 2 4 63816 - 0210 or 63816 - 0260 battery charger (110 v) or (220 v) not shown 1 note: the following modular crimp heads and battery power ed crimp adapters are sold separately and are not i ncluded with the 63816-0200 (110 v) or the 63816-0250 (220 v) batter y powered tool. the chart below shows all applications for the batt ery powered tool. see figure 6-2 and 6-3. applications for the battery powered tool crimp head order no. (sold separately) tool order no. tool description adapter order no. (sold separately) adapter description (sold separately) figure 6-2 modular 638xx - xx70 (type 4a) 63816-0200 (110 v) or 63816-0250 (220 v) battery power tool 63816-0600 battery power crimp adapter 6400x - xx00 (at) 63816-0900 figure 6-3 power 63816 - 0300 (type 2c or 4c) 63816-0200 (110 v) or 63816-0250 (220 v) battery power tool n/a n/a 63816 - 0800 (type 4d)
battery powered crimping tool order no: tm-638160200 release date: 12.06-07 uncontrolled copy page 32 of 33 revision: e revision date: 06-07-12 figure 6 - 2 modular crimp head figure 6 - 3 power crimp head type 4a locki ng pins (2) battery powered tool type 4a modular crimp head with tooling 63816 - 0600 adapter locking pins (2) type 4d battery powered tool type 4d power crimp head (no tooling shown) locking pins (2) type 2c or 4 c battery powered tool type 2c or 4c power crimp head (no tooling shown) locking pins (2) type at slotted screws (2) battery powered tool type at modular crimp head with tooling 63816 - 0900 adapter locking pins (2)
battery powered crimping tool order no: tm-638160200 release date: 12.06-07 uncontrolled copy page 33 of 33 revision: e revision date: 06-07-12 6.2 troubleshooting make sure the battery is charged before toubleshoot ing this tool. symptom cause solution tool is inoperative. dirt, contaminants, etc., in ram area of tool. clean the tool. battery unit contacts corroded. clean contacts with pencil eraser or contact cleaner battery unit contacts damaged. reform the contacts. tool parts worn or damaged. contact a molex representative. dies stop during operation. battery charge is low. charge or replace battery unit. led glows for 20 seconds. battery charge is low. charge or replace battery un it. visit our web site at http://www.molex.com

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