molex 63816-0200 Bedienungsanleitung
Battery Powered Crimping Tool
Doc No: TM-638160200 elease Date: 12-06-07 UNCONTROLLED COPY Page 1 of 23
evision: D evision Date: 05-20-11
BATTERY POWERED CRIMPING TOOL
Operation Manual
Order No. 6 816-0200 (110 V)
Order No. 6 816-0250 (220 V)
Description
Operation
Maintenance
This datasheet has been downloaded fromhttp://www.digchip.com at this page
Battery Powered Crimping Tool
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Table of Contents
SECTION
1 Safety Warnings and Information
2 General Description
3 Set-up and Adjustments
4 Terminal Specifications and Crimping Operation
5 Preventive Maintenance
6 Parts List, Assembly Drawing and Troubleshooting”
Battery Powered Crimping Tool
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Section 1
Safety Warnings and Information
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 this tool.
eplacement manuals are available upon request at no charge at
www.molex.com.
SAFETY
ALERT SYMBOL
This symbol is used to call your attention to hazards or unsafe practices which could
result in an injury or property damage. The signal word, defined below, indicates
the severity of the hazard. The message after the signal word provides information
for preventing or avoiding the hazard.
DANGER
DANGER:
Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury.
WARNING
WARNING:
Indicates a potentially hazardous 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 near energized electrical lines,
use proper personal protective
equipment.
Failure to observe this warning could
result in severe injury or death.
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.
WARNING
Pinch points:
Keep hands away from the crimping head when crimping.
Failure to observe this warning could result In severe injury or death.
Battery Powered Crimping Tool
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WARNING 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.
An incomplete crimp can cause a fire.
Use proper die, connector, and cable combinations.
Improper combinations can result in an
incomplete crimp.
The relief valve will sound to indicate a completed
crimp. If you do not hear the sound of the relief valve,
the crimp is not complete.
Failure to observe these warnings could result in severe
injury or death.
WARNING 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
Inspect tool and dies before use. eplace any worn or
damaged parts. A damaged or improperly assembled
tool can break and strike someone nearby.
Failure to observe this warning could result in severe
injury or death.
CAUTION CAUTION
Do not operate the tool without the dies. Damage to the ram or crimping
head can result.
Do not operate with the crimping head open. Damage to the ram or
seals can result.
This tool is not designed for continuous use. After 100 crimping cycles,
allow the crimping 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 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 terminals.
Do not immerse the battery in liquid. Liquid may
create a short circuit and damage the battery.
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 property damage.
CAUTION CAUTION
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 damage.
Do not perform any service or maintenance other than as
described in this manual.
Failure to observe this precaution may result in injury
and property damage.
For Service, Contact Your Local Molex Sales Office
Molex Application Tooling Group
2200 Wellington Court
Lisle, Illinois 605 2 USA
Tel: 1-6 0-969-4550
Fax: 1-6 0-505-0049
Battery Powered Crimping Tool
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Section 2
General Description
2.1 Description
2.2 Features
2.3 Technical Specifications
2.4 Delivery Check
Battery Powered Crimping Tool
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Figure 2-1
LOCKING
PINS (2)
TRIGGER
CRIMPING
HEAD
ADAPTER
RECHARGEABLE
(NiCad 9.6V) BATTERY
UNLOCKING
SWITCH
RETRACTOR
SLIDE
2 General Description
Principal Mechanical Parts of the 6 816-0200 (110 V) and the 6 816-0250 (220 V) Battery Powered
Tool (Battery charger not shown).
2.1 Description
The Molex Battery Powered Tool is designed to crimp terminals with the use of interchangeable crimp die kits.
This tool 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 360°
for better access in difficult working situations.
2.2 Features
Crimps a wide range of products with interchangeable modular crimp heads or power crimp heads, and tool
kits, which reduce the overall cost and provide production flexibility.
Modular crimp heads or power crimp head and dies are easily and quickly interchanged to reduce production
down time.
Complete portable system that allows tool to be moved and stored easily.
Battery Powered Crimping Tool
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2. Technical Specifications
Dimensions (with battery)
Length 292.1mm (11.50”)
Width 76.2mm (3.00“)
Depth 50.8mm (2.00“)
Unpacked Weight 1.50kg (3.31lbs)
Production Rate
250 cycles per hour maximum, depending on operator skill and tool kit installed.
Battery
Voltage 9.6V
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 tonne-force)
Cycle Time 2.0 seconds
Stroke Length 9.00mm (.354”)
Ambient Temperature -20oC to +40oC
Sound Level 75dB (A) in a distance of 1.0m
Vibrations <2.5m/s2
2.4 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 6 816-0200 (110 V):
63816-0200 Battery Crimping Tool with battery
63816-0210 Battery Charger
Carrying Case
TM-638160200 Operation Manual
For the 6 816-0250 (220 V):
63816-0250 Battery Crimping Tool with battery
63816-0260 Battery Charger
Carrying Case
TM-638160200 Operation Manual
Battery Powered Crimping Tool
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Section
Set-Up and Adjustments
3.1. Set-up
3.2. Operation
3.3. Preventive Instructions
Battery Powered Crimping Tool
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.1 Set-Up
Figure -1 Replacing Power or Modular Crimp Heads
Type AT Type 4A
Type 2C OR 4C Type 4D
Before starting any work on electrical applications make sure there are no live cables or parts in the immediate
area of the user.
BATTERY
POWERED TOOL
TYPE 4
D
POWER CRIMP HEAD
NO TOOLING SHOWN
CRIMP HEAD
ADAPTER
LOCKING
PINS (2)
RETRACT
SLIDE
YOKE
LOCKING
PINS (2)
TYPE
2C OR
4
C
POWER CRIMP HEAD
NO TOOLING SHOWN
BATTERY
POWERED TOOL
YOKE
CRIMP HEAD
ADAPTER
LOCKING
LATCH
RETRACT
SLIDE
RETRACT
SLIDE
LOCKING
PINS (2)
BATTERY
POWERED
TOOL
TYPE 4A
MODULAR CRIMP
HEAD
WITH TOOLING
6 816
-
0600
ADAPTER
LOCKING
PINS (2) YOKE
SLOTTED
SCREWS (2)
BATTERY
POWERED TOOL
TYPE AT
MODULAR CRIMP
HEAD
WITH TOOLING
6 816
-
0900
ADAPTER
LOCKING
PINS (2)
RETRACT
SLIDE
YOKE
Battery Powered Crimping Tool
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WITH
LOCATOR
HOLD
TRIGGER
DOWN
TERMINAL
AND WIRE
IN PLACE
MODULAR
CRIMP HEAD
Figure -2
WITH LOCATOR
TERMINAL
AND WIRE
IN PLACE
HOLD
TRIGGER
DOWN
POWER CRIMP
HEAD
WARNING
emove the battery from the crimping tool before
installing and removing dies in the crimp head.
1. Select the appropriate modular crimp head or power crimp head with the proper tooling kit inserted for the
application needed. The Modular Crimp Head with the Battery Powerd Crimp Adapter or the Power Crimp
Head are sold separately.
2. emove the locking pins (2) from the battery powered crimp yoke.
3. Place the modular crimp head into the yoke and push down until it engages into the slot of the adapter. The
Power Crimp Heads do not require a separate Power Crimp Adapter.
4. eplace the locking pins (2) making sure the modular crimp head or the Power Crimp Head are secure. The
locking pins can be inserted from either side of the yoke. See Figure 3-1.
WARNING
WARNING
Electric shock hazard:
This tool is not insulated. 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.
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.
.2 Operation
1. Insert the proper terminal or connector into the tooling nest and push on the trigger in the handle just
enough so the dies contact the terminal or connector securely. elease the trigger. This allows the operator
to make adjustments to the connector before the final termination. See Figure 3-2.
2. Insert the wire or cable into the terminal. Push on the wire or cable to assure it is fully seated in the
terminal.
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