molex 63816-0200 User manual

Battery Powered Crimping Tool
Order No: TM-638160200 Relea e Date: 12.06-07 UNCONTROLLED COPY Page 1 of 33
Revi ion: E Revi ion Date: 06-07-12
BATTERY POWERED CRIMPING TOOL
Operation Manual
Order No. 6 816-0200 (110 V)
Order No. 6 816-0250 (220 V)

Battery Powered Crimping Tool
Order No: TM-638160200 Relea e Date: 12.06-07 UNCONTROLLED COPY Page 2 of 33
Revi ion: E Revi ion Date: 06-07-12
Table of Contents
BATTERY POWERED CRIMPING TOOL ........................................................................................................................ 1
Safety Warning and Information ..................................................................................................................................... 3
SECTION 1 ...................................................................................................................................................................... 7
De cription ................................................................................................................................................................................... 7
1.1. Feature ....................................................................................................................................................................... 7
1.2. Technical Specification .............................................................................................................................................. 8
1.3 Delivery Check ............................................................................................................................................................. 8
SECTION 2 ...................................................................................................................................................................... 9
Power Crimp Head and Adapter ............................................................................................................................................... 9
2.1 Compari on Chart - Hand and Power Crimp Tool .................................................................................................... 10
2.2 63816-0600 Power Crimp Adapter for Type 4A Hand Crimp Tool ........................................................................... 11
2.3 63816-0300 Power Crimp Head for Type 2C and 4C Hand Crimp Tool .................................................................. 13
2.4 63816-0800 Power Crimp Head for Type 4D Hand Crimp Tool ............................................................................... 15
2.5 63816-0900 Power Adapter for Type AT Air Crimp Head ........................................................................................ 18
SECTION 3 .................................................................................................................................................................... 20
Set-Up and Adju tment ............................................................................................................................................................ 20
3.1 Set-Up ........................................................................................................................................................................ 21
3.2 Operation ................................................................................................................................................................... 22
3.3 Preventive In truction .............................................................................................................................................. 23
SECTION 4 .................................................................................................................................................................... 24
General Terminal Specification and Crimping Operation ......................................................................................................... 24
4.1 Scope ......................................................................................................................................................................... 25
4.2 Crimping Terminal .................................................................................................................................................... 25
SECTION 5 .................................................................................................................................................................... 26
Preventive Maintenance ............................................................................................................................................................ 26
5.1 Periodic Cleaning ....................................................................................................................................................... 27
5.2 Battery and Charging Unit.......................................................................................................................................... 28
5.3 Di po al ..................................................................................................................................................................... 29
5.4 Warranty .................................................................................................................................................................... 29
SECTION 6 .................................................................................................................................................................... 30
Part Li t, A embly Drawing , and Trouble hooting ................................................................................................................ 30
6.1 Part Li t and A embly Drawing ............................................................................................................................ 31
6.2 Trouble hooting ........................................................................................................................................................ 33

Battery Powered Crimping Tool
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Revi ion: E Revi ion Date: 06-07-12
Safety Warnings and Information
Read
and
understand
all of the in truction and afety information in thi
manual before operating or ervicing thi tool.
Keep thi manual available when u ing thi tool.
Replacement manual are available for download at no charge at
www.molex.com.
SAFETY ALERT SYMBOL
Thi ymbol i u ed to call your attention to hazard or un afe practice which could re ult in an injury
or property damage. The ignal word, defined below, indicate the everity of the hazard. The me age
after the ignal word provide information for preventing or avoiding the hazard.
DANGER
DANGER:
Indicate an imminently hazardou ituation which, if not avoided, could re ult in death or eriou injury.
WARNING
WARNING:
Indicate a potentially hazardou ituation which, if not avoided, could re ult in death or eriou injury.
CAUTION
CAUTION:
Indicate a potentially hazardou ituation which, if not avoided, may re ult in minor or moderate injury.
CAUTION may al o be u ed to alert again t un afe practice a ociated with event that could lead
to per onal injury.
WARNING
WARNING
Always
wear proper eye protection when
Operating or ervicing thi tool.
Failure to wear eye protection could re ult in
eriou eye injury from flying debri or hydraulic oil.
Always wear proper ear protection when
Operating or ervicing thi tool.
WARNING
WARNING
Never wear clothing or jewelery that i loo e or
That could potentially get caught in thi tool.
Failure to ob erve thi warning could re ult in
Severe Injury or death.
Electric hock hazard:
Thi tool i not in ulated. When u ing thi unit near
energized electrical line , u e proper per onal
protective equipment.
Failure to ob erve thi warning could re ult in
evere injury or death
WARNING
WARNING
Never operate, ervice, in tall, or adju t thi
tool without proper in truction and without
fir t reading and under tanding the in truction
in thi manual and all applicable manual .
Pinch point :
Keep hand away from the crimping head when
crimping.
Failure to ob erve thi warning could re ult In
evere injury or death.

Battery Powered Crimping Tool
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Revi ion: E Revi ion Date: 06-07-12
WARNING
WARNING
Do not u e olvent or flammable liquid
to clean the crimping tool.
Solvent or flammable liquid could ignite and
cau e eriou injury or property damage.
Do not use
compre ed air to clean thi tool.
The force created by compre ed air can
force debri into the tool.
Failure to ob erve the e precaution may
re ult in injury or property damage.
WARNING
WARNING
Do not di po e of the battery in a fire. It will
vent fume and may explode.
Failure to ob erve thi warning could re ult in
evere injury from harmful fume or burn from
flying debri
In pect tool and die before u e. Replace any
worn or damaged part . A damaged or
improperly a embled tool can break and trike
omeone nearby.
Failure to ob erve thi warning could re ult in
evere injury or death.
CAUTION

Do not operate the tool without the die . Damage to the ram or crimping head can re ult.
 Do not operate with the crimping head open. Damage to the ram or eal can re ult.
 Thi tool i not de igned for continuou u e. After 100 crimping cycle , allow the crimping tool to cool down for 15 minute .
 Do not place the tool in a vi e. The crimping tool i de igned for hand-held operation only.
 Thi tool may be u ed in damp or wet environment ; however, we recommend air-drying the tool before u e if it become oaked.
 U e thi tool for the manufacturer’ intended purpo e only.
 Failure to ob erve the e precaution may re ult in injury or property damage
CAUTION

Do not allow anything to contact the battery’ terminal .
 Do not immer e the battery in liquid. Liquid may create a hort circuit and damage the battery.
 If the battery i immer ed, contact your ervice center for proper handling.
 Do not place the battery into a pocket, tool pouch, or tool box with conductive object .
 Conductive object may create a hort circuit and damage the battery.
 Do not place a battery on moi t ground or gra . Moi ture may create a hort circuit and damage the battery.
Failure to ob erve the e precaution may re ult in injury or property damage.
CA
UTION

Do not tore the battery at more than 60 °C (140 °F). Damage to the battery can re ult.
 Do not u e another manufacturer’ charger. Other manufacturer ’ charger may overcharge and damage the battery.
 Do not attempt to open the battery. It contain no u er- erviceable part .

Failure to ob erve the e precaution may re ult in injury or property damage.
CAUTION
Never
perform any ervice or maintenance other than a de cribed in thi manual.
Never modify, alter or mi u e the equipment
Molex crimp pecification are valid only when u ed with Molex terminal , applicator and tooling.
Failure to ob erve thi precaution may re ult in injury and property damage.

Battery Powered Crimping Tool
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Revi ion: E Revi ion Date: 06-07-12
Tooling Technical Assistance
Molex offer tooling technical a i tance for cu tomer who may need ome guidance for tooling adju tment . Thi upport
can be obtained by calling either of the two number li ted below and a king for the Molex Tooling Group.
Call Toll Free 1-800-786-6539 (US) 1-630-969-4550 (Global).
Thi a i tance i limited to the operation and et-up of a cu tomer’ Molex tool. Que tion with regard to Molex connector
product or how to identify the proper tooling and/ or tooling documentation hould be directed to your local Molex per onnel
or Cu tomer Service Repre entative.
When calling for ervice on thi tool, a copy of the Tooling Manual and Specific Application Tooling Specification (ATS) Sheet
hould be pre ent and a per on that i familiar with thi tool hould be pre ent. Be ure the following information i upplied:
1. Cu tomer name
2. Cu tomer addre
3. Per on to contact uch a (name, title, e-mail, and telephone number
4. Power tool order number (Lea e number al o if applicable)
5. Serial number (Lea e number al o if applicable)
6. Molex Connector product order number
7. Urgency of reque t
8. Nature of problem
Molex Application Tooling Group
2200 Wellington Court
Li le, IL 60532, USA
Tel: [phone]
Fax:[phone]
Vi it our Web ite at http://www.molex.com

Battery Powered Crimping Tool
Order No: TM-638160200 Relea e Date: 12.06-07 UNCONTROLLED COPY Page 6 of 33
Revi ion: E Revi ion Date: 06-07-12
Table of Contents
SECTIONS
1. General De cription
2. Power Crimp Head and Adapter
3. Set-up and Adju tment
4. Terminal Specification and Crimping Operation
5. Preventive Maintenance
6. Part Li t, A embly Drawing, and Trouble hooting

Battery Powered Crimping Tool
Order No: TM-638160200 Relea e Date: 12.06-07 UNCONTROLLED COPY Page 7 of 33
Revi ion: E Revi ion Date: 06-07-12
Figure 1-1
LOCKING
PINS (2)
TRIGGER
CRIMPING
HEAD
ADAPTER
RECHARGEABLE
(NiCad 9.6V) BATTERY
UNLOCKING
SWITCH
RETRACTOR
SLIDE
SECTION 1
Principal Mechanical Part of the 63816-0200 (110 V) and the 63816-0250 (220 V) Battery Powered Tool. Battery charger
not hown.
Description
The Molex Battery Powered Tool i de igned to crimp terminal with the u e of interchangeable modular crimp head or
power crimp head , and tool kit . Thi tool ha an automatic retractable y tem which return the crimping adapter along
with the crimping die to the tarting po ition when the maximum force i reached. It i equipped with a pecial brake that
will top the forward motion of the crimping die when the trigger i relea ed. The crimping head can be rotated 360° for
better acce in difficult working ituation .
1.1. Features
 Crimp a wide range of product with interchangeable modular crimp head or power crimp head , and tool kit , which
reduce the overall co t and provide production flexibility.
 Modular crimp head or power crimp head and die are ea ily and quickly interchanged to reduce production down time.
 Complete portable y tem that allow tool to be moved and tored ea ily.

Battery Powered Crimping Tool
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Revi ion: E Revi ion Date: 06-07-12
1.2. Technical Specifications
Dimensions (with battery)
Length 292.1mm (11.50”)
Width 76.2mm (3.00“)
Depth 50.8mm (2.00“)
Unpacked Weight 1.50kg (3.31lb )
Production Rate
250 cycle per hour maximum, depending on operator kill and tool kit in talled.
Battery
Voltage 9.6V
Capacity 1.3 Ah
Charging Time Approximately 40 minute , about 15 minute with fa t-charger
Crimp /battery-charge 150 at 10mm2
Operating Parameters
Maximum Force 15kN (1.7 tonne-force)
Cycle Time 2.0 econd
Stroke Length 9.00mm (.354”)
Ambient Temperature -20oC to +40oC
Sound Level 75dB (A) in a di tance of 1.0m
Vibration <2.5m/ 2
1. Delivery Check
Carefully remove the Battery Powered Tool from it hipping container and determine that the following item are included in
the package.
For the 6 816-0200 (110 V):
 63816-0200 Battery Crimping Tool
 63816-0202 Battery Unit (2)
 63816-0210 Battery Charger
 Carrying Ca e
 TM-638160200 Operation Manual
For the 6 816-0250 (220 V):
 63816-0250 Battery Crimping Tool
 63816-0202 Battery Unit (2)
 63816-0260 Battery Charger
 Carrying Ca e
 TM-638160200 Operation Manual

Battery Powered Crimping Tool
Order No: TM-638160200 Relea e Date: 12.06-07 UNCONTROLLED COPY Page 9 of 33
Revi ion: E Revi ion Date: 06-07-12
SECTION 2
Power Crimp Heads and Adapters
2.1 Compari on Chart - Hand and Power Tool
2.2 63816-0600 Power Crimp Adapter for Type 4A Hand Crimp Tool
2.3 63816-0300 Power Crimp Head for Type 2C and 4C Hand Crimp Tool
2.4 63816-0800 Power Crimp Head for Type 4D Hand Crimp Tool
2.5 63816-0900 Adapter for Type AT Air Crimp Tool (with 64005-0000 Head for Type RHT
Hand Crimp Tool )
NOTE: Hand Crimp tool “Type” with a pictorial illustration, is displayed on the upper right corner of the Hand Crimp
Tool Specification Sheet (ATS) and in the following pages of this manual.

Battery Powered Crimping Tool
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Revi ion: E Revi ion Date: 06-07-12
2.1 Comparison Chart - Hand and Power Crimp Tools
SCOPE
Modular crimp head , power crimp head, adapter , and die are ea ily and quickly interchanged between the hand crimp
tool and the battery powered tool . See chart below.
Battery Power Crimp Tool and Adapters for Hand Crimp Tools
Type 4A Type 2C Type 4C Type 4D Type AT
Type RHT
• See Note
6 8160600 6 8160 00 6 8160 00 6 8160800 6 8160900
64005xx00
+ 6 8160900
Adapter Head Head Head Adapter
AT Head
+ Adapter
6 816-0200
Battery Powered Crimp Tool
•
NOTE: Un-tooled AT head are not available eparately. Cu tomer can in tall RHT Tooling into one of their exi ting AT head .
Caution mu t be taken a the marking on the AT head will not match the tooling from an RHT tool for a different terminal.
Comparison
Chart
Battery
Power and
Crimp Hand Tools

Battery Powered Crimping Tool
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Revi ion: E Revi ion Date: 06-07-12
6 816
-
0001
LOCKING PINS (2)
TYPE 4A
MODULAR CRIMP
HEAD WITH TOOLING
6 816
-
0600
ADAPTER
Figure 2-1
2.2 6 816-0600 Power Crimp Adapter for Type 4A Hand Crimp Tools
Scope
The 6 816-0600 Power Crimp Adapter wa created for u e with the Type 4A Modular Crimp Head when u ed with the
Battery Powered Tool (Order No. 63816-0200).
Installation of Type 4A Modular Crimp Heads onto Power Crimp Adapter
To mount the Type 4A Modular Crimp Head to the 63816-0600 Modular Crimp Adapter, lide the locking pin outward until
they top. Then place the crimp head in the upper lot and align the hole with the pin . Then, pu h in the pin until they lock.
See Figure 2-1.
Installation of Type 4A Power Crimp Adapter to Battery Powered Crimping Tool
To in tall the 63816-0600 Power Crimp Adapter onto the 63816-0200 Battery Powered Tool, refer to Section 3, “Set-Up and
Adjustments”.
Operation
1. Load the terminal a de cribed in the Operation ection of the pecification heet for the tool.
2. Cycle the Battery Powered Tool to crimp the terminal to the wire. Hold the trigger until the tool complete the cycle.
3. Remove the crimped terminal from the terminal locator by pre ing down on the wire top and gently pulling on the wire.
The terminal locator can be in either po ition.
4. Vi ually in pect the crimped terminal for proper crimp location.
WARNING: Never place finger into the tooling ne t.
6 816-0600
Power Crimp
Adapter
Application Tooling
For
Type 4A Hand Crimp Tools
TYPE 4A

Battery Powered Crimping Tool
Order No: TM-638160200 Relea e Date: 12.06-07 UNCONTROLLED COPY Page 12 of 33
Revi ion: E Revi ion Date: 06-07-12
Figure 2
-
1
LUBRICATION
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY MONTH
OR
5,000 CRIMPS)
Figure 2
-
2
Maintenance
It i recommended that each operator of the tool be made aware of, and re pon ible for, the following maintenance tep :
1. Thi tool wa engineered for durability, but like any fine piece of equipment, it need cleaning and lubrication for a
maximum ervice life of trouble-free crimping
2. Remove du t, moi ture and other contaminant with a clean bru h, or oft,
lint-free cloth.
3. Do not u e any abra ive material that could damage the tool.
4. Make certain all pin , pivot point and bearing urface in the tool head are
protected with a thin coat of high quality machine oil. Do not oil exce ively.
U e light oil, uch a SAE 30 weight automotive oil, every 5,000 crimp or
monthly, will ignificantly enhance the tool life and en ure a table
calibration. See Figure 2-2 for lubrication point .
5. Store the tool in a clean and dry area when not in u e.
Warranty
Thi tool i for electrical terminal crimping purpo e only. Thi tool i made of
the be t quality material . All vital component are long life-te ted. All tool are
warranted free of manufacturing defect for a period of 0 days. Should uch a
defect occur, we will repair or exchange the tool if it cannot be repaired, free of
charge. Thi repair or exchange will not be applicable to altered, mi u ed, or damaged tool .
Parts List
Item
Order No.
Description
Quantity
1
6381
6
-
0
6
00
Power Crimp Adapter
1

Battery Powered Crimping Tool
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Revi ion: E Revi ion Date: 06-07-12
ANVILS
POWER
CRIMP HEAD
Figure
2
-
4
PUNCHES
M4 X 10 LONG
BHCS
M4 X 18 LONG
BHCS
2. 6 816-0 00 Power Crimp Head for Type 2C and 4C Hand Crimp Tools
SCOPE
The 6 816-0 00 Power Crimp Head wa created for u e with the Type 2C and 4C Crimp Die and Locator Kit when u ed
with the Battery Powered Tool (Order No. 63816-0200).
Installation of Type 2C or 4C Crimp Tool Kit Installation into Power Crimp Head
1. Remove the Crimp Tool Kit from the Type 2C or 4C Hand Crimp Tool. To do thi , ee the in truction heet included with the
hand crimp tool.
2. To in tall the Crimp Tool Kit into the Power Crimp Head, follow the tep below:
1. In ert the Anvil into the bottom lot of the ne t. The wire ize marking face toward the front of the head, oppo ite
from the locator pivot haft. In tall the M4 x 10 long BHCS and tighten in place.
2. In ert the Punche into the top lot of the ne t with wire ize marking to the front. In tall the M4 x 18 long BHCS and
tighten in place. See Figure 2-4.
3. Po ition the locator with the hole over the bra pivot haft and nap it into place. See Figure 2-5.
WARNING: Never place finger into the tooling ne t.
Power Crimp Head Installation onto Battery Powered Crimping Tool
To in tall the 63816-0300 Power Crimp Head onto the 63816-0200 Battery Powered Crimping Tool, refer to Section 3, “Set-
Up and Adjustments”.
6 816-0 00
Power Crimp
Head
Application Tooling Type 2C Type 4C
Hand Crimp Tools

Battery Powered Crimping Tool
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Revi ion: E Revi ion Date: 06-07-12
2
Figure 2
-
7
1
M4 X 8 LONG
BHCS (REF)
Operation
1. Load the terminal a de cribed in the Operation ection of the pecification heet for the tool.
2. Cycle the Battery Powered Tool to crimp the terminal to the wire. Hold the trigger until the tool complete the cycle.
3. Remove the crimped terminal from the terminal locator by pre ing down on the wire top and gently pulling on the wire.
The terminal locator can be in either po ition.
4. Vi ually in pect the crimped terminal for proper crimp location.
Maintenance
It i recommended that each operator of the tool be made aware of, and re pon ible for,
the following maintenance tep :
1. Remove du t, moi ture and other contaminant with a clean bru h, or oft, lint-free
cloth.
2. Do not u e any abra ive material that could damage the tool.
3. Make certain all pin , pivot point and bearing urface in the tool head are
protected with a thin coat of high quality machine oil. Do not oil exce ively. Thi
tool wa engineered for durability, but like any fine piece of equipment, it need
cleaning and lubrication for a maximum ervice life of trouble-free crimping. U e
light oil, uch a SAE 30 weight automotive oil, every 5,000 crimp or monthly, will
ignificantly enhance the tool life and en ure a table calibration. See Figure 2-6 for
lubrication point .
4. Store the tool in a clean and dry area when not in u e.
Warranty
Thi tool i for electrical terminal crimping purpo e only. Thi tool i made of the be t quality material . All vital component
are long life-te ted. All tool are warranted free of manufacturing defect for a period of 0 days. Should uch a defect
occur, we will repair or exchange the tool if it cannot be repaired, free of charge. Thi repair or exchange will not be
applicable to altered, mi u ed, or damaged tool .
Parts List
Item
Order No
Description
Quantity
1
63816
-
0300
Power Crimp Head
1
2
63811
-
4773
Univer al Locator Mount
1
LUBRICATION
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY MONTH
OR
5,000 CRIMPS)
Figure 2-6

Battery Powered Crimping Tool
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Revi ion: E Revi ion Date: 06-07-12
2.4 6 816-0800 Power Crimp Head for Type 4D Hand Crimp Tools
SCOPE
The 6 816-0800 Power Crimp Head wa created for u e with Type 4D Crimp Die and Locator when u ed with the Battery
Powered Tool (Order No. 63816-0200).
Installation for Type 4D Crimp Tooling Installation into Power Crimp Head
Fir t, remove the crimp tooling from the Type 4D Hand Crimp Tool. To do thi , ee the in truction heet included with the
hand crimp tool.
To remove the locator from the Power Crimp Head
1. Open the Power Crimp Head to remove the locator.
2. Squeeze gently on the lower area of the locator a embly, hown in Figure 2-8 with your thumb and index finger. The
lower tab of the locator hould di engage from the Power Crimp Head.
3. Lift and pull away from the Power Crimp Head. The top locator hook hould lip out of the top lot ea ily. See Figure
2-8.
To install the locator in the Power Crimp Head
1. In tall the locator a embly.
2. Pre the red in ert down a far a it will go. See Figure 2-9.
3. The locator goe on the oppo ite ide from the die with the wire gauge marking .
4. While holding onto the lower part of the locator with your thumb and index finger, in ert the
locator top hook (2) into the Power Crimp Head top lot .
5. Rotate the locator down and pre the lower tab into the two bottom lot of the head. To
ecure the locator into place, the lower tab mu t nap into place on the head frame.
Removing the Crimp Dies from the Power Crimp Head
1. Open the Power crimp Head.
2. Remove the two M3 BHCS.
3. Remove the crimp die a hown in Figure 2-10.
4. Make ure all of component removed from the Power Crimp Head are rein talled into the Power Crimp Head in the ame
manner.
6 816-0800
Power Crimp
Head
Application Tooling
Type 4
D
Hand Crimp Tools
TOP SLOT
OF THE
HANDTOOL
TOP HOOKS
TOP SLOT
OF
THE HANDTOOL
LOWER TABS
SQUEEZE
HERE
SQUEEZE
HERE
LOCATOR
Figure
2
-
8
MAKE SUR
E
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
Figure 2
-
9
TYPE 4D

Battery Powered Crimping Tool
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Revi ion: E Revi ion Date: 06-07-12
Figure 2-10
M BHCS
X 8 LONG
E1
E2
I2
I1
POWER CRIMP HEAD
M BHCS
X 14 LONG
Figure 2-11
MATCH UP
MARKINGS
WIRE GAUGE
IDENTIFICATIONS
SHOWING
FRONT
BACK
Installing the Crimp Dies in the Power Crimp Head
1. Select the de ired Type 4D crimping die .
2. In ert the Anvil or die (E1 and I1) into the bottom lot of the ne t. In tall the M3 x 14 long BHCS and lightly tighten in
place.
Note: The tool part number marking on the die go inward o they will not be vi ible when in talled.
3. In ert the Punche or die (E2 and I2) into the top lot of the ne t. In tall the M3 x 8 long BHCS and lightly tighten in
place. See Figure 2-10
4. Make ure the mall marking on the individual die match up and wire gauge identification (AWG) mark hould be facing
out and aligned a hown in Figure 2-11.
5.
Note: Make ure the longer crew only goe into the lower die .
6. Completely clo e the crimp die until they are touching, and then ecurely tighten the M3 BHCS.
Power Crimp Head Installation onto Battery Powered Crimping Tool
To in tall the 63813-0800 Power Crimp Head onto the 63816-0200 Battery Powered
Tool, refer to Section 3, “Set-Up and Adjustments”.
Adjustments
The crimp height on the 63816-0800 Power Crimp Head can be adju ted, if
nece ary. To do thi , fir t mea ure the conductor crimp height of a crimped
terminal and compare to the crimp pecification li ted in the product pecification for
that terminal. If an adju tment i required, follow the procedure, below:
1. Loo en the locking et crew located ju t below the knurled knob at the top of
the Power Crimp Head. See Figure 2-12.
2. If the crimp height i too loo e, rotate the knob, a mall amount, in the counter-
clockwi e direction. Crimp another terminal and re-check the crimp height.
3. If the crimp height i too tight, turn the knob clockwi e and follow the ame procedure.
4. Do thi until the proper crimp height i achieved.
5. When the proper crimp height i achieved, lock the et crew.
LOCKING
SET SCREW
Figure 2
-
12
KN
URLED
KNOB

Battery Powered Crimping Tool
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Revi ion: E Revi ion Date: 06-07-12
2
2
Figure 2
-
11
1
Operation
1. To load a terminal and po ition the wire in the terminal in the Power Crimp
Head, follow the loading procedure a explained in the Hand Crimp Tool
Specification heet.
2. Crimp the terminal by queezing the trigger on the ide of the battery actuator
until the tool cycle and return and the jaw open.
3. Remove the terminal from the locator and in pect the crimp for proper quality.
WARNING: Never place finger into the tooling ne t.
Maintenance
It i recommended that each operator of the tool be made aware of, and
re pon ible for, the following maintenance tep :
Thi tool wa engineered for durability, but like any fine piece of equipment, it
need cleaning and lubrication for a maximum ervice life of trouble-free crimping
Remove du t, moi ture and other contaminant with a clean bru h, or oft, lint-
free cloth.
Do not u e any abra ive material that could damage the tool.
U e light oil, uch a SAE 30 weight automotive oil, every 5,000 crimp , or
monthly, will ignificantly enhance the tool life and en ure a table calibration.
Make certain all liding urface in the tool head are protected with a thin coat of high quality machine oil. See Figure 2-13
for lubrication point . Do not oil exce ively and wipe exce oil from the tool frame when complete.
Store the tool in a clean and dry area when not in u e.
Warranty
Thi tool i for electrical terminal crimping purpo e only. Thi tool i made of the be t quality material . All vital component
are long life-te ted. All tool are warranted free of manufacturing defect for a period of 0 days. Should uch a defect
occur, we will repair or exchange the tool if it cannot be repaired, free of charge. Thi repair or exchange will not be
applicable to altered, mi u ed, or damaged tool .
Parts List
Item
Order No
Description
Quantity
1
63816
-
0800
Power Crimp Head (for tyle 4D crimp tool )
1
2
63816
-
0801
Return Spring
2
LUBRICATION
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY MONTH
OR
5,000 CRIMPS)
Figure 2-1

Battery Powered Crimping Tool
Order No: TM-638160200 Relea e Date: 12.06-07 UNCONTROLLED COPY Page 18 of 33
Revi ion: E Revi ion Date: 06-07-12
2.5 6 816-0900 Power Adapter for Type AT Air Crimp Heads
(With 64005-0000 Head for Type RHT Hand Crimp Tools)
SCOPE
The 6 816-0900 Power Adapter wa created to adapt the 64005 and 64007 erie Type AT Crimp Head for u e in the
63816-0200 Battery Powered Tool.
The addition, cu tomer who have Type RHT hand crimp tool along with a Type AT Crimp Head, can load the RHT die
and locator into the AT crimp head and then in the Battery Powered Tool
Installation
Type AT Air Crimp Head Installation into AT Power Adapter
In tall the AT Air Crimp Head onto the AT Power Adapter a hown in Figure 2-15.
Type RHT Crimp Tool Kit into AT Head and AT Power Adapter (One AT Crimp Head required)
Remove the Crimp Tooling Kit from the Type RHT Hand Crimp Tool. To do thi , ee the in truction heet included with the
hand crimp tool.
1. In tall the RHT tooling kit with locator, into the AT Power Crimp Head. See Figure 2-14.
2. Then in tall the crimp head onto the AT Power Adapter. Thi i a typical Type RHT Crimp Tooling Kit arrangement in AT
Head. See Figure 2-15.
For pecific tooling, ee the pecification heet that i included with the RHT tool.
WARNING: Never place finger into the tooling ne t.
6 816-0900
Power Adapter
Application Tooling
Type RHT
Type AT
Hand Crimp Tools and Air Crimp Heads
AT CRIMP
HEAD
ADAPTER
Figure 2-15
AT CRIMP HEAD
SLOTTED SCREW (2)
Figure 2
-
1
4
AT HEAD
RHT CRIMP
TOOLING KIT

Battery Powered Crimping Tool
Order No: TM-638160200 Relea e Date: 12.06-07 UNCONTROLLED COPY Page 19 of 33
Revi ion: E Revi ion Date: 06-07-12
2
Figure 2
-
17
1
Installation of Power Crimp Head with Power Adapter to the Battery Powered Crimping Tool
To in tall the 63816-0900 Power Adapter onto the 63816-0200 Battery Powered Tool, refer to Section 4, “Set-Up and
Adju tment ”.
Operation
1. To load a terminal and po ition the wire in the terminal in the Power Crimp Head,
follow the loading procedure a explained in the AT Crimp Head (or RHT Hand Crimp
Tool) in truction heet.
2. Crimp the terminal by queezing the trigger on the ide of the battery actuator until
the tool cycle and return and the jaw open.
3. Remove the terminal from the locator and in pect the crimp for proper quality.
Maintenance
It i recommended that each operator of the tool be made aware of, and re pon ible for,
the following maintenance tep :
6. Thi tool wa engineered for durability, but like any fine piece of equipment, it need
cleaning and lubrication for a maximum ervice life of trouble-free crimping
7. Remove du t, moi ture and other contaminant with a clean bru h, or oft, lint-free
cloth.
8. Do not u e any abra ive material that could damage the tool.
9. Make certain all pin , pivot point and bearing urface in the tool head are protected with a thin coat of high quality
machine oil. Do not oil exce ively. U e light oil, uch a SAE 30 weight automotive oil, every 5,000 crimp or
monthly, will ignificantly enhance the tool life and en ure a table calibration. See Figure 2-16 for lubrication point .
10. Store the tool in a clean and dry area when not in u e.
Warranty
Thi tool i for electrical terminal crimping purpo e only. Thi tool i made of the be t quality material . All vital component
are long life-te ted. All tool are warranted free of manufacturing defect for a period of 0 days. Should uch a defect
occur, we will repair or exchange the tool if it cannot be repaired, free of charge. Thi repair or exchange will not be
applicable to altered, mi u ed, or damaged tool .
Parts List
Item
Order No.
Description
Quantity
1
63816
-
0900
Power Crimp Adapter
1
2
19279
-
0161
Slotted Screw
2
LUBRICATION
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY MONTH
OR
5,000 CRIMPS)
Figure 2
-
16

Battery Powered Crimping Tool
Order No: TM-638160200 Relea e Date: 12.06-07 UNCONTROLLED COPY Page 20 of 33
Revi ion: E Revi ion Date: 06-07-12
SECTION
Set-Up and Adjustments
3.1. Set-up
3.2. Operation
3.3. Preventive In truction