molex CS 150 User manual

CS 150 Battery Crimping Tool
Doc No: ATS-638160200 Release Date:12-06-07 UNCONTROLLED COPY Page 1 of21
Revision: A Revision Date:12-06-07
BATTERY POWERED CRIMPING TOOL
Instruction Manual
Order No. 63816-0200
 Description
 Operation
 Maintenance

CS 150 Battery Crimping Tool
Doc No: ATS-638160200 Release Date:12-06-07 UNCONTROLLED COPY Page 2 of21
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

CS 150 Battery Crimping Tool
Doc No: ATS-638160200 Release Date:12-06-07 UNCONTROLLED COPY Page 3 of21
Revision: A Revision Date:12-06-07
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 requestat 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 signalword 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 notavoided, will result in
Death or serious injury.
CAUTION
CAUTION:
Indicates a potentially hazardous situation which,ifnot avoided,may resultin
Minor or moderate injury. CAUTION may also be used to alertagainst unsafe
practices associated with events thatcould 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 WARNING
Skin injection hazard:
Do not use hands to check for oil leaks.
High pressure oil easily punctures skin
causing serious injury, gangrene, ordeath.
If injured, seek medical help immediately
to remove oil.
Pinch points:
Keep hands away from the crimping
head when crimping.
Failure to observe this warning could
Result In severe injury or death.

CS 150 Battery Crimping Tool
Doc No: ATS-638160200 Release Date:12-06-07 UNCONTROLLED COPY Page 4 of21
Revision: A Revision Date:12-06-07
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. Replace 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 60532
Tel: [phone]
Fax: [phone]

CS 150 Battery Crimping Tool
Doc No: ATS-638160200 Release Date:12-06-07 UNCONTROLLED COPY Page 5 of21
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

CS 150 Battery Crimping Tool
Doc No: ATS-638160200 Release Date:12-06-07 UNCONTROLLED COPY Page 6 of21
Revision: A Revision Date:12-06-07
Figure 2
-1
LOCKING
PINS (2)
TRIGGER
CRIMPING
HEAD
ADAPTER
RECHARGEABLE
(NiCad 9.6V) BATTERY
UNLOCKING
SWITCH
RETRACT
SLIDE
2General Description
Principal MechanicalParts of the 63816-0200 (Battery charger not shown)
2.1 Description
The Molex Battery Crimping Tool is designed to crimp 8 to4/0 AWG insulated and uninsulated terminals and
splices. This tool has an automatic retractable system which returns the crimping adapter along with the
crimping dies to the starting position when the maximumforce is reached. Itis equipped with a special brake
thatwill stop the forward motion ofthe crimping dies when the trigger is released. The crimping head can be
rotated 360ofor better access in difficult working situations.
2.2 Features
 Crimps a wide range ofproducts with interchangeable tool heads and tool kits, which reduce the overallcost
and provide production flexibility.
 Crimping heads and dies are easily and quickly interchanged to reduce production down time.
 Complete portable system thatallows toolto be moved and stored easily.

CS 150 Battery Crimping Tool
Doc No: ATS-638160200 Release Date:12-06-07 UNCONTROLLED COPY Page 7 of21
Revision: A Revision Date:12-06-07
2.3 Technical Specification
Dimensions (with battery)
Length 292.1mm (11.50”)
Width 76.2mm (3.00“)
Depth 50.8mm (2.00“)
Unpacked Weight 1.5kg (3.31lbs)
Production Rate
250 cycles per hour maximum,depending on operator skill and tool kitinstalled.
Battery
Voltage 9.6V
Capacity 1.3 Ah
Charging Time: Approximately 40 Minutes, about15 minutes with fast-charger
Crimps/battery-charge 150 at 10mm2
Operating Parameters
MaximumForce 15kN (1.7 tons)
Cycle Time 2.0 seconds
Stroke Length 9.0mm (.354”)
AmbientTemperature -20oC to +40oC
Sound Level 75dB (A) in a distance of1.0m
Vibrations <2.5m/s2
2.4 Delivery Check
Carefully remove the CS150 Battery Crimping Tool from its shipping container and determine thatthe
following items are included in the package.
á CS 150 Battery Crimping Tool with battery
á Battery Charger
á Carrying Case
á 63816-0200 Instruction Manual

CS 150 Battery Crimping Tool
Doc No: ATS-638160200 Release Date:12-06-07 UNCONTROLLED COPY Page 8 of21
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 

CS 150 Battery Crimping Tool
Doc No: ATS-638160200 Release Date:12-06-07 UNCONTROLLED COPY Page 9 of21
Revision: A Revision Date:12-06-07
3.1 Set-Up
Before starting any work on electrical applications make sure there are no
live cables or parts in the immediate area ofthe user.
WARNING
Remove the battery from the crimping toolbefore
installing and removing dies inthe crimp head.
1. Select the appropriate crimping head with the proper tooling kit
inserted for the application needed.
2. Remove the locking pins (2) fromthe adapter plate on the crimping
tool.
3. Place the crimping head into the adapter and push down until it
engages into the slot ofthe adapter.
4. Replace the locking pins (2) making sure the crimping head is secure.
The locking pins can be inserted fromeither side ofthe adapter plate.
See Figure 3-1.
WARNING
Electric shock hazard:
This tool is not insulated. When usingthis
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 the tooling nest and push on the
trigger in the handle just enough so the dies contact the terminal or connector
securely. Release the trigger. This allows the operator to make adjustments
to the connector before the final termination.
2. Insert the wire or cable into the terminal. Push on the wire or cable to assure itis fully seated in the
terminal.
3. Hold the trigger down again until the crimping tool achieves pressure relief,which is accompanied by an
audible “pop”.
Figure 3-2
WITH LOCATOR
HOLD
TRIGGER
DOWN
TERMINAL
AND WIRE
IN PLACE
Figure 3-1
LOCKING
PINS (2)
CRIMPING
TOOL
CRIMPING
HEAD
ADAPTER
CRIMPING
HEAD WITH
TOOLING
ADAPTER
PLATES
LOCKING
LATCH
RETRACT
SLIDE

CS 150 Battery Crimping Tool
Doc No: ATS-638160200 Release Date:12-06-07 UNCONTROLLED COPY Page 10 of21
Revision: A Revision Date:12-06-07
The crimping operation can be interrupted atany time during the cycle by releasing the trigger.
4. The crimping cycle is complete when the dies are completely closed and the maximum crimping force is
reached. The dies will automatically release and will go back to their original position.
Note: In case ofan error or emergency, the ramcan be retracted before the crimping cycle is complete. Todo
this push the retractor slide towards the battery. See Figure 3-1.
Warning: DO NOT crimp copper and AIconducting material together or special connecting material. If
a different conducting material has to be crimped, please contactthe manufacturer.
WARNING
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 resultin 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 resultin severe injury from harmfulfumes orburns fromflyingdebris.
WARNING
Inspect tool and dies before use. Replace any worn or damaged parts. A damaged or improperly
assembled toolcan break and strike someone nearby.
Failure to observe this warning could resultin severe injury or death.
CAUTION
 Do not operate the tool without the dies. Damage to the ram or crimping head can result.
 Do not operate withthe crimping head open. Damage to the ram or seals can result.
 This tool is notdesigned 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 ifit becomes soaked.
 Use this tool for the manufacturer’s intended purpose only.
Failure to observe these precautions may resultininjury or property damage.

CS 150 Battery Crimping Tool
Doc No: ATS-638160200 Release Date:12-06-07 UNCONTROLLED COPY Page 11 of21
Revision: A Revision Date:12-06-07
CAUTION
 Do not allow anything to contactthe battery’s terminals.
 Do not immerse the battery inliquid. Liquid may create a short circuitand damage the battery.
Ifthe battery is immersed,contact your service center for proper handling.
 Do not place the battery into a pocket,toolpouch, 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 createa shortcircuitand damage
the battery.
Failure to observe these precautions may resultininjury or property damage.
Avoid dropping this tool. Extreme shock may damage the internalmechanism and result in malfunction ofthe
tool.

CS 150 Battery Crimping Tool
Doc No: ATS-638160200 Release Date:12-06-07 UNCONTROLLED COPY Page 12 of21
Revision: A Revision Date:12-06-07
Section 4
Terminal Specifications and Crimping Operation
4.1 Scope
4.2 Terminal Specifications Chart

CS 150 Battery Crimping Tool
Doc No: ATS-638160200 Release Date:12-06-07 UNCONTROLLED COPY Page 13 of21
Revision: A Revision Date:12-06-07
4.1 SCOPE
This tool is designed to crimp various Molex terminals and splices using our offering of crimping heads.
Testing
Mechanical
The tensile test,or pull test,is a means of evaluating the mechanical properties ofthe crimped connections.
The following charts show the UL specifications for various wire sizes. The tensile strength is shown in
pounds, which indicates the minimumacceptable force to break or separate the terminal fromthe 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 (Copper Conductors Only)
**UL –486C –ButtSlices and Parallel Slices (Over 6 AWG use 486A values)
***MIL-T-7928 - Military Approved Terminals only as listed
4.2 Crimping Terminals
Specifications and Instructions for crimping are included with the individual Battery Powered Crimp Tool
Heads.

CS 150 Battery Crimping Tool
Doc No: ATS-638160200 Release Date:12-06-07 UNCONTROLLED COPY Page 14 of21
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

CS 150 Battery Crimping Tool
Doc No: ATS-638160200 Release Date:12-06-07 UNCONTROLLED COPY Page 15 of21
Revision: A Revision Date:12-06-07
5.1 Periodic Cleaning
Always clean toolafter use and keep moving parts clear ofdirt and debris.
This tool is basically maintenance free, only the bolt joints atthe crimping head have to be oiled regularly.
Before use:
1. Inspectdies for wear or damage such as cracks,gouges, or chips.
2. Inspect the tool for damage or leaks. Ifdamage is detected, return the tool to a Molex representative for
inspection.
After use:
1. Wipe all tool surfaces clean with a damp cloth and mild detergent. Excessive dirtand gritcan contribute
to the premature wear of the tool’s internalmechanical parts. Ifthis tool becomes dirty with excessive
debris it may jam and become damaged during operation.
3. Fully retract the ram. Place the toolin 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 pressure oil easily punctures skin
causing serious injury, gangrene, ordeath.
If injured, seek medical help immediately
to remove oil.
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.
A routine should be established to keep the tool as free from dirtas possible.

CS 150 Battery Crimping Tool
Doc No: ATS-638160200 Release Date:12-06-07 UNCONTROLLED COPY Page 16 of21
Revision: A Revision Date:12-06-07
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 you own schedule or use your company’s standard
chart,ifapplicable.
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 (2) bolts in crimping head Use SAE 10W
Hydraulicoil
Schedule should be adjusted up or down depending on usage. Molex recommends thata log ofpreventive
maintenance be kept with the tool.
5.2 Storage
In order to protect the tool against damages, this tool should be cleaned carefully after every use. It should
then be placed into the carrying case along with the charging unit,crimp heads and the instruction manual
and stored 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 damage.
Do not dispose of the battery ina 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
CAUTION
 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.

CS 150 Battery Crimping Tool
Doc No: ATS-638160200 Release Date:12-06-07 UNCONTROLLED COPY Page 17 of21
Revision: A Revision Date:12-06-07
The charging unit is run with a nominal voltage of 110Vand a frequency of 50-60Hz . New batteries mustbe
charged before use. To remove the battery from the crimping tool push down on the battery lock and pull out.
See Figure 4-1. To charge the battery plug in the charging unit into a power source and slide the battery
upside down into the charging unit. The normal charging time is about40 minutes. The charging level of the
battery cartridge can be checked by the right LED (multicolor) of the charging unit.
Color Left LED (red) Right LED (multicolor)
Red Charging Unitis readytooperate. Battery defect
Red
Flashing
Charging Unitis out oforder.
New or unused battery’s
voltage capacity is insufficient.
Battery too hot or too cold. Remove the battery.
Safety components possibly defected.
Green --- Charging cycle stared.
Green
Flashing ---
Battery fully charged. Charging unit switches automatically
into a maintaining level.
Battery can stay in charge for an indefinite time with out
being damaged.
Yellow --- Battery is at least90% charged. Chargingcanbe terminated.
--- ---
Ifthe Right LED does not lightup,the circuitof the battery
is disconnected or the battery is incorrectly polarized.
Notes:
1. If the standard capacity ofthe battery is not achieved,itdoes 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 atroom temperature between 10oC-40oC (500F-104oF).
3. The battery should be charged before storing.
Cautions:
1. Charging a battery which has been used recently or in the sun or a long period
of time the rightLED might flash red, (Temperatures greater than 65oC (149oF).
In this case let the battery cool down and try again.
2. Charging the battery at low temperatures under 5oC (41oF) is not possible. The
battery temperature must be warmed up before starting the battery cycle again.
3. Do not expose the charging unitto rainor snow.
4. Do not charge the battery in or around explosive materials or gases.
5. Do not use any other (dry or car) battery with the charging unitor the crimping
tool.
6. Do not use the cord as a handle to carry the battery unit.
7. Do not pull the cord out ofa wall socket with force.
8. Do not pull the plug ofthe charging unituntil after the battery has been charged.
9. Do not insert foreign objects into the ducts of the charging unit.
10. Do not disassemble the charging unit.
11. Do not place the battery in your pocket or a toolbox, ifthere are conductive materials such as coins,
keys,tools or other metallic parts may cause injury or property damage.
PUCH DOWN
ON SWITH
Figure 4-1
BATTERY
UNIT

CS 150 Battery Crimping Tool
Doc No: ATS-638160200 Release Date:12-06-07 UNCONTROLLED COPY Page 18 of21
Revision: A Revision Date:12-06-07
5.4 Disposal
When this tool is no longer operating properly the different components of this tool will need to be disposed of
separately.
1. The hydraulic oil mustbe disposed of at a local drop-offrecycling center.
ATTENTION
Disposal ofHydraulic fluid represents a danger to ground-water. Uncontrolled draining of
or improper disposal is under penalty (environmentalliabilitylaw) thru theEnvironmental
Protection Agency (EPA) guidelines.
2. The battery mustbe disposed ofaccording to the Rechargeable Battery Recycling Corporation
(RBRC) guidelines.
3. The remaining parts of this tool mustbe disposed of according to the domestic environmental
standards or the Environmental Protection Agency (EPA) guidelines.
4. Because of possible environmentaldamage, we recommend disposal of the toolby a professional
company.
ATTENTION
Do not dispose ofthis tool in your residential orcommercialwaste,
as it would be hazardous to the environment.
5.5 Warranty
Alltools are warranted to be free of manufacturing defects for a period of30 days. Should such a defect
occur, we 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. After one year Molex recommends the crimping toolbe returned to
a Molex representative for inspection. Only the heads of the crimping tool are permitted to be changed by the
operator.
ATTENTION
Do not damage the seals of this tool.
Ifseals are damaged the warranty is invalid.
CAUTION: Molex crimp specifications are valid only when used with Molex terminals and tooling.

CS 150 Battery Crimping Tool
Doc No: ATS-638160200 Release Date:12-06-07 UNCONTROLLED COPY Page 19 of21
Revision: A Revision Date:12-06-07
Section 6
6.1. Parts List and Assembly Drawing
6.2. Troubleshooting

CS 150 Battery Crimping Tool
Doc No: ATS-638160200 Release Date:12-06-07 UNCONTROLLED COPY Page 20 of21
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 UnitCS 150 1
2
3
Figure 6-1
1