molex CS 150 Instruction Manual
CS 150 Battery Crim pi ng Tool
BATTERY POWERED CRIMPING TOOL
Description
Operation
Maintenance
Doc No: ATS-638160200 Release Date: 12-06-07
Revision: A Revision Date: 12-06-07
Instruct ion Manual
Order No. 63816- 0200
UNCONTRO L L ED CO P Y Page 1 of 21
CS 150 Battery Crim pi ng Tool
1 Safety Warnings and Information
2 General Description
3 Setup and Adjustments
4 Crimping Dies Go-No go
5 Preventive Maintenance
6 Troubleshooting
Table of Content s
SECTION
Doc No: ATS-638160200 Release Date: 12-06-07
Revision: A Revision Date: 12-06-07
UNCONTRO L L ED CO P Y Page 2 of 21
CS 150 Battery Crim pi ng Tool
Read and understand all of the instructions and safety information in this
Manual before operating or servicing this tool.
Keep this manual available when using t hi s t ool
Replacement manuals are available upon request at no charge at
www.molex.com.
SAFETY
ALERT
SYMBOL
This symbol is used to call your attenti on t o hazards or unsafe pract ices which could result i n an i njury
or property damage. The signal word, def i ned below, indicates the severity of the hazard. The message
after the signal word provides inf orm ation for preventing or avoiding t he hazard.
DANGER
WARNING
CAUTION
WARNING WARNING
Electric shock hazard:
This tool is not i nsul ated. When using this
unit near energized electrical lines, use
proper personal protective equipment.
Failure to observe this warning coul d
Result in severe injury or death.
WARNING WARNING
Skin injection hazard:
Do not use hands to check for oil l eaks.
High pressure oil easily punct ures ski n
causing serious injury, gangrene, or death.
If injured, seek m edi cal help immediately
to remove oil.
DANGER:
Indicates an imminently hazardous situation which, if not avoided, will result in
Death or serious injury.
WARNING:
Indicates a potentially hazardous situation which, if not avoided, will result in
Death or serious injury.
CAUTION:
Indicates a potential ly hazardous situat i on whi ch, if not avoided, may result in
Minor or moderate injury. CA UTION may also be used to alert against unsaf e
practices associated with events that could l ead t o personal injury.
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection coul d
result in serious eye injury from flying
debris or hydraulic oil.
Pinch points:
Keep hands away from the crimpi ng
head when crimping.
Failure to observe this warning coul d
Result In severe inj ury or death.
Doc No: ATS-638160200 Release Date: 12-06-07
Revision: A Revision Date: 12-06-07
UNCONTRO L L ED CO P Y Page 3 of 21
CS 150 Battery Crim pi ng Tool
Do not use solvents or flammable liquids to cl ean
the crimping tool .
Solvents or flammable liquids could ignit e and
cause serious injury or property damage.
WARNING WARNING
WARNING WARNING
Do not dispose of the battery in a fire. It will vent fumes and may explode.
Failure to observe this warning coul d resul t i n severe i nj ury f rom harm f ul
fumes or burns from flyi ng debris
CAUTION CAUTION
Do not operate the tool wi thout the dies. Damage t o the ram or crimping
head can result.
Do not operate with t he cri m pi ng head open. D am age to the ram or
seals can result.
This tool is not desi gned for continuous use. After 100 crimpi ng cycl es,
allow the crimpi ng 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 dam p or wet environments; however, we
recommend air-drying the tool bef ore use if it becomes soaked.
Use this tool f or t he m anuf acturer’s intended purpose only.
Failure to observe these precautions m ay result in injury or property damage.
An incomplete crim p can cause a f i re.
Use proper die, connector, and cable combi nations.
Improper combinations can resul t i n an
incomplete crimp.
The relief valve will sound to indicate a completed
crimp. If you do not hear t he sound of t he rel i ef valve,
the crimp is not com pl et e.
Failure to observe these warnings could resul t in severe
injury or death.
Inspect tool and di es bef ore use. Replace any worn or
damaged parts. A damaged or improperly assembl ed
tool can break and strike someone nearby.
Failure to observe this warning coul d resul t in severe
injury or death.
Do not allow anything to contact the battery’s terminals.
Do not immerse the bat tery in liquid. Liqui d m ay
create a short circuit and damage t he bat t e ry.
If the batt ery is i m mersed, contact your service
center for proper handling.
Do not place the batt ery i nt o a pocket, tool pouch, or
tool box with conduct ive objects.
Conductive objects m ay creat e a short circuit and
damage the battery.
Do not place a battery on moist ground or grass.
Moisture may create a short ci rcuit and damage the
battery.
Failure to observe these precautions m ay resul t i n injury
or property damage.
CAUTION CAUTION
Do not store the batt ery at m ore t han 60 °C (140 °F). Dam age t o the
battery can result.
Do not use another manufact urer’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 m ay result in injury or property damage.
For Service, Contact Your Local Molex Sales Office
Doc No: ATS-638160200 Release Date: 12-06-07
Revision: A Revision Date: 12-06-07
Do not perform any service or maintenance other than as
described in this manual .
Failure to observe this precauti on m ay resul t i n i njury
and property damage.
Molex Application Tooling Group
2200 Wellington Court
Lisle, Illinois 60532
Tel: 630-969-4550
Fax: 630-505-0049
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CS 150 Battery Crim pi ng Tool
2.1 Description
2.2 Features
2.3 Technical Specifications
2.4 Delivery Check
2.5 Tools
Section 2
General Description
Doc No: ATS-638160200 Release Date: 12-06-07
Revision: A Revision Date: 12-06-07
UNCONTRO L L ED CO P Y Page 5 of 21
CS 150 Battery Crim pi ng Tool
Figure 2
General Description
2
Principal M echani cal Parts of the 63816-0200 (Battery charger not shown)
TRIGGER
2.1 Description
The Molex Battery Crimpi ng Tool i s designed t o crimp 8 to 4/0 AWG insulated and uninsulat ed terminals and
splices. This tool has an automatic retractabl e system which returns the crimpi ng adapter along with the
crimping dies to the start i ng posit i on when the maximum force is reached. It i s equipped wi th a special brake
that will stop the forward motion of t he crimping dies when the trigger is released. The crimping head can be
rotated 360o for better access in diff i cul t worki ng sit uations.
2.2 Features
Crimps a wide range of products with i nt erchangeable tool heads and tool kits, which reduce the overall cost
and provide production flexibility.
Crimping heads and dies are easily and quickly interchanged to reduce production down t i m e.
Complete portable system that allo ws t ool to be moved and stored easily.
LOCKING
PINS (2 )
CRIMPING
HEAD
ADAPTER
RECHARGEABLE
(NiCad 9.6V) BATTERY
RETRACT
SLIDE
UNLOCKING
SWITCH
-1
Doc No: ATS-638160200 Release Date: 12-06-07
Revision: A Revision Date: 12-06-07
UNCONTRO L L ED CO P Y Page 6 of 21
CS 150 Battery Crim pi ng Tool
2.3 Technical Specification
Dimensions
(with battery)
Length 292.1mm (11.50”)
Width 76.2mm (3.00“)
Depth 50.8mm (2.00“)
Unpacked Weight 1.5kg (3.31lbs)
Production Rate
250 cycles per hour maximum, dependi ng on operat or sk ill and t ool kit inst alled.
Battery
Voltage 9.6V
Capacity 1.3 Ah
Charging Time: Approximately 40 Minut es, about 15 m i nutes with fast-charger
Crimps/battery-charge 150 at 10mm
2
Operating Parameters
Maximum Force 15kN (1.7 tons)
Cycle Time 2.0 seconds
Stroke Length 9.0mm (.354”)
Ambient Temperat ure -20oC to +40oC
Sound Level 75dB (A) in a distance of 1. 0m
Vibrations <2.5m/s
2
2.4 Delivery Check
Carefully remove the CS 150 B attery Crimping Tool from i t s shippi ng cont ainer and determine that the
following item s are included i n the package.
á
CS 150 Battery Cri m ping Tool wi th battery
á
Battery Charger
á
Carrying Case
á
63816-0200 Instruction Manual
Doc No: ATS-638160200 Release Date: 12-06-07
Revision: A Revision Date: 12-06-07
UNCONTRO L L ED CO P Y Page 7 of 21
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