Battery Crimping Tool
Doc. No: 638160270
Release Date: 05-14-18
UNCONTROLLED COPY
Page 1 of 32
Revision: A
Revision Date: 05-14-18
BATTERY CRIMPING TOOL
Operation Manual
Order No. 63816-0270 (110V) Order No. 63816-0280 (220V)
Страница 1: ...y Crimping Tool Doc No 638160270 Release Date 05 14 18 UNCONTROLLED COPY Page 1 of 32 Revision A Revision Date 05 14 18 BATTERY CRIMPING TOOL Operation Manual Order No 63816 0270 110V Order No 63816 0280 220V ...
Страница 2: ...llation 10 6 1 Battery Charging 10 6 2 Battery Charge Level 11 7 Commissioning 12 7 1 Available Adapters Tool Heads and Die Sets 12 7 2 Mounting a Tool Head or Adapter on the Tool 13 7 3 Turning the LED Light On Off for Illumination of the Workplace 14 7 3 1 Turn On the LED 14 7 3 2 Turn Off the LED 14 8 Normal Operation Production Cycle 15 8 1 Overview 16 8 2 63816 0600 Power Crimp Adapter for Ty...
Страница 3: ...imping tool are only permitted with written permission of the manufacturer For all unauthorized applications of the battery crimping tool the manufacturer cannot be held liable for any resultant damage or injury 1 2 Conformity The tool may only be used for the purpose specified in the operating instruction The manufacturers and suppliers will not be liable for any damages that may result due to th...
Страница 4: ... deterioration of the operating procedure 2 2 Safety Precautions The battery crimping tool has been constructed according to state of the art technology and the acknowledged technical safety regulations When carrying out jobs such as installation putting the tool into operation or setting it up operation changing the conditions of use and the mode of operation or carrying out maintenance and servi...
Страница 5: ...dges or moving parts Damaged or entangled cords increase the risk of electric shock When the battery pack is not in use keep it away from other metal objects like paper clips coins keys nails screws or other small metal objects that can make a connection from one terminal to another Shorting the battery terminals together may cause burns or a fire Under abusive conditions liquid may be ejected fro...
Страница 6: ...y instructions warnings and precautions contained in the individual chapters must be strictly observed by all users and operators 2 4 Designed Use Realization of crimp connections up to a cable Ø of 16mm wire end ferrules up to 50mm depending on the terminal design The battery crimping tool is designed for use with Molex approved adapters or tool heads The adapter or tool head should only be used ...
Страница 7: ...pproximately 410mm 16 Width Approximately 460mm 18 Height Approximately 120mm 5 Gross weight Approximately 5 kg 11 lbs 3 2 Packing Contents Quantity Description 1 Battery crimping tool with battery without adapter tool head and die set 1 Battery charger 1 Operating instructions 1 Tool case with foam insert 1 Declaration of conformity Figure 3 1 ...
Страница 8: ...d 360 rotation 2 Locking pins 3 Trigger 4 LED for illumination of the workplace 5 10 8V Li Ion battery 6 Unlocking device for the battery 7 Slider for manual retraction in case of an error or emergency 8 Service light 9 Battery charge level button 10 Battery charge level 11 Battery identification plate on the bottom side of the battery 12 Product seal with serial number in the housing of the batte...
Страница 9: ...contacts the battery crimping tool can be opened as follows 1 Push the retraction slide 1 in the direction of the battery 2 The tool jaws will open 3 Remove and discard the damaged contact Item Description 1 Serial Number 2 Seal 3 Address Dimension Specification Length 90mm 3 5 Width 64mm 2 5 Height 270mm 10 6 Weight Including Battery Approximately 1 3 kg 2 9 lb Crimp Speed Approximately 2s depend...
Страница 10: ... or entangled cords increase the risk of electric shock DANGER Use the battery crimping tool only with specifically designated battery packs When the battery pack is not in use keep it away from other metal objects like paper clips coins keys nails screws or other small metal objects that can make a connection from one terminal to another Shorting the battery terminals together may cause burns or ...
Страница 11: ...n must be stopped and the malfunction must be fixed before continuing work with the battery crimping tool Only one person is allowed to work on or with the battery crimping tool at a time Only trained personnel are allowed to work on or with the battery crimping tool Instructions 1 Remove the battery from the battery crimping tool by pressing the battery unlocking device 2 Connect the charger to t...
Страница 12: ...imp adapters are sold separately and are not included with the 63816 0270 110V or 63816 0280 220V battery crimping tool TYPE 4A LOCKING PINS 2 BATTERY POWERED TOOL TYPE 4A MODULAR CRIMP HEAD WITH TOOLING 63816 0600 ADAPTER LOCKING PINS 2 TYPE AT SLOTTED SCREWS 2 BATTERY POWERED TOOL TYPE AT MODULAR CRIMP HEAD WITH TOOLING 63816 0900 ADAPTER LOCKING PINS 2 TYPE 2C or TYPE 4C BATTERY POWERED TOOL TY...
Страница 13: ...crimp tool is only allowed to be used with the mounted adapter with tool head or tool head with die set When working with the battery crimping tool do not wear loose clothing jewelery or long loose hair that can get caught in the mechanism Work with caution In cases of a tool malfunction production must be stopped and the malfunction must be fixed before continuing work with the battery crimping t...
Страница 14: ...the Workplace 7 3 1 Turn On the LED Remove the battery from the battery crimping tool Reinsert the battery without pressing the trigger 1 The LED 2 lights up during and after the crimping process 7 3 2 Turn Off the LED Remove the battery from the battery crimping tool Press the trigger 1 and keep it pressed while inserting the battery Keep the trigger pressed for some seconds The LED 2 is turned o...
Страница 15: ...g tool may only be set up and operated in perfect technical conditions observing all the safety regulations and considering any possible dangers Before commissioning the tool it is always important to check if a Molex approved adapter tool head or die set is installed and functioning correctly The crimp tool is only allowed to be used with mounted adapter with tool head or tool head with die set W...
Страница 16: ...y Powered Crimp Tool and Adapters for Hand Crimp Tools Type 4A Type 2C Type 4C Type 4D Type 4E Type AT Type RHT See Note 63816 0600 63816 0300 63816 0300 63816 0800 63816 1600 63816 0900 64005 xx00 63816 0900 Adapter Head Head Head Head Adapter AT Head Adapter 63816 0200 Battery Powered Crimp Tool NOTE Untooled AT heads are not available separately Customers can install RHT tooling into one of the...
Страница 17: ...p Then place the crimp head in the upper slot and align the holes with the pins Push the pins inward until they lock See Figure 8 1 Installation of Type 4A Power Crimp Adapter to Battery Powered Crimping Tool To install the 63816 0600 power crimp adapter onto the battery powered tool refer to Section 7 2 Operation 1 Load the terminal as described in the Operation section of the Application Tooling...
Страница 18: ...essively Using a light oil such as SAE 30 weight automotive oil every 5 000 crimps or monthly will significantly enhance the tool life and ensure a stable calibration See Figure 8 2 for lubrication points 5 Store the tool in a clean and dry area when not in use Warranty This tool is for electrical terminal crimping purposes only This tool is made of the best quality materials All vital components ...
Страница 19: ...the crimp tool kit into the power crimp head follow the steps below 1 Insert the anvils into the bottom slots of the nest The wire size markings face toward the front of the head opposite from the locator pivot shaft Install the M4 x 10 long BHCS and tighten in place 2 Insert the punches into the top slots of the nest with wire size markings to the front Install the M4 x 18 long BHCS and tighten i...
Страница 20: ...could damage the tool 4 Make certain all pins pivot points and bearing surfaces in the tool head are protected with a thin coat of high quality machine oil Do not oil excessively Using a light oil such as SAE 30 weight automotive oil every 5 000 crimps or monthly will significantly enhance the tool life and ensure a stable calibration See Figure 8 5 for lubrication points 5 Store the tool in a cle...
Страница 21: ... of the locator should disengage from the power crimp head 3 Lift and pull away from the crimp hand tool The top locator hooks should slip out of the top slots easily See Figure 8 7 Removing the Crimp Dies From the Type 4D Hand Crimp Tool 1 Open the crimp hand tool by squeezing the handles together 2 Remove the two M3 BHCS 3 Remove the crimp dies as shown in Figure 8 8 4 Make sure all of the compo...
Страница 22: ...S Power Crimp Head Installation Onto Battery Powered Crimping Tool To install the 63813 0800 power crimp head onto the battery powered tool refer to Section 7 2 Adjustments The crimp height on the 63816 0800 power crimp head can be adjusted if necessary To do this first measure the conductor crimp height of a crimped terminal and compare to the crimp specification listed in the product specificati...
Страница 23: ...clean brush or a soft lint free cloth Do not use any abrasive materials that could damage the tool Using a light oil such as SAE 30 weight automotive oil every 5 000 crimps or monthly will significantly enhance the tool life and ensure a stable calibration Make certain all sliding surfaces in the tool head are protected with a thin coat of high quality machine oil See Figure 8 14 for lubrication p...
Страница 24: ...mp Tool 1 Remove the M4 lock nut from the locator 2 Loosen and remove the pegs on the locator assembly from the mating holes on the back side of the power crimp head See Figure 8 16 Removing the Crimp Dies From the Type 4E Hand Crimp Tool 1 Open the hand crimp tool 2 Remove the two M4 BHCS 3 Remove the crimp dies as shown in Figure 8 17 4 Make sure all of the components removed from the hand crimp...
Страница 25: ...ne Application Tooling Specification ATS sheet 2 Crimp the terminal by actuating the crimp tool until it cycles and returns and the jaws open 3 Remove the terminal from the locator and inspect the crimp for proper quality CAUTION Never place fingers into the tooling nest area Maintenance It is recommended that each operator of the tool be made aware of and responsible for the following maintenance...
Страница 26: ... are long life tested All tools are warranted to be free of manufacturing defects for a period of 30 days Should such a defect occur Molex will repair or exchange the tool free of charge This repair or exchange will not be applicable to altered misused or damaged tools This tool is designed for hand use only Any clamping fixturing or use of handle extensions voids this warranty Parts List Item Ord...
Страница 27: ...nstall the AT air crimp head onto the AT power adapter as shown in Figure 8 23 Type RHT Crimp Tooling Kit Installation Into AT Crimp Head and AT Power Crimp Head Adapter One AT Crimp Head Required Remove the crimp tooling kit from the Type RHT hand crimp tool To do this see the Application Tooling Specification ATS sheet included with the hand crimp tool 1 Install the RHT crimp tooling kit with lo...
Страница 28: ...e and other contaminants with a clean brush or a soft lint free cloth Do not use any abrasive materials that could damage the tool Using a light oil such as SAE 30 weight automotive oil every 5 000 crimps or monthly will significantly enhance the tool life and ensure a stable calibration Make certain all sliding surfaces in the tool head are protected with a thin coat of high quality machine oil S...
Страница 29: ...ng correctly When working with the battery crimping tool do not wear loose clothing jewelery or long loose hair that can get caught in the mechanism Work with caution In cases of a tool malfunction production must be stopped and the malfunction must be fixed before continuing work with the battery crimping tool Only one person is allowed to work on or with the battery crimping tool Regular mainten...
Страница 30: ... this operating instruction The safety instructions warnings and precautions contained in the individual chapters must be strictly observed by all users and operators when working on or with the battery crimping tool The battery crimping tool may only be set up and operated in perfect technical conditions observing all the safety regulations and considering any possible dangers Before commissionin...
Страница 31: ...ervice address for inspection 11 Removal from Service Demounting and Disassembly DANGER Due to the risk of hand or finger injury never try to reach into the battery crimping tool before having assured that the battery has been removed Remove the battery from the battery crimping tool before mounting or exchanging the adapter tool head or die set CAUTION When working with the battery crimping tool ...
Страница 32: ...V 1 Item Order No Description Quantity 1 63816 0280 Battery Powered Tool 220V 1 2 63816 0001 Modular Crimp Head Locking Pins 2 3 63816 0272 10 8V Lithium Battery 2 4 63816 0285 Battery Charger 220V 1 Application Tooling Support Phone 402 458 TOOL 8665 E Mail applicationtooling molex com Website www molex com applicationtooling Molex is a registered trademark of Molex LLC in the United States of Am...
