molex 63816-1000, Operation Manual

Page 1: ...r No TM 638161000 Release Date 04 03 13 UNCONTROLLED COPY Page 1 of 21 Revision D Revision Date 12 16 15 Battery Powered Crimping Tool Operation Manual Order No 63816 1000 115V Order No 63816 1050 230V Description Operation Maintenance ...

Page 2: ...cipal Mechanical Parts of the 63816 1000 Battery Powered Tool 7 1 3 Technical Specifications 8 1 4 Delivery Check 8 Section 2 9 Set Up and Adjustments 9 2 1 Set Up 10 2 2 Operation 11 2 3 Preventive Instructions 12 Section 3 13 General Terminal Specifications and Crimping Operation 13 3 1 Scope 14 3 2 Crimping Terminals 14 Section 4 15 Preventive Maintenance 15 4 1 Periodic Cleaning 16 4 2 Battery...

Page 3: ...tion 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 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 prote...

Page 4: ...he 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 Failure to observe these precautions may result in injury or property damage CAUTION Do not allow anything to contact the battery s terminals...

Page 5: ...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 a...

Page 6: ...00 Release Date 04 03 13 UNCONTROLLED COPY Page 6 of 21 Revision D Revision Date 12 16 15 Section 1 General Description 1 1 Features 1 2 Principal Mechanical Parts of the 63816 1000 Battery Powered Tool 1 3 Technical Specifications 1 4 Delivery Check ...

Page 7: ...changeable modular crimp heads or adapters and tool kits which reduce the overall cost and provide production flexibility Power crimp heads and dies are easily and quickly interchanged to reduce production down time Complete portable system that allows the tool to be moved and stored easily 1 2 Principal Mechanical Parts of the 63816 1000 Battery Powered Tool The Battery charger is not shown Item ...

Page 8: ...i Ion Charging Time 15 minutes Crimps battery charge 150 at a medium force Operating Parameters Maximum Force 130 kN 14 6 ton force Cycle Time 7 seconds Stroke Length 18 00mm 709 1 4 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 1000 115V 63816 1000 Battery Crimping Tool 1 63816 ...

Page 9: ...ered Crimping Tool Order No TM 638161000 Release Date 04 03 13 UNCONTROLLED COPY Page 9 of 21 Revision D Revision Date 12 16 15 Section 2 Set Up and Adjustments 2 1 Set up 2 2 Operation 2 3 Preventive Instructions ...

Page 10: ...pper portion of the crimp head to the Power Crimping Tool and slide the pins back through the mating holes in the crimp head to secure it to the Power Crimping Tool See Figure 2 2 6 Check the crimp head to insure that the locking pins are fully inserted WARNING Electric shock hazard This tool is not insulated When using this unit near energized electrical lines use proper personal protective equip...

Page 11: ... is complete 5 Push the return lever button see Item 5 in Figure 1 to bring the stroke back to the starting position 6 Take the crimped terminal out of the profile See Figure 2 6 7 The crimping operation can be interrupted at any time during the cycle by releasing the trigger 8 The crimping cycle is complete when the dies are completely closed and the maximum crimping force is reached Note In case...

Page 12: ...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 use if it becomes soaked Use this tool for the manufacturer s intended purpose only Failure to observe these precautions may result in injury or property damage CAUTION Do not allow anyth...

Page 13: ...imping Tool Order No TM 638161000 Release Date 04 03 13 UNCONTROLLED COPY Page 13 of 21 Revision D Revision Date 12 16 15 Section 3 General Terminal Specifications and Crimping Operation 3 1 Scope 3 2 Crimping terminals ...

Page 14: ...486A UL 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 486A Terminals Copper Conductors Only UL 486C Butt Slices and Parallel Slices Over 6 AWG use 486A values MIL T 7928 Military Approved Terminals only as listed 3 2 ...

Page 15: ...Tool Order No TM 638161000 Release Date 04 03 13 UNCONTROLLED COPY Page 15 of 21 Revision D Revision Date 12 16 15 Section 4 Preventive Maintenance 4 1 Periodic Cleaning 4 2 Battery and Battery Charger 4 3 Disposal 4 4 Warranty ...

Page 16: ...ry place 3 Charge the battery WARNING 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 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 Monthly T...

Page 17: ...ry 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...

Page 18: ...separately 1 The battery must be disposed of according to the Rechargeable Battery Recycling Corporation RBRC in the USA or other applicable guidelines in other countries 2 The remaining parts of this tool must be disposed of according to the domestic environmental standards or the Environmental Protection Agency EPA in the USA or other applicable guidelines in other countries 3 Because of possibl...

Page 19: ...ool Order No TM 638161000 Release Date 04 03 13 UNCONTROLLED COPY Page 19 of 21 Revision D Revision Date 12 16 15 Section 5 Parts List Assembly Drawings and Troubleshooting 5 1 Parts List and Assembly Drawing 5 2 Troubleshooting ...

Page 20: ...1 Revision D Revision Date 12 16 15 1 2 Figure 5 1 5 1 Parts List and Assembly Drawings Item Order No Description Quantity 1 63816 1000 or 63816 1050 Battery Powered Tool 110 V or Battery Powered Tool 220 V 1 2 63816 1002 Battery Unit 2 3 63816 1010 or 63816 1060 Battery Charger 110 V or 220 V Not Shown 1 ...

Page 21: ... 130 kN Figure 5 3 U Die 63816 1200 Figure 5 4 Cutting Tool 63816 1400 Power Crimp and Cutting Heads Dies not included with Crimp Heads 63816 1100 DIN style Crimp Head 63816 1200 U Die Crimp Head Figure 5 2 Figure 5 3 63816 1400 Cutting Tool Head Figure 5 4 5 2 Troubleshooting Make sure the battery is charged before toubleshooting this tool Symptom Cause Solution Tool is inoperative Dirt contamina...