molex 63816-0200, 63816-0250 Operation Manual
Battery Powered Crimping Tool
BATTERY POWERED CRIMPING TOOL
Operation Manual
Order No. 63816-0200 (110 V)
Order No. 63816-0250 (220 V)
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
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 Crimp 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 Heads ........................................................................................ 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 Operation ......................................................................................................... 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
Order No: TM-638160200 Release Date: 12.06-07 UNCONTROLLED COPY Page 2 of 33
Revision: E Revision Date: 06-07-12
Battery Powered Crimping Tool
Read
and
understand
all of the instructions and safety information in this
SAFETY ALERT SYMBOL
CAUTION:
WARNING
WARNING
Always
wear proper eye protection when
WARNING
WARNING
Electric shock hazard:
WARNING
WARNING
Pinch points:
Safety Warnings and Information
manual before operating or servicing this tool.
Keep this manual available when using this tool.
Replacement manuals are available for download at no charge at
www.molex.com.
This symbol is used to call your attention to hazards or unsafe practices which could result in an injury
or property damage. The signal word, defined below, indicates the severity of the hazard. The message
after the signal word provides information for preventing or avoiding the hazard.
DANGER:
DANGER
WARNING
Indicates an imminently hazardous situation which, if not avoided, could result in death or serious injury.
WARNING:
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
CAUTION may also be used to alert against unsafe practices associated with events that could lead
to personal injury.
Operating or servicing this tool.
Failure to wear eye protection could result in
serious eye injury from flying debris or hydraulic oil.
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.
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.
Always wear proper ear protection when
Operating or servicing this tool.
This tool is not insulated. When using this unit near
energized electrical lines, use proper personal
protective equipment.
Failure to observe this warning could result in
severe injury or death
Keep hands away from the crimping head when
crimping.
Failure to observe this warning could result In
severe injury or death.
Order No: TM-638160200 Release Date: 12.06-07 UNCONTROLLED COPY Page 3 of 33
Revision: E Revision Date: 06-07-12
Battery Powered Crimping Tool
WARNING
WARNING
Do not use
compressed air to clean this tool.
WARNING
WARNING
Inspect tool and dies before use. Replace any
CAUTION
Do not operate the tool without the dies. Damage to the ram or crimping head can result.
CAUTION
CA
UTION
CAUTION
Never
perform any service or maintenance other than as described in this manual.
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 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
Do not operate with the crimping head open. Damage to the ram or seals can result.
This tool is not designed for continuous use. After 100 crimping cycles, allow the crimping tool to cool 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 use if it becomes soaked.
Use this tool for the manufacturer’s intended purpose only.
The forces created by compressed air can
force debris into the tool.
Failure to observe these precautions may
result in injury or property damage.
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.
Failure to observe these precautions may result in injury or property damage
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.
Conductive objects may create a short circuit and damage the battery.
Do not place a battery on moist ground or grass. Moisture may create a short circuit and damage the battery.
Failure to observe these precautions may result in injury or property damage.
Do not store the battery at more than 60 °C (140 °F). Damage to the battery can result.
Do not use another manufacturer’s charger. Other manufacturers’ chargers may overcharge and damage the 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.
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.
Order No: TM-638160200 Release Date: 12.06-07 UNCONTROLLED COPY Page 4 of 33
Revision: E Revision Date: 06-07-12
Battery Powered Crimping Tool
Tooling Technical Assistance
Molex offers tooling technical assistance for customers who may need some guidance for tooling adjustments. This support
can be obtained by calling either of the two numbers listed below and asking for the Molex Tooling Group.
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.
When calling for service on this tool, a copy of the Tooling Manual and Specific Application Tooling Specification (ATS) Sheet
should be present and a person that is familiar with this tool should be present. Be sure the following 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 applicable)
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
Order No: TM-638160200 Release Date: 12.06-07 UNCONTROLLED COPY Page 5 of 33
Revision: E Revision Date: 06-07-12
Battery Powered Crimping Tool
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
Order No: TM-638160200 Release Date: 12.06-07 UNCONTROLLED COPY Page 6 of 33
Revision: E Revision Date: 06-07-12
Battery Powered Crimping Tool
LOCKING
TRIGGER
CRIMPING
RECHARGEABLE
UNLOCKING
RETRACTOR
SECTION 1
Principal Mechanical Parts of the 63816-0200 (110 V) and the 63816-0250 (220 V) Battery Powered Tool. Battery charger
not shown.
PINS (2)
HEAD
ADAPTER
SLIDE
SWITCH
(NiCad 9.6V) BATTERY
Figure 1-1
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 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. The crimping head can be rotated 360° for
better access in difficult working situations.
1.1. Features
Crimps a wide range of products with interchangeable modular crimp heads or power crimp heads, and tool kits, which
reduce the overall cost and provide production flexibility.
Modular crimp heads or power crimp head and dies are easily and quickly interchanged to reduce production down time.
Complete portable system that allows tool to be moved and stored easily.
Order No: TM-638160200 Release Date: 12.06-07 UNCONTROLLED COPY Page 7 of 33
Revision: E Revision Date: 06-07-12
Battery Powered Crimping Tool
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 minutes 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 -20oC to +40oC
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
Order No: TM-638160200 Release Date: 12.06-07 UNCONTROLLED COPY Page 8 of 33
Revision: E Revision Date: 06-07-12
Battery Powered Crimping Tool
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 Crimp 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 illustration, is displayed on the upper right corner of the Hand Crimp
Tool Specification Sheet (ATS) and in the following pages of this manual.
Order No: TM-638160200 Release Date: 12.06-07 UNCONTROLLED COPY Page 9 of 33
Revision: E Revision Date: 06-07-12
Battery Powered Crimping Tool
Type RHT
64005xx00
AT Head
•
Battery
Power and
Comparison
Chart
Crimp Hand Tools
2.1 Comparison Chart - Hand and Power Crimp Tools
SCOPE
Modular crimp heads, power crimp head, adapters, and dies are easily and quickly interchanged between the hand crimp
tools and the battery powered tools. See chart below.
Battery Power Crimp Tool and Adapters for Hand Crimp Tools
Type 4A Type 2C Type 4C Type 4D Type AT
638160600 638160300 638160300 638160800 638160900
Adapter Head Head Head Adapter
63816-0200
Battery Powered Crimp Tool
• See Note
+ 638160900
+ Adapter
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.
Order No: TM-638160200 Release Date: 12.06-07 UNCONTROLLED COPY Page 10 of 33
Revision: E Revision Date: 06-07-12
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