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molex 63816-1700, Operation Manual

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molex 63816-1700 Operation Manual Download Page 17

Hydraulic Dieless Crimping Tool

 

Doc No. TM-638161700  Release Date: 03-21-14 

UNCONTROLLED COPY

 

Page 17 of 29 

Revision: D 

Revision Date: 05-10-17 

Wire Size: 1/0 AWG     50.00mm² 

Terminal 

No. 

Terminal 

Eng No. (REF) 

Wire Strip Length 

Insulation Diameter 

Maximum 

In 

mm 

In 

mm 

19193-0330 

H-381-14 

.765 

19.43 

N/A 

N/A 

19193-0331 

H-381-38 

.765 

19.43 

N/A 

N/A 

19193-0333 

H-381-56 

.765 

19.43 

N/A 

N/A 

19193-0556 

H-381-12 

.765 

19.43 

N/A 

N/A 

19202-0058 

H-783 

.578 

14.68 

.590 

14.98 

19205-0009 

H-384 

.718 

18.23 

N/A 

N/A 

19215-0047 

H-383 

.625 

15.88 

N/A 

N/A 

19221-0176 

HDC-10382-CC 

1.070 

27.18 

N/A 

N/A 

19221-0242 

BCL-1012-PL 

.703 

17.85 

N/A 

N/A 

19221-0240 

BCL-10516-PL 

.703 

17.85 

N/A 

N/A 

19221-0241 

BCL-1038-PL 

.703 

17.85 

N/A 

N/A 

19221-0274 

HDC-1014-CC 

.875 

22.23 

N/A 

N/A 

19221-0275 

HDC-10516-CC 

.875 

22.23 

N/A 

N/A 

19221-0276 

HDC-1038-CC 

.875 

22.23 

N/A 

N/A 

19221-0277 

HDC-1012-CC 

.875 

22.23 

N/A 

N/A 

19221-0297 

HDCL-105162-CC 

1.520 

38.61 

N/A 

N/A 

19221-0298 

HDCL-10382-CC 

1.520 

38.61 

N/A 

N/A 

19221-0336 

HDCL-10516-CC 

1.406 

35.71 

N/A 

N/A 

19221-0337 

HDCL-1038-CC 

1.406 

35.71 

N/A 

N/A 

19221-0353 

HDCL-105162-CC 

.860 

21.84 

N/A 

N/A 

19221-0377 

BCL-1038 

.703 

17.85 

N/A 

N/A 

19221-0393 

BCL-1012 

.703 

17.85 

N/A 

N/A 

19221-0394 

BCL-10516 

.703 

17.85 

N/A 

N/A 

19221-0422 

BCL-1014-PL 

.703 

17.85 

N/A 

N/A 

19221-0423 

BCL-1014 

.703 

17.85 

N/A 

N/A 

19221-0436 

BCL-1012-WP-PL 

.703 

17.85 

N/A 

N/A 

19221-0437 

BCL-1012-PL 

.703 

17.85 

N/A 

N/A 

19221-0440 

BCL-1038-WP-PL 

.703 

17.85 

N/A 

N/A 

19221-0441 

BCL-1038-WP 

.703 

17.85 

N/A 

N/A 

19221-0847 

BCL-1010MM-PL 

.703 

17.85 

N/A 

N/A 

 

Wire Size: 2/0 AWG     70.00mm² 

Terminal 

No. 

Terminal 

Eng No. (REF) 

Wire Strip Length 

Insulation Diameter 

Maximum 

In 

mm 

In 

mm 

19063-0129 

J-785-12 

.781 

19.83 

.675 

17.14 

19063-0130 

J-785-14 

.781 

19.83 

.675 

17.14 

19063-0131 

J-785-38 

.781 

19.83 

.675 

17.14 

19063-0132 

J-785-56 

.781 

19.83 

.675 

17.14 

19063-0133 

J-785-76 

.781 

19.83 

.675 

17.14 

19063-0134 

J-787-12 

.781 

19.83 

.675 

17.14 

19063-0135 

J-787-34 

.781 

19.83 

.675 

17.14 

19063-0136 

J-787-58 

.781 

19.83 

.675 

17.14 

19063-0137 

J-787-78 

.781 

19.83 

.675 

17.14 

19067-0109 

J-985-12 

.781 

19.83 

.765 

19.43 

19067-0110 

J-985-14 

.781 

19.83 

.765 

19.43 

19067-0111 

J-985-38 

.781 

19.83 

.765 

19.43 

19067-0112 

J-985-56 

.781 

19.83 

.765 

19.43 

19067-0113 

J-985-76 

.781 

19.83 

.765 

19.43 

19067-0114 

J-987-12 

.781 

19.83 

.765 

19.43 

19067-0115 

J-987-34 

.781 

19.83 

.765 

19.43 

19067-0116 

J-987-58 

.781 

19.83 

.765 

19.43 

19071-0309 

J-685-12X 

.781 

19.83 

.735 

18.66 

19071-0310 

J-685-14X 

.781 

19.83 

.735 

18.66 

19071-0311 

J-685-38X 

.781 

19.83 

.735 

18.66 

19071-0312 

J-685-56X 

.781 

19.83 

.735 

18.66 

19071-0313 

J-685-76X 

.781 

19.83 

.735 

18.66 

19071-0314 

J-687-12X 

.781 

19.83 

.675 

17.14 

19071-0339 

J-687-34X 

.781 

19.83 

.675 

17.14 

19071-0340 

J-687-58X 

.781 

19.83 

.675 

17.14 

19193-0341 

J-385-12 

.781 

19.83 

N/A 

N/A 

19193-0342 

J-385-14 

.781 

19.83 

N/A 

N/A 

19193-0345 

J-385-38 

.781 

19.83 

N/A 

N/A 

19193-0346 

J-385-56 

.781 

19.83 

N/A 

N/A 

19193-0348 

J-385-76 

.781 

19.83 

N/A 

N/A 

Wire Size: 2/0 AWG     70.00mm² 

Terminal 

No. 

Terminal 

Eng No. (REF) 

Wire Strip Length 

Insulation Diameter 

Maximum 

In 

mm 

In 

mm 

19193-0350 

J-387-12 

.781 

19.83 

N/A 

N/A 

19193-0351 

J-387-34 

.781 

19.83 

N/A 

N/A 

19193-0352 

J-387-58 

.781 

19.83 

N/A 

N/A 

19193-0353 

J-387-78 

.781 

19.83 

N/A 

N/A 

19202-0059 

J-788 

.688 

17.47 

.670 

17.02 

19205-0010 

J-389 

.718 

18.23 

N/A 

N/A 

19215-0048 

J-388 

.640 

16.25 

N/A 

N/A 

19221-0105 

HDC-20516-CC 

.985 

25.02 

N/A 

N/A 

19221-0106 

HDC-2038-CC 

.985 

25.02 

N/A 

N/A 

19221-0107 

HDC-2012-CC 

.985 

25.02 

N/A 

N/A 

19221-0178 

HDC-20382-CC 

.980 

24.90 

N/A 

N/A 

19221-0179 

HDC-20122-CC 

.980 

24.90 

N/A 

N/A 

19221-0195 

HDC-205162-CC 

.980 

24.90 

N/A 

N/A 

19221-0234 

BCL-2014-PL 

.750 

19.05 

N/A 

N/A 

19221-0243 

BCL-20516-PL 

.750 

19.05 

N/A 

N/A 

19221-0244 

BCL-2038-PL 

.750 

19.05 

N/A 

N/A 

19221-0245 

BCL-2012-PL 

.750 

19.05 

N/A 

N/A 

19221-0249 

BCL-2014 

.750 

19.05 

N/A 

N/A 

19221-0278 

HDC-2014-CC 

.985 

25.02 

N/A 

N/A 

19221-0299 

HDCL-20382-CC 

1.690 

42.93 

N/A 

N/A 

19221-0300 

HDCL-20122-CC 

1.690 

42.93 

N/A 

N/A 

19221-0338 

HDCL-2038-CC 

1.422 

36.12 

N/A 

N/A 

19221-0339 

HDCL-2012-CC 

1.422 

36.12 

N/A 

N/A 

19221-0379 

BCL-2038 

.750 

19.05 

N/A 

N/A 

19221-0397 

BCL-2012 

.750 

19.05 

N/A 

N/A 

19221-0398 

BCL-20516 

.750 

19.05 

N/A 

N/A 

19221-0597 

BCL-2058 

.750 

19.05 

N/A 

N/A 

19221-0598 

BCL-2058-PL 

.750 

19.05 

N/A 

N/A 

19221-0848 

BCL-2010MM-PL 

.750 

19.05 

N/A 

N/A 

 

Wire Size: 3/0 AWG     95.00mm² 

Terminal 

No. 

Terminal 

Eng No. (REF) 

Wire Strip Length 

Insulation Diameter 

Maximum 

In 

mm 

In 

mm 

19202-0060 

K-793 

.640 

16.25 

.731 

18.56 

19205-0012 

K-393 

.672 

17.06 

N/A 

N/A 

19215-0049 

K-394 

.672 

17.06 

N/A 

N/A 

19221-0108 

HDC-3014-CC 

1.110 

28.19 

N/A 

N/A 

19221-0109 

HDC-30516-CC 

1.110 

28.19 

N/A 

N/A 

19221-0110 

HDC-3038-CC 

1.110 

28.19 

N/A 

N/A 

19221-0180 

HDC-305162-CC 

1.100 

27.94 

N/A 

N/A 

19221-0181 

HDC-30382-CC 

1.100 

27.94 

N/A 

N/A 

19221-0182 

HDC-30122-CC 

1.100 

27.94 

N/A 

N/A 

19221-0246 

BCL-30516-PL 

.812 

20.63 

N/A 

N/A 

19221-0247 

BCL-3038-PL 

.812 

20.63 

N/A 

N/A 

19221-0248 

BCL-3012-PL 

.812 

20.63 

N/A 

N/A 

19221-0301 

HDCL-30382-CC 

1.650 

41.91 

N/A 

N/A 

19221-0302 

HDCL-30122-CC 

1.650 

41.91 

N/A 

N/A 

19221-0325 

HDCL-3038-CC 

1.547 

39.29 

N/A 

N/A 

19221-0326 

HDCL-3012-CC 

1.547 

39.29 

N/A 

N/A 

19221-0355 

HDC-3012-CC 

1.110 

28.19 

N/A 

N/A 

19221-0381 

BCL-3038 

.812 

20.63 

N/A 

N/A 

19221-0401 

BCL-3012 

.812 

20.63 

N/A 

N/A 

19221-0402 

BCL-30516 

.812 

20.63 

N/A 

N/A 

19221-0478 

BCL-3014 

.812 

20.63 

N/A 

N/A 

19221-0570 

BCL-3014-PL 

.812 

20.63 

N/A 

N/A 

19221-0862 

BCL-3010MM-PL 

.750 

19.05 

N/A 

N/A 

 

Wire Size: 4/0 AWG     120.00mm² 

Terminal 

No. 

Terminal 

Eng No. (REF) 

Wire Strip Length 

Insulation Diameter 

Maximum 

In 

mm 

In 

mm 

19202-0061 

L-778 

.750 

19.05 

.831 

21.10 

19205-0013 

L-378 

.750 

19.05 

N/A 

N/A 

Summary of Contents for 63816-1700

Page 1: ... 14 UNCONTROLLED COPY Page 1 of 29 Revision D Revision Date 05 10 17 Hydraulic Dieless Crimping Tool With Swivel Bench Adapter and Terminal Locator Operation Manual Order No 63816 1700 For Insulated and Non Insulated Terminal and Splices Description Operation Maintenance ...

Page 2: ... 9 2 1 Setup 10 Air Supply Hook Up 10 Hydraulic Connections and Bench Mounting 10 2 2 Adjustments 11 2 3 Alternative Pump Settings 11 Section 3 12 Terminal Specifications and Crimping Operation 12 3 1 Scope 13 3 2 Terminal Chart 13 3 3 Crimping Terminals 19 3 4 Adjusting the Pump Release Mechanism 20 Section 4 21 4 1 Lubrication 22 4 2 Bleeding Air From The System 22 4 3 Inspecting The Hydraulic F...

Page 3: ...y 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 equipment Failure to wear eye protection could result in serious eye injury from flying debris Heavy Object To avoid muscle strain or back injury use lifting aids and proper lifting techniques when removing or ...

Page 4: ...ire extreme heat or cold sharp surfaces or heavy impact Do not allow the hose to kink twist curl or bend so tightly that the oil flow within the hose is blocked or reduced Periodically inspect the hose for wear because any of these conditions can damage the hose and possibly result in personal injury Do not use the hose to move attached equipment Stress may damage hose and possibly cause personal ...

Page 5: ...US 1 630 969 4550 Global This assistance is limited to the operation and set up of a customer s Molex Press Assembly 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 the tool a copy of the Tooling Manual and Specific App...

Page 6: ...Tool Doc No TM 638161700 Release Date 03 21 14 UNCONTROLLED COPY Page 6 of 29 Revision D Revision Date 05 10 17 Section 1 General Description 1 1 Description 1 2 Features 1 3 Technical Specifications 1 4 Delivery Check 1 5 Tools ...

Page 7: ...zes four crimp nibs 3 moving and one stationary The three movable nibs close against the terminal which nests on the fourth nib creating crimp indentations from the top bottom and both sides resulting in a four sided quad crimp The operator adjusts the air pressure thru the air gauge to produce the proper crimp This tool is designed to crimp 8 AWG to 500MCM insulated and uninsulated terminals and ...

Page 8: ...echnical Specification Pneumatic Supply Pressure 100 PSI 6 9 Bars Air Pressure 125 PSI max 8 6 Bars max Cycle Time 15 seconds 1 4 Delivery Check Carefully remove the Hydraulic Dieless Crimping Tool from its shipping container and determine that the following items are included in the package Description Quantity 63816 1710 Crimp Head Assembly 1 63916 1711 Hydraulic Hose Assembly 1 63816 1720 Air H...

Page 9: ...eless Crimping Tool Doc No TM 638161700 Release Date 03 21 14 UNCONTROLLED COPY Page 9 of 29 Revision D Revision Date 05 10 17 Section 2 Setup and Adjustments 2 1 Setup 2 2 Adjustments 2 3 Alternative Pump Settings ...

Page 10: ...he filter regulator gauge unit The air supply should be 20 CFM 550 L M and 100 PSI 6 9 Bars to obtain the rated hydraulic output Air pressure should be regulated to a maximum of 125 PSI 8 6 Bars See Figure 2 1 Hydraulic Connections and Bench Mounting 1 Remove the dust cap from the hose where it attaches to the crimp head 2 Connect the quick connect coupler onto the cylinder inlet on the crimp head...

Page 11: ...ef 8 40 PSI 4000 PSI 4960 PSI 6 45 PSI 4500 PSI 5580 PSI 4 50 PSI 5000 PSI 6200 PSI 2 55 PSI 5500 PSI 6820 PSI 1 65 PSI 6500 PSI 8060 PSI 1 0 65 PSI 6500 PSI 8060 PSI 2 0 70 PSI 7000 PSI 8680 PSI 3 0 75 PSI 7500 PSI 9300 PSI 4 0 75 PSI 7500 PSI 9300 PSI 250 MCM 85 PSI 8500 PSI 10 540 PSI 300 MCM 90 PSI 9000 PSI 11 160 PSI 350 MCM 90 PSI 9000 PSI 11 160 PSI 400 MCM 100 PSI 10 000 PSI 12 400 PSI 500...

Page 12: ... Release Date 03 21 14 UNCONTROLLED COPY Page 12 of 29 Revision D Revision Date 05 10 17 Section 3 Terminal Specifications and Crimping Operation 3 2 Scope 3 3 Terminal Specifications Chart 3 4 Crimping Terminals 3 5 Adjusting the Pump Release Mechanism ...

Page 13: ...D 750 14 438 11 11 265 6 73 19063 0012 D 750 56 438 11 11 265 6 73 19063 0019 D 750 38 438 11 11 265 6 73 19063 0021 D 750 56 438 11 11 265 6 73 19063 0025 D 752 10 438 11 11 265 6 73 19063 0026 D 752 12 438 11 11 265 6 73 19063 0028 D 752 14 438 11 11 265 6 73 19063 0029 D 752 38 438 11 11 265 6 73 19063 0031 D 752 58 438 11 11 265 6 73 19063 0032 D 752 78 438 11 11 265 6 73 19063 0033 D 753 12 4...

Page 14: ...0204 D 356 14 438 11 11 N A N A 19202 0054 D 754 375 9 53 265 6 73 19205 0004 D 355 312 7 92 N A N A 19215 0034 D 354 375 9 53 170 4 32 19221 0167 HDC 8102 CC 610 15 49 N A N A Wire Size 8 AWG 8 50mm Terminal No Terminal Eng No REF Wire Strip Length Insulation Diameter Maximum In mm In mm 19221 0212 HDC 810 CC 516 13 11 N A N A 19221 0223 BCL 810 PL 438 11 11 N A N A 19221 0224 BCL 814 PL 438 11 1...

Page 15: ...8 520 13 20 19067 0086 F 969 38 531 13 48 520 13 20 19067 0087 F 969 58 531 13 48 520 13 20 19067 0088 F 970 34 531 13 48 520 13 20 19067 0089 F 970 58 531 13 48 520 13 20 Wire Size 4 AWG 25 00mm Terminal No Terminal Eng No REF Wire Strip Length Insulation Diameter Maximum In mm In mm 19071 0231 F 666 10X 531 13 48 515 13 08 19071 0234 F 666 12X 531 13 48 515 13 08 19071 0237 F 666 14X 531 13 48 5...

Page 16: ...14 68 N A N A 19193 0319 G 377 14 578 14 68 N A N A 19193 0320 G 377 34 578 14 68 N A N A 19193 0321 G 377 38 578 14 68 N A N A 19193 0322 G 377 56 578 14 68 N A N A 19193 0324 G 377 76 578 14 68 N A N A 19193 0611 G 377 76 578 14 68 N A N A Wire Size 2 AWG 35 00mm Terminal No Terminal Eng No REF Wire Strip Length Insulation Diameter Maximum In mm In mm 19202 0057 G 772 531 13 48 509 12 92 19205 0...

Page 17: ...1 0340 J 687 58X 781 19 83 675 17 14 19193 0341 J 385 12 781 19 83 N A N A 19193 0342 J 385 14 781 19 83 N A N A 19193 0345 J 385 38 781 19 83 N A N A 19193 0346 J 385 56 781 19 83 N A N A 19193 0348 J 385 76 781 19 83 N A N A Wire Size 2 0 AWG 70 00mm Terminal No Terminal Eng No REF Wire Strip Length Insulation Diameter Maximum In mm In mm 19193 0350 J 387 12 781 19 83 N A N A 19193 0351 J 387 34...

Page 18: ...25038 PL 859 21 8 N A N A Wire Size 300 MCM AWG 152 00mm Terminal No Terminal Eng No REF Wire Strip Length Insulation Diameter Maximum In mm In mm 19221 0187 HDC 300382 CC 1 330 33 78 N A N A 19221 0188 HDC 300122 CC 1 330 33 78 N A N A Wire Size 300 MCM AWG 152 00mm Terminal No Terminal Eng No REF Wire Strip Length Insulation Diameter Maximum In mm In mm 19221 0307 HDCL 300382 CC 2 060 52 32 N A ...

Page 19: ...t the properly stripped wire into the terminal barrel The wire ends should butt up against the wire stop of the locator 4 If the terminal is to big or the barrel of the terminal has a closed end take off the locators and the wire stop Position the terminal in the center of the jaws Insert the properly stripped wire visually into the terminal barrel as shown in Figure 3 4 5 Depress the pedal on the...

Page 20: ...ild pressure 4 Release the Foot Pedal The pump will stop running but the hydraulic pressure will be held 5 With the Foot Pedal resting on the Air Inlet Stem rotate the Adjusting Plate clockwise until a stop is felt Note If the end of the slot in theAdjusting Plate is met before a stop is felt the Adjusting Plate must berepositioned one step counter clockwise on the Hex Stem then repeat step 5 6 Ti...

Page 21: ...age 21 of 29 Revision D Revision Date 05 10 17 Section 4 Maintenance 4 1 Lubrication 4 2 Bleeding Air From the System 4 3 Inspecting the Hydraulic Fluid Level 4 4 Draining and Flushing the Reservoir 4 5 Refilling the Bladder 4 6 Periodic Cleaning 4 7 Spare Parts 4 8 Perishable Parts 4 9 Storage ...

Page 22: ... must be at a lower level than the pump to allow air to be released through the pump bladder 4 3 Inspecting The Hydraulic Fluid Level CAUTION Always disconnect the air supply before all maintenance 1 Check the oil level in the bladder after every 10 hours of use 2 Drain and replenish the bladder with Power Team hydraulic oil after every 300 hours of use Hoses Hydraulic hoses on this unit carry a r...

Page 23: ...hydraulic oil in this unit and change as recommended every 300 hours An example of a maintenance chart is shown below Copy and use this chart to track the maintenance of your 63816 1700 Dieless Crimping Tool or use this as a template to create your own schedule or use your company s standard chart if applicable Preventive Maintenance Chart Daily Clean See Section 3 5 As Required Lubricate See Sect...

Page 24: ...the Repair Parts List See Section 5 2 4 8 Perishable Parts Customers are responsible for maintaining the 63816 1700 Dieless Crimping Tool Perishable parts are those parts that come in contact with the product and will wear out over time Molex recommends that all customers keep at least one set of the perishable tooling in stock at all times This will reduce the amount of production down time 4 9 S...

Page 25: ...raulic Dieless Crimping Tool Doc No TM 638161700 Release Date 03 21 14 UNCONTROLLED COPY Page 25 of 29 Revision D Revision Date 05 10 17 Section 5 5 1 Parts Lists and Assembly Drawings 5 2 Troubleshooting ...

Page 26: ...igure 5 1 2 4 3 1 5 1 Main Parts List and Assembly Drawing 63816 1700 Main Assembly Figure 5 1 Item Order No Description Qty 1 63816 1710 Crimp Head Assembly 1 2 63816 1711 Hydraulic Hose Assembly 10 ft 1 3 63816 1720 Air Hydraulic Pump Power Unit 1 4 19286 0049 Filter Regulator with Gauge 1 5 19286 0103 Air Hose 1 4 NPT Male Fitting 10 Feet 1 ...

Page 27: ... of spare and perishable parts that are available 63816 1710 Repair Parts Figure 5 2 Item Order No Description Qty 1 63816 1712 Hydraulic Cylinder 1 Ref Repair Part 2 63816 1713 Main Seal for Item 1 1 Ref Repair Part 3 63816 1714 Retract Spring for Item 1 1 Ref Repair Part 4 63816 1715 Indenter large 2 Ref Repair Part 5 63816 1716 Indenter small 2 Ref Repair Part 6 63816 1717 Base and locator asse...

Page 28: ...e air cylinder tube Hydraulic failure Air in hydraulic system Check the oil filter for contamination Clean and reinstall See Bleeding Air From The System Section 4 2 Release improperly adjusted See Adjusting the Pump Release Mechanism Section 3 4 Pump will not build to maximum pressure No visible leakage Check the air supply 100 PSI 7 BAR is required to obtain maximum pressure Pump builds pressure...

Page 29: ...OPY Page 29 of 29 Revision D Revision Date 05 10 17 For more information use the Crimping Testing and Inspection Handbook for Industrial Closed Barrel products There is no charge for this book which can be found on the Molex website www molex com or contact your local Molex sales engineer ...

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