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air powered tool order no: tm-638160100 release date: 02-20-08 uncontrolled copy page 1 of 17 revision: b revision date: 05-28-10 air powered tool operating and maintenance instructions order no: 63816-0100 optional bench adapter with foot switch order no: 63816-0500 description operation maintenance
air powered tool order no: tm-638160100 release date: 02-20-08 uncontrolled copy page 2 of 17 revision: b revision date: 05-28-10 table of contents 1. safety warnings and information 2. general description 3. set-up and adjustments 4. preventive maintenance 5. parts list, assembly drawings and troubleshooting
air powered tool order no: tm-638160100 release date: 02-20-08 uncontrolled copy page 3 of 17 revision: b revision date: 05-28-10 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. replacement manuals are available upon request at n o charge at www.molex.com. safety alert symbol this symbol is used to call your attention to hazar ds or unsafe practices which could result in an inj ury or property damage. the signal word, defined below , indicates the severity of the hazard. the messag e after the signal word provides information for prev enting 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 wear eye protection when operating or servicing this tool. failure to wear eye protection could result in serious eye injury from flying debris. pinch points: keep hands away from the crimping head when crimping. failure to observe this warning could result in severe injury or death. warning warning wear appropriate ear protection when operating this tool . failure to wear ear protection could result in loss of hearing over a period of time. inspect tool and dies before use. replace any worn or damaged parts. a damaged or improperly assembled tool can break an d strike someone nearby. failure to observe this warning could result in sev ere injury or death.
air powered tool order no: tm-638160100 release date: 02-20-08 uncontrolled copy page 4 of 17 revision: b revision date: 05-28-10 never install or service this machine while connected to the compressed air source. never wear loose clothing or jewelry that may catch in th e moving parts of this tool. caution the molex 63816-0100 air powered tool is designed t o be used with crimp tool heads and tooling supplied by molex. use of tool h eads or tooling from any other source may result in damage or injury. molex will not be liable for any damage or injury from use of non-molex components i n this tool. work safely at all times for service, contact your local molex sales office molex application tooling group 2200 wellington court lisle, illinois 60532 usa tel: 1-630-969-4550 fax: 1-630-505-0049
air powered tool order no: tm-638160100 release date: 02-20-08 uncontrolled copy page 5 of 17 revision: b revision date: 05-28-10 section 2 general description 2.1 description 2.2 features 2.3 technical specifications 2.4 delivery check 2.5 tools
air powered tool order no: tm-638160100 release date: 02-20-08 uncontrolled copy page 6 of 17 revision: b revision date: 05-28-10 figure 2-1 air hose trigger air powered crimp adapter swivel lock bench mount clamp (optional) foot switch (optional) main unit 2 general description principal mechanical parts 2.1 description the molex air powered tool is designed to crimp a v ariety of insulated and uninsulated terminals and s plices. this tool has an automatic retractable system which retu rns the crimping adapter along with the crimping di es to the starting position when the maximum force is reached . it is equipped with a special brake that will st op the forward motion of the crimping dies when the trigger is rel eased. the crimping head can be rotated 360 for b etter access in difficult working situations. this unit require s a power unit and a modular crimp tool head. 2.2 features light weight tool for high quantities of terminatio ns. crimps a wide range of products with interchangeabl e tool heads and tool kits, which reduce the overal l cost and provide production flexibility. modular crimp heads are easily and quickly intercha nged to reduce production down time. operated by hand or foot, stationary unit available . modular crimp heads can be rotated to at any angle to accommodate the operator.
air powered tool order no: tm-638160100 release date: 02-20-08 uncontrolled copy page 7 of 17 revision: b revision date: 05-28-10 2.3 technical specifications dimensions (with tool head adaptor) length 342.9mm (13.50) diameter 65.0mm (2.56) weight 1.3kg (2.98lbs) production rate 600 cycles per hour maximum, depending on operator skill and tool kit installed. operating parameters cycle time 1.0 seconds air consumption per cycle .721 l (.025 cubic feet) required pressure of filtered air suppy 6 to 6.5 ba r (87 to 94 psi) 8 bar maximum (116 psi) 2.4 delivery check carefully remove the pneumatic crimping tool from i ts shipping container and determine that the follow ing items are included in the package. 63816-0100 pneumatic crimping unit with tooling ada ptor tm-638160100 operation manual 2.5 tools the following tools are recommended for setup and a djustments to this tool. 1. metric standard hex wrench set 2. adjustable wrench 3. wire stripper / cutter 4. screwdriver
air powered tool order no: tm-638160100 release date: 02-20-08 uncontrolled copy page 8 of 17 revision: b revision date: 05-28-10 section 3 set-up and adjustments 3.1. set-up 3.2. installing or changing modular crimp heads 3.3. operation 3.4. terminal crimping
air powered tool order no: tm-638160100 release date: 02-20-08 uncontrolled copy page 9 of 17 revision: b revision date: 05-28-10 trigger safety air hose filter regulator lubricator (not supplied) to air supply trigger figure 3-1 module crimp head (ref) filter regulator lubricator (not supplied) foot switch (optional) bench adapter (optional) to air supply secure air crimping tool in position module crimp head (reference) figure 3-2 connect tubing from foot switch with fitting (not supplied) 3.1 set-up 1. read the following instructions before attempting t o operate this tool. 2. connect an 8mm or 5/16 air hose to the fitting att ached to the rear of the tool and to air supply 6 t o 6.5 bar (87 to 94 psi). do not exceed 8 bar (116 psi). may cause injury or damage to the tool. air supply must be equipped with an air filter regulator (not supplied by molex). (available from any industrial supply co.). see figure 3-1. if changing to the optional bench adapter, remove t he air hose and connect the tubing from the footswi tch. see figure 3-2.
air powered tool order no: tm-638160100 release date: 02-20-08 uncontrolled copy page 10 of 17 revision: b revision date: 05-28-10 safety (unlocked) safety (locked) trigger figure 3-3 3. next lock the trigger on the actuator by flipping t he safety switch. push the safety switch all the w ay down on the end of the trigger to lock. see figure 3-3. note: always use the safety or disconnect air suppl y when changing crimping heads. 4. for the proper crimping head see the tool part numb er on the label of the terminal/connector container . 5. strip proper wire to minimum length located on labe l of terminal/connector container or on the air pow ered crimp tool head specification sheet. 3.2 installing or changing modular crimp heads before starting any work on any electrical applicat ions: 1. make sure there are no live cables or parts in the immediate area of the user. 2. make sure the safety is in the locked position befo re changing heads. warning remove the power source from the crimping tool befo re installing and removing the modular crimp head. installing or changing heads procedure: 1. remove the locking pins (2) from the air powered cr imp adapter on the air powered tool. 2. pull the modular crimp head out of the adapter head . 3. to replace the modular crimp head, select the corre ct modular crimp head for the application needed. 4. while holding the air powered tool in one hand, gra sp the modular crimp head with the other hand and s lide it into the air powered crimp adapter until the holes in th e side plates of the crimp head line up with the ho les in the adapter. 5. replace the locking pins (2) making sure that the m odular crimp head is secure. the locking pins can be inserted from either side of the adapter. see figure 3-4.
air powered tool order no: tm-638160100 release date: 02-20-08 uncontrolled copy page 11 of 17 revision: b revision date: 05-28-10 modular crimp head (not included) locking pins (2) air powered crimp adapter figure 3-4 3.3 operation: to actuate the crimping tool, first lift the safety lock lever on the trigger. see figure 3-3. the tool can now be actuated by depressing the trig ger and holding until the ram is fully extended. after the ram has been extended fully, release the trigger and the ram will return. if using the optional bench mount, lift the safety lock lever as described above. the tool is now act uated by depressing the footswitch. 3.4 terminal crimping specifications and instructions for crimping are in cluded with the individual modular crimp heads.
air powered tool order no: tm-638160100 release date: 02-20-08 uncontrolled copy page 12 of 17 revision: b revision date: 05-28-10 section 4 preventive maintenance 4.1 periodic cleaning 4.2 storage 4.3 warranty 4.4 maintenance
air powered tool order no: tm-638160100 release date: 02-20-08 uncontrolled copy page 13 of 17 revision: b revision date: 05-28-10 4.1 periodic cleaning always clean tool after use and keep moving parts c lear of dirt and debris. this tool is maintenance free, only the sliding ram in the crimping head has to be oiled regularly. before use: 1. inspect dies for wear or damage such as cracks, gou ges, or chips. 2. inspect the tool for damage or leaks. if damage is detected, contact molex to have the tool evaluated . after use: 1. wipe all tool surfaces clean with a damp cloth and mild detergent. excessive dirt and grit can contri bute to the premature wear of the tools internal mechanical pa rts. if this tool becomes dirty with excessive deb ris it may jam and become damaged during operation. 2. fully retract the ram. store in a cool, dry place. 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: 1. thoroughly clean all surfaces. annually or after 10,000 crimps 1. return the tool to a molex representative for inspe ction. a routine should be established to keep the tool as free from dirt as possible.
air powered tool order no: tm-638160100 release date: 02-20-08 uncontrolled copy page 14 of 17 revision: b revision date: 05-28-10 an example of a maintenance chart is shown below. copy and use this chart to track the maintenance of this crimping tool or use this as a template to create y our own schedule or use your companys standard cha rt, if applicable. preventive maintenance chart check sheet month year _________ days of the week week daily use mon tue wed thu fri sat sun solution 1 2 3 4 cleaning daily after use lubrication sliding ram into crimping head use sae no. 10 oil schedule should be adjusted up or down depending on usage. molex recommends that a log of preventive maintenance be kept with the tool. 4.2 storage in order to protect the tool against damages, this tool should be cleaned carefully and stored in a cl ean and dry location. 4.3 warranty all tools are warranted free of manufacturing defec ts for a period of 30 days. should such a defect o ccur, we will repair or exchange the tool free of charge. this r epair or exchange will not be applicable to altered , misused, or damaged tools. this tool is designed for hand use only. after one year molex recommends the crimping tool be returned to molex for inspection. only the heads o f the crimping tool are permitted to be changed by the operator. if seals are damaged the warranty is void. caution : molex crimp specifications are valid only when u sed with molex terminals and tooling. 4.4 maintenance crimping nest should be kept free of oil and all fo reign particles. crimp tool head assemblies should be lubricated mon thly by placing a few drops of light machine oil on the sliding ram of the crimping tool. check the lubricator in the air supply and fill wit h sae 10w oil as needed. check the air filter. to clean, remove the bowl an d the filter element and clean with denatured alcoh ol.
air powered tool order no: tm-638160100 release date: 02-20-08 uncontrolled copy page 15 of 17 revision: b revision date: 05-28-10 section 5 parts list, assembly drawing and troubleshooting 5.1. parts list and assembly drawings 5.2. troubleshooting
air powered tool order no: tm-638160100 release date: 02-20-08 uncontrolled copy page 16 of 17 revision: b revision date: 05-28-10 3 figure 5-1 2 3 3 module crimp tool (reference) 1 5.1 parts list and assembly drawings item order no description quantity 1 63816-0100 air powered crimp tool 1 2 63816-0700 air powered crimp adapter (included) 3 63816-0500 optional bench adapter with foot switc h (sold separately)
air powered tool order no: tm-638160100 release date: 02-20-08 uncontrolled copy page 17 of 17 revision: b revision date: 05-28-10 5.2 troubleshooting symptom cause solution power unit not connected to main air supply. connect power unit to main air supply. hand actuated unit power unit piston will not extend when actuated. faulty hand switch assembly. replace switch assembl y. foot actuated unit power unit piston will not extend when actuated. air line connections to power unit reversed. faulty foot switch. disconnect main air supply, then reverse the air line connections on crimping unit. replace switch assembly. improper lubrication. check for lubrication in the main air supply. loss of power. internal seals of crimping unit worn or damaged. replace the seals or contact a molex sales engineer. americas headquarters lisle, illinois 60532 u.s.a. 1-800-78molex amerinfo@molex.com far east north headquarters yamato, kanagawa, japan 81-462-65-2324 feninfo@molex.com far east south headquarters jurong, singapore 65-6-268-6868 fesinfo@molex.com european headquarters munich, germany 49-89-413092-0 eurinfo@molex.com corporate headquarters 2222 wellington ct. lisle, il 60532 u.s.a. 630-969-4550 fax: 630-969-1352 visit our web site at http://www.molex.com

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