molex CS 150, Instruction Manual

Page 1: ...ping Tool Doc No ATS 638160200 Release Date 12 06 07 UNCONTROLLED COPY Page 1 of 21 Revision A Revision Date 12 06 07 BATTERY POWERED CRIMPING TOOL Instruction Manual Order No 63816 0200 Description Operation Maintenance ...

Page 2: ...ase Date 12 06 07 UNCONTROLLED COPY Page 2 of 21 Revision A Revision Date 12 06 07 Table of Contents SECTION 1 Safety Warnings and Information 2 General Description 3 Setup and Adjustments 4 Crimping Dies Go No go 5 Preventive Maintenance 6 Troubleshooting ...

Page 3: ...rdous situation which if not avoided will result in Death or serious injury CAUTION 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 WARNING WARNING Electric shock hazard This tool is not insulated When using this unit n...

Page 4: ...t 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 Do not allow anything to contact the battery s terminal...

Page 5: ...ol Doc No ATS 638160200 Release Date 12 06 07 UNCONTROLLED COPY Page 5 of 21 Revision A Revision Date 12 06 07 Section 2 General Description 2 1 Description 2 2 Features 2 3 Technical Specifications 2 4 Delivery Check 2 5 Tools ...

Page 6: ...ol 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 360o for better access in difficult working situations 2 2 Features Crimps a wide ran...

Page 7: ...V Capacity 1 3 Ah Charging Time Approximately 40 Minutes about 15 minutes with fast charger Crimps battery charge 150 at 10mm2 Operating Parameters Maximum Force 15kN 1 7 tons Cycle Time 2 0 seconds Stroke Length 9 0mm 354 Ambient Temperature 20o C to 40o C Sound Level 75dB A in a distance of 1 0m Vibrations 2 5m s2 2 4 Delivery Check Carefully remove the CS 150 Battery Crimping Tool from its ship...

Page 8: ...ery Crimping Tool Doc No ATS 638160200 Release Date 12 06 07 UNCONTROLLED COPY Page 8 of 21 Revision A Revision Date 12 06 07 Section 3 Set Up and Adjustments 3 1 Setup 3 2 Operation 3 3 Installation of Tool Kits ...

Page 9: ...lated 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 WARNING Wear 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 3 2 Operation 1 Insert the proper terminal or connector into ...

Page 10: ...nd of the relief valve the crimp is not complete Failure to observe these warnings could 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 severe injury from harmful fumes or burns from flying debris WARNING Inspect tool and dies before use Replace any worn ...

Page 11: ...y 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...

Page 12: ...mping Tool Doc No ATS 638160200 Release Date 12 06 07 UNCONTROLLED COPY Page 12 of 21 Revision A Revision Date 12 06 07 Section 4 Terminal Specifications and Crimping Operation 4 1 Scope 4 2 Terminal Specifications Chart ...

Page 13: ...own in pounds which indicates the minimum acceptable force to break or separate the terminal from the conductor Wire Size AWG Tooling Color Code UL 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 ...

Page 14: ...Doc No ATS 638160200 Release Date 12 06 07 UNCONTROLLED COPY Page 14 of 21 Revision A Revision Date 12 06 07 Section 5 Preventive Maintenance 5 1 Periodic Cleaning 5 2 Storage 5 3 Battery and Charging Unit 5 4 Disposal 5 5 Warranty ...

Page 15: ...ld detergent Excessive dirt and grit can contribute to the premature wear of the tool s internal mechanical parts If this tool becomes dirty with excessive debris it may jam and become damaged during operation 3 Fully retract the ram Place the tool in the carrying case Store in a cool dry place 4 Charge the battery WARNING WARNING Skin injection hazard Do not use hands to check for oil leaks High ...

Page 16: ... in a dry location 5 3 Battery and Charging Unit CAUTION WARNING 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 d...

Page 17: ...If the standard capacity of the battery is not achieved it does not mean that the battery is faulty The full capacity of the battery can be achieved after 3 charging discharging cycles 2 If there is a noticeable decrease in speed of the crimping tool the battery should be recharged Charge the battery at room temperature between 10o C 40o C 500 F 104o F 3 The battery should be charged before storin...

Page 18: ...nmental Protection Agency EPA guidelines 4 Because of possible environmental damage we recommend disposal of the tool by a professional company ATTENTION Do not dispose of this tool in your residential or commercial waste as it would be hazardous to the environment 5 5 Warranty All tools are warranted to be free of manufacturing defects for a period of 30 days Should such a defect occur we will re...

Page 19: ...S 150 Battery Crimping Tool Doc No ATS 638160200 Release Date 12 06 07 UNCONTROLLED COPY Page 19 of 21 Revision A Revision Date 12 06 07 Section 6 6 1 Parts List and Assembly Drawing 6 2 Troubleshooting ...

Page 20: ...ED COPY Page 20 of 21 Revision A Revision Date 12 06 07 6 1 Parts List and Assembly Drawings Item Order No Description Quantity 1 63816 0200 Battery Crimp Tool CS 150 1 2 63816 0201 Battery Powered Tool Head without tooling CSE30 1 3 63816 0202 Battery Unit CS 150 1 2 3 Figure 6 1 1 ...

Page 21: ...ex representative Dies stop during operation Air in Hydraulic system Pull the trigger and hold the retract slide simultaneously for about 10 seconds LED glows for 20 seconds Battery charge is low Charge or replace battery unit Crimping Tool loses oil Damage to the internal seal Contact a Molex representative Americas Headquarters Lisle Illinois 60532 U S A 1 800 78MOLEX amerinfo molex com Far East...