molex 63816-0100 Manual

Air Powered Tool
Order No: TM-638160100 Release Date: 02-20-08 UNCONTROLLED COPY Page 1 of 17
Revisio : B Revisio Date: 05-28-10
AIR POWERED TOOL
Operating and Maintenance Instructions
Order No: 63816-0100
Optional Bench Adapter with Foot Switch
Order No: 63816-0 00
 Descriptio
 Operatio
 Mai te a ce

Air Powered Tool
Order No: TM-638160100 Release Date: 02-20-08 UNCONTROLLED COPY Page 2 of 17
Revisio : B Revisio Date: 05-28-10
Table of Contents
1. Safety War i gs a d I formatio
2. Ge eral Descriptio
3. Set-Up a d Adjustme ts
4. Preve tive Mai te a ce
5. Parts List, Assembly Drawi gs a d Troubleshooti g

Air Powered Tool
Order No: TM-638160100 Release Date: 02-20-08 UNCONTROLLED COPY Page 3 of 17
Revisio : B Revisio Date: 05-28-10
Section 1
Safety War i gs a d I formatio
Read a d understand all of the i structio s a d safety i formatio i this
ma ual before operati g or servici g this tool.
Keep this ma ual available whe usi g this tool.
Replaceme t ma uals are available upo request at o charge at
www.molex.com.
SA ETY
ALERT
SYMBOL
This symbol is used to call your atte tio to hazards or u safe practices which could result i a i jury
or property damage. The sig al word, defi ed below, i dicates the severity of the hazard. The message
after the sig al word provides i formatio for preve ti g or avoidi g the hazard.
DANGER
DANGER:
I dicates a immi e tly hazardous situatio which, if ot avoided, will result i
death or serious i jury.
WARNING
WARNING:
I dicates a pote tially hazardous situatio which, if ot avoided, will result i
death or serious i jury.
CAUTION
CAUTION:
I dicates a pote tially hazardous situatio which, if ot avoided, may result i
mi or or moderate i jury. CAUTION may also be used to alert agai st u safe
practices associated with eve ts that could lead to perso al i jury.
WARNING WARNING
Wear eye protectio whe operati g
or servici g this tool.
Failure to wear eye protectio could
result i serious eye i jury from flyi g
debris.
Pi ch poi ts:
Keep ha ds away from the crimpi g
head whe crimpi g.
Failure to observe this war i g could
result I severe i jury or death.
WARNING WARNING
Wear appropriate ear protectio whe
operati g this tool.
Failure to wear ear protectio could
result i loss of heari g over a period
of time.
I spect tool a d dies before use. Replace a y wor or damaged parts.
A damaged or improperly assembled tool ca break a d strike someo e
earby.
Failure to observe this war i g could result i severe i jury or death.

Air Powered Tool
Order No: TM-638160100 Release Date: 02-20-08 UNCONTROLLED COPY Page 4 of 17
Revisio : B Revisio 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 THE MOVING PARTS OF THIS
TOOL.
CAUTION THE MOLEX 63816-0100 AIR POWERED TOOL IS DESIGNED TO BE USED WITH CRIMP TOOL
HEADS AND TOOLING SUPPLIED BY MOLEX. USE OF TOOL HEADS 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 IN THIS TOOL.
WORK SA ELY AT ALL TIMES
or Service, Contact Your Local Molex Sales Office
Molex Application Tooling Group
2200 Wellington Court
Lisle, Illinois 60532 USA
Tel: [phone]
ax: 1-630-505-0049

Air Powered Tool
Order No: TM-638160100 Release Date: 02-20-08 UNCONTROLLED COPY Page 5 of 17
Revisio : B Revisio Date: 05-28-10
Section 2
General Description
2.1 Descriptio
2.2 Features
2.3 Tech ical Specificatio s
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
Revisio : B Revisio Date: 05-28-10
igure 2-1
AIR HOSE
TRIGGER
AIR POWERED
CRIMP ADAPTER
SWIVEL LOCK
BENCH MOUNT
CLAMP (Optional)
OOT SWITCH
(Optional)
MAIN UNIT
2 General Description
Principal Mechanical Parts
2.1 Description
The Molex Air Powered Tool is desig ed to crimp a variety of i sulated a d u i sulated termi als a d splices. This
tool has a automatic retractable system which retur s the crimpi g adapter alo g with the crimpi g dies to the
starti g positio whe the maximum force is reached. It is equipped with a special brake that will stop the forward
motio of the crimpi g dies whe the trigger is released. The crimpi g head ca be rotated 360° for better access
i difficult worki g situatio s. This u it requires a power u it a d a modular crimp tool head.
2.2 Features
 Light weight tool for high qua tities of termi atio s.
 Crimps a wide ra ge of products with i tercha geable tool heads a d tool kits, which reduce the overall cost a d
provide productio flexibility.
 Modular crimp heads are easily a d quickly i tercha ged to reduce productio dow time.
 Operated by ha d or foot, statio ary u it available.
 Modular crimp heads ca be rotated to at a y a gle to accommodate the operator.

Air Powered Tool
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Revisio : B Revisio Date: 05-28-10
2.3 Technical Specifications
Dimensions (with tool head adaptor)
Le gth 342.9mm (13.50”)
Diameter 65.0mm (2.56“)
Weight 1.3kg (2.98lbs)
Production Rate
600 cycles per hour maximum, depe di g o operator skill a d tool kit i stalled.
Operating Parameters
Cycle Time 1.0 seco ds
Air Co sumptio per Cycle .721 L (.025 cubic feet)
Required pressure of filtered air suppy 6 to 6.5 bar (87 to 94 psi) 8 bar maximum (116 psi)
2.4 Delivery Check
Carefully remove the P eumatic Crimpi g Tool from its shippi g co tai er a d determi e that the followi g
items are i cluded i the package.
 63816-0100 P eumatic Crimpi g U it with tooli g adaptor
 TM-638160100 Operatio Ma ual
2. Tools
The followi g tools are recomme ded for setup a d adjustme ts to this tool.
1. Metric sta dard hex wre ch set
2. Adjustable wre ch
3. Wire stripper / cutter
4. Screwdriver

Air Powered Tool
Order No: TM-638160100 Release Date: 02-20-08 UNCONTROLLED COPY Page 8 of 17
Revisio : B Revisio Date: 05-28-10
Section 3
Set-Up and Adjustments
3.1. Set-up
3.2. I stalli g or Cha gi g Modular Crimp Heads
3.3. Operatio
3.4. Termi al Crimpi g

Air Powered Tool
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Revisio : B Revisio Date: 05-28-10
TRIGGER
SA ETY
AIR HOSE
ILTER REGULATOR
LUBRICATOR
(NOT SUPPLIED)
TO AIR
SUPPLY
TRIGGER
igure 3-1
MODULE CRIMP
HEAD (RE )
ILTER REGULATOR
LUBRICATOR
(NOT SUPPLIED)
OOT SWITCH
(OPTIONAL)
BENCH
ADAPTER
(OPTIONAL)
TO AIR
SUPPLY
SECURE AIR
CRIMPING TOOL
IN POSITION
MODULE CRIMP
HEAD
(Reference)
igure 3-2
CONNECT TUBING ROM
OOT SWITCH
WITH ITTING
(NOT SUPPLIED)
3.1 Set-Up
1. Read the followi g i structio s before attempti g to operate this tool.
2. Co ect a 8mm or 5/16” air hose to the fitti g attached to the rear of the tool a d to air supply 6 to 6.5 bar (87
to 94 psi). Do ot exceed 8 bar (116 psi). May cause injury or damage to the tool. Air supply must be
equipped with a air filter regulator ( ot supplied by Molex). (Available from a y i dustrial supply co.). See
Figure 3-1.
If cha gi g to the Optio al be ch adapter, remove the air hose a d co ect the tubi g from the footswitch. See
Figure 3-2.

Air Powered Tool
Order No: TM-638160100 Release Date: 02-20-08 UNCONTROLLED COPY Page 10 of 17
Revisio : B Revisio Date: 05-28-10
SA ETY
(UNLOCKED)
SA ETY
(LOCKED)
TRIGGER
igure 3-3
3. Next lock the trigger o the actuator by flippi g the safety switch. Push the safety switch all the way dow o the
e d of the trigger to lock. See Figure 3-3.
Note: Always use the safety or disco ect air supply whe cha gi g crimpi g heads.
4. For the proper crimpi g head see the tool part umber o the label of the termi al/co ector co tai er.
5. Strip proper wire to mi imum le gth located o label of termi al/co ector co tai er or o the air powered crimp
tool head specificatio sheet.
3.2 Installing or Changing Modular Crimp Heads
Before starti g a y work o a y electrical applicatio s:
1. Make sure there are o live cables or parts i the immediate area of the user.
2. Make sure the safety is i the locked positio before cha gi g heads.
WARNING
Remove the power source from the crimpi g tool before
i stalli g a d removi g the modular crimp head.
Installing or Changing heads procedure:
1. Remove the locki g pi s (2) from the air powered crimp adapter o the air powered tool.
2. Pull the modular crimp head out of the adapter head.
3. To replace the modular crimp head, select the correct modular crimp head for the applicatio eeded.
4. While holdi g the air powered tool i o e ha d, grasp the modular crimp head with the other ha d a d slide it i to
the air powered crimp adapter u til the holes i the side plates of the crimp head li e up with the holes i the
adapter.
5. Replace the locki g pi s (2) maki g sure that the modular crimp head is secure. The locki g pi s ca be i serted
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
Revisio : B Revisio Date: 05-28-10
MODULAR
CRIMP HEAD
(NOT INCLUDED)
LOCKING PINS (2)
AIR POWERED
CRIMP ADAPTER
igure 3-4
3.3 Operation:
To actuate the crimpi g tool, first lift the safety lock lever o the trigger. See Figure 3-3.
The tool ca ow be actuated by depressi g the trigger a d holdi g u til the ram is fully exte ded.
After the ram has bee exte ded fully, release the trigger a d the ram will retur .
If usi g the optio al be ch mou t, lift the safety lock lever as described above. The tool is ow actuated by
depressi g the footswitch.
3.4 Terminal Crimping
Specificatio s a d I structio s for crimpi g are i cluded with the i dividual Modular Crimp Heads.

Air Powered Tool
Order No: TM-638160100 Release Date: 02-20-08 UNCONTROLLED COPY Page 12 of 17
Revisio : B Revisio Date: 05-28-10
Section 4
Preventive Maintenance
4.1 Periodic Clea i g
4.2 Storage
4.3 Warra ty
4.4 Mai te a ce

Air Powered Tool
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Revisio : B Revisio Date: 05-28-10
4.1 Periodic Cleaning
Always clea tool after use a d keep movi g parts clear of dirt a d debris.
This tool is mai te a ce free, o ly the slidi g ram i the crimpi g head has to be oiled regularly.
Before use:
1. I spect dies for wear or damage such as cracks, gouges, or chips.
2. I spect the tool for damage or leaks. If damage is detected, co tact Molex to have the tool evaluated.
After use:
1. Wipe all tool surfaces clea with a damp cloth a d mild deterge t. Excessive dirt a d grit ca co tribute to the
premature wear of the tool’s i ter al mecha ical parts. If this tool becomes dirty with excessive debris it may jam
a d become damaged duri g operatio .
2. Fully retract the ram. Store i a cool, dry place.
WARNING
Do ot use solve ts or flammable liquids to
clea the crimpi g tool.
Solve ts or flammable liquids could ig ite a d
cause serious i jury or property damage.
Monthly:
1. Thoroughly clea all surfaces.
Annually or After 10,000 Crimps
1. Retur the tool to a Molex represe tative for i spectio .
A routi e 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
Revisio : B Revisio Date: 05-28-10
A example of a mai te a ce chart is show below. Copy a d use this chart to track the mai te a ce of this
crimpi g tool or use this as a template to create your ow schedule or use your compa y’s sta dard chart, if
applicable.
Preventive Maintenance Chart
CHECK SHEET MONTH YEAR _________
Days of the Week
Week Daily
Use MON TUE WED THU RI SAT SUN Solution
1
2
3
4
Clea i g Daily After use
Lubricatio Slidi g ram
i to crimpi g head Use SAE No. 10 Oil
Schedule should be adjusted up or dow depe di g o usage. Molex recomme ds that a log of preve tive
mai te a ce be kept with the tool.
4.2 Storage
I order to protect the tool agai st damages, this tool should be clea ed carefully a d stored i a clea a d dry
locatio .
4.3 Warranty
All tools are warra ted free of ma ufacturi g defects for a period of 30 days. Should such a defect occur, we will
repair or excha ge the tool free of charge. This repair or excha ge will ot be applicable to altered, misused, or
damaged tools. This tool is desig ed for ha d use o ly. After o e year Molex recomme ds the crimpi g tool be
retur ed to Molex for i spectio . O ly the heads of the crimpi g tool are permitted to be cha ged by the operator.
If seals are damaged the warra ty is void.
CAUTION: Molex crimp specificatio s are valid o ly whe used with Molex termi als a d tooli g.
4.4 Maintenance
Crimpi g est should be kept free of oil a d all foreig particles.
Crimp tool head assemblies should be lubricated mo thly by placi g a few drops of light machi e oil o the slidi g
ram of the crimpi g tool.
Check the lubricator i the air supply a d fill with SAE 10W oil as eeded.
Check the air filter. To clea , remove the bowl a d the filter eleme t a d clea with de atured alcohol.

Air Powered Tool
Order No: TM-638160100 Release Date: 02-20-08 UNCONTROLLED COPY Page 15 of 17
Revisio : B Revisio Date: 05-28-10
Section 5
Parts List, Assembly Drawing and Troubleshooting
5.1. Parts List a d Assembly Drawi gs
5.2. Troubleshooti g

Air Powered Tool
Order No: TM-638160100 Release Date: 02-20-08 UNCONTROLLED COPY Page 16 of 17
Revisio : B Revisio Date: 05-28-10
3
igure 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 (I cluded)
3 63816-0500 Optio al Be ch Adapter with Foot Switch (Sold Separately)

Air Powered Tool
Order No: TM-638160100 Release Date: 02-20-08 UNCONTROLLED COPY Page 17 of 17
Revisio : B Revisio Date: 05-28-10
.2 Troubleshooting
Symptom Cause Solution
 Power u it ot co ected to
mai air supply. Co ect power u it to mai air supply. Ha d Actuated U it
Power u it pisto
will ot
exte d whe actuated.
 Faulty ha d switch assembly. Replace switch assembly.
Foot Actuated U it
Power u it pisto
will ot
exte d whe actuated.
 Air li e co ectio s to power
u it reversed.
 Faulty foot switch.
Disco ect mai air supply, the reverse
the air li e co ectio s o crimpi g u it.
Replace switch assembly.
 Improper lubricatio . Check for lubricatio i the mai air supply.
Loss of power.  I ter al seals of crimpi g u it
wor or damaged.
Replace the seals or co tact a Molex
Sales E gi eer.
Americas Headquarters
Lisle, Illi ois 60532 U.S.A.
1-800-78MOLEX
ameri [email protected]
ar East North Headquarters
Yamato, Ka agawa, Japa
81-462-65-2324
fe i [email protected]
ar East South Headquarters
Juro g, Si gapore
65-6-268-6868
fesi [email protected]
European Headquarters
Mu ich, Germa y
49-89-413092-0
euri [email protected]
Corporate Headquarters
2222 Welli gto Ct.
Lisle, IL 60532 U.S.A.
630-969-4550
Fax: [phone]
Visit our Web site at http://www.molex.com