molex 63816-0270 User manual

Battery Crimping Tool
Doc. No: 638160270 Release Date: 05-14-18 UNCONTROLLED COPY Page 1 of 32
Revision: A Revision Date: 05-14-18
BATTERY CRIMPING TOOL
Operation Manual
Order No. 63816-0270 (110V)
Order No. 63816-0280 (220V)

Battery Crimping Tool
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Revision: A Revision Date: 05-14-18
Table of Contents
1Introduction ........................................................................................................................3
1.1 Product Specification .....................................................................................................3
1.2 Conformity ...................................................................................................................3
1.3 Understanding the Operating Instruction ..........................................................................3
2Safety ................................................................................................................................4
2.1 Warnings and Safety Precautions in this Operating Instruction ............................................4
2.2 Safety Precautions.........................................................................................................4
2.3 Responsibilities .............................................................................................................5
2.4 Designed Use................................................................................................................6
2.5 Predictable Misuse .........................................................................................................6
2.6 Hazardous Areas ...........................................................................................................6
3Shipment............................................................................................................................6
3.1 Packing ........................................................................................................................6
3.2 Packing Contents...........................................................................................................7
4Technical Description ...........................................................................................................8
4.1 Overview Battery Crimping Tool ......................................................................................8
4.2 Tool Identification..........................................................................................................9
4.3 Overview Battery Charger ..............................................................................................9
4.4 Technical Data ..............................................................................................................9
4.5 Operating Elements .......................................................................................................9
4.5.1 Slider for Manual Retraction.......................................................................................9
4.5.2 Tool Head Holding Device ........................................................................................ 10
5Transport ......................................................................................................................... 10
6Installation ....................................................................................................................... 10
6.1 Battery Charging ......................................................................................................... 10
6.2 Battery Charge Level ................................................................................................... 11
7Commissioning.................................................................................................................. 12
7.1 Available Adapters, Tool Heads and Die Sets................................................................... 12
7.2 Mounting a Tool Head or Adapter on the Tool.................................................................. 13
7.3 Turning the LED Light On/Off for Illumination of the Workplace ......................................... 14
7.3.1 Turn On the LED..................................................................................................... 14
7.3.2 Turn Off the LED .................................................................................................... 14
8Normal Operation: Production Cycle..................................................................................... 15
8.1 Overview.................................................................................................................... 16
8.2 63816-0600 Power Crimp Adapter for Type 4A Hand Crimp Tools ...................................... 17
8.3 63816-0300 Power Crimp Head for Type 2C and 4C Hand Crimp Tools ............................... 19
8.4 63816-0800 Power Crimp Head for Type 4D Hand Crimp Tools ......................................... 21
8.5 63816-1600 Power Crimp Head for Type 4E Hand Crimp Tools .......................................... 24
8.6 63816-0900 Power Crimp Head Adapter for Type AT Air Crimp Heads ................................ 27
9Maintenance ..................................................................................................................... 29
9.1 Maintenance Plan ........................................................................................................ 29
9.1.1 Daily ..................................................................................................................... 29
9.1.2 After 10,000 Cycles or Every Two Years .................................................................... 29
10 Problem Handling/Service Light ........................................................................................... 30
11 Removal from Service, Demounting and Disassembly............................................................. 31
12 Storage ............................................................................................................................ 31
13 Disposal ........................................................................................................................... 31
14 Manufacturing ................................................................................................................... 31
15 Parts List .......................................................................................................................... 32

Battery Crimping Tool
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Revision: A Revision Date: 05-14-18
1Introduction
1.1 Product Specification
The battery crimping tool is an electric crimping tool for the Molex interchangeable crimping
system.
The tool is especially developed for industrial applications. Because of the interchangeable tool
heads as well as the crimp die sets of the Molex crimp system, which can easily be adapted, a wide
range of different contacts can be crimped. Adapters, tool heads and die sets can easily be
exchanged without any additional tooling.
The battery crimping tool incorporates an automatic retraction, which returns the ram into its
starting position when the maximum force is reached. Furthermore, the tool is equipped with a
special brake that stops the forward motion of the ram and the dies when the trigger is released.
The low weight, the small and handy design as well as the ergonomic 2-component housing
guaranties a comfortable secure one-handed operation. To simplify operation and gain better
access to tight corners and other difficult working areas, the crimping head may be rotated by hand
360° relative to the body.
All other applications of the battery crimping tool are only permitted with written permission of the
manufacturer. For all unauthorized applications of the battery crimping tool, the manufacturer
cannot be held liable for any resultant damage or injury.
1.2 Conformity
The tool may only be used for the purpose specified in the operating instruction. The
manufacturers and suppliers will not be liable for any damages that may result due to the
tool being used for a purpose other than that for which it was intended. This is done
entirely at the user’s own risk.
RoHS Information
The battery crimping tool complies with the EU-Guideline 2011/65/EU (RoHS2).
CE
The battery crimping tool is CE compliant.
The original declaration of conformity was supplied together with the operating instructions of the
battery crimping tool in the tool case.
1.3 Understanding the Operating Instruction
The operating instruction contains all information concerning operating elements, operation,
commissioning and maintenance work as well as technical data.
The operating instruction must be constantly within reach of the battery crimping tool. Every tool
operator must read and understand the operating instruction to ensure safe and efficient
production with this piece of equipment.
The manufacturer and the distributor decline to accept any liability for damages that are incurred
due to the fact that the instructions on the tool or in the operating instruction have been
disregarded.

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The user is responsible for supplementing the operating instruction with any instructions resulting
from current national regulations for accident prevention and protection of the environment.
2Safety
2.1 Warnings and Safety Precautions in this Operating Instruction
The following warnings and safety-related cautionary notices in the individual chapters alert you to
various levels of danger:
DANGER
Identifies dangerous voltage and live parts, which will lead to serious injuries or even death
when touching it.
DANGER
Identifies an imminent, serious danger, which, if not avoided, will lead to serious injuries or
death.
CAUTION
Identifies a possible danger, which, if not avoided, will lead to serious injuries or death.
ATTENTION
Identifies a potential dangerous situation, which, if not avoided, can lead to medium or minor
injuries or material damages.
INFORMATION
If this information is not followed, it can lead to a deterioration of the operating procedure.
2.2 Safety Precautions
The battery crimping tool has been constructed according to state-of-the-art technology and the
acknowledged technical safety regulations.
When carrying out jobs such as installation, putting the tool into operation or setting it up,
operation, changing the conditions of use and the mode of operation or carrying out maintenance
and service jobs, it is important to observe the procedures for switching off the tool as described in
the operation instruction.
Please observe the national regulations according to the minimum age of the personnel operating
the battery crimping tool. Allowing younger persons access to the tool is strictly prohibited.
Do not operate the battery crimping tool before having read and understood all operating
instructions.
Every tool operator must have read and understood this operating instruction. The safety
instructions, warnings and precautions contained in the individual chapters must be strictly
observed by all users and operators when working on or with the battery crimping tool.
Should the user make any changes to the tool without consulting the manufacturers or the
suppliers, the latter will not be liable for any damage that may result.

Battery Crimping Tool
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Wear suitable safety shoes when transporting the crimping tool.
Due to the risk of hand or finger injury, never try to reach into the battery crimping tool
before having assured that the battery has been removed.
Before commissioning the tool, it is always important to check if a Molex-approved adapter,
tool head or die set is installed and is functioning correctly.
This tool is not to be used on live circuits.
Remove the battery from the battery crimping tool before mounting or exchanging the
adapter, tool head or die set.
The battery crimping tool is only allowed to be operated with properly mounted Molex-
approved adapters, crimp heads and crimp die sets.
The battery crimping tool may only be set up and operated in perfect technical conditions,
observing all the safety regulations and considering any possible dangers.
In case of a die jam, press the slider for automatic retraction.
In cases of tool malfunctions, production must be stopped and the malfunction must be
fixed before continuing work with the battery crimping tool.
Use the battery crimping tool only with specifically designated battery packs.
Recharge only with the charger specified by the manufacturer.
Do not expose the charger to rain or humidity.
Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the charger.
Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled cords
increase the risk of electric shock.
When the battery pack is not in use, keep it away from other metal objects like paper, clips,
coins, keys, nails, screws or other small metal objects that can make a connection from one
terminal to another. Shorting the battery terminals together may cause burns or a fire.
Under abusive conditions, liquid may be ejected from the battery; avoid contact. If contact
accidentally occurs, flush with water. If liquid contacts eyes, additionally seek medical help.
Liquid ejected from the battery may cause irritations or burns.
Work with caution.
Only one person is allowed to work on or with the tool at a time.
Only trained personnel are allowed to work on or with the tool.
When working with the battery crimping tool, do not wear loose clothing, jewelry or long,
loose hair that can get caught in the mechanism.
Use safety gear and always wear eye protection. Safety equipment will reduce personal
injuries.
Strictly observe the exchange and maintenance intervals.
2.3 Responsibilities
The battery crimping tool may only be operated by suitably trained and authorized personnel. The
user must clearly define and observe the responsibilities of the personnel for operation, setup,
maintenance and service.
Should the user make any changes to the tool without consulting the manufacturers or the
suppliers, the latter will not be liable for any damage that may result.
The user of the battery crimping tool is responsible for making sure that all persons involved in any
way, either in the installation or in the maintenance of the tool, have been thoroughly trained on
the system using this operating instruction.

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The user is also responsible for the training of operators, and the instruction must include the
following aspects:
Purpose of the tool
Hazardous areas
Safety rules and regulations
Functionality of the various components of the tool
Proper operation of the tool
To assure full familiarization with the system, the training must be conducted in the native
language of the operators involved.
Staff Qualifications Required in Conjunction with the Use of the Battery
Crimping Tool
Installation
Technical personnel with language proficiency in either English or
German, in addition to the native language of the operator
Setup
Instruction
Operation
Through qualified personnel trained as indicated above
Maintenance
Technical personnel with proficiency in English or German
Service
The safety instructions, warnings and precautions contained in the individual chapters must be
strictly observed by all users and operators.
2.4 Designed Use
Realization of crimp connections up to a cable Ø of 16mm² (wire end ferrules up to 50mm²),
depending on the terminal design.
The battery crimping tool is designed for use with Molex-approved adapters or tool heads. The
adapter or tool head should only be used with the tool heads or dies specified by Molex. Users are
only allowed to use the battery crimping tool together with the adapter, tool head and die set for
the preparation of crimp connections.
2.5 Predictable Misuse
Every application that is not mentioned in Section 2.4, Designed Use
2.6 Hazardous Areas
Hazardous area: Area of interchangeable crimping dies or tool heads
Person at risk: Operator
Type of hazard: Hand injuries
3Shipment
3.1 Packing
Upon receipt, carefully unpack the battery crimping tool and check that you have received all
components against the packing slip, declaration of conformity and operating instructions. It is
recommended that you retain the packing for further dispatch and for storage.

Battery Crimping Tool
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Dimensions
Length: Approximately 410mm (16”)
Width: Approximately 460mm (18”)
Height: Approximately 120mm (5”)
Gross weight: Approximately 5 kg (11 lbs)
3.2 Packing Contents
Quantity
Description
1
Battery crimping tool with battery (without
adapter, tool head and die set)
1
Battery charger
1
Operating instructions
1
Tool case with foam insert
1
Declaration of conformity
Figure 3.1

Battery Crimping Tool
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4Technical Description
4.1 Overview Battery Crimping Tool
Item
Description
1
Holding device for adapter or tool head, 360° rotation
2
Locking pins
3
Trigger
4
LED for illumination of the workplace
5
10.8V Li-Ion battery
6
Unlocking device for the battery
7
Slider for manual retraction in case of an error or emergency
8
Service light
9
Battery charge level button
10
Battery charge level
11
Battery identification plate (on the bottom side of the battery)
12
Product seal with serial number (in the housing of the battery bay)
04
05
06
07
08
09
10
1
3
2
4
5
6
7
8
9
10
11
12
Figure 4.1

Battery Crimping Tool
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4.2 Tool Identification
4.3 Overview Battery Charger
Item
Description
1
Charger connected to power
supply and carries voltage
2
Charger defect
3
Charging
4
Battery fully charged
5
Battery defect
6
Battery too hot or too cold
4.4 Technical Data
4.5 Operating Elements
4.5.1 Slider for Manual Retraction
If the jaws become jammed because of operation or
handling errors or wrongly placed contacts, the battery
crimping tool can be opened as follows:
1. Push the retraction slide (1) in the direction of the
battery.
2. The tool jaws will open.
3. Remove and discard the damaged contact.
Item
Description
1
Serial Number
2
Seal
3
Address
Dimension
Specification
Length
90mm (3.5”)
Width
64mm (2.5”)
Height
270mm (10.6”)
Weight Including Battery
Approximately 1.3 kg (2.9 lb)
Crimp Speed
Approximately 2s (depending on the terminal cross section)
Crimp Force
13 kN (1.5t) Max
Stroke
Approximately 12mm
Noise Level
70 dB (A) in 1m distance
Vibrations
< 2.5 m/s²
Environmental Temperature
-10-40°C
Battery Capacity
1.5 Ah, Li-Ion
Battery Charging Time
40 minutes
Battery Voltage
10.8V
1
Figure 4.4
1
2
3
Figure 4.2
3
4
5
6
1
2
Figure 4.3

Battery Crimping Tool
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4.5.2 Tool Head Holding Device
The tool head holding device may be rotated by hand
360° relative to the body, offering the operator the
possibility to adjust the tool head to a suitable working
position.
5Transport
The weight of the battery crimping tool is approximately 1.3 kg (2.9 lbs).
ATTENTION
Wear suitable safety shoes when transporting the machine.
Store and transport the battery crimping tool in the carrying case to protect it against damage.
6Installation
6.1 Battery Charging
Before using the battery crimping tool for the first time, the batteries have to be charged.
DANGER
Recharge only with the charger specified by the manufacturer.
Do not expose the charger to rain or humidity.
Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the charger. Keep
the cord away from heat, oil, sharp edges or moving parts. Damaged or entangled cords
increase the risk of electric shock.
DANGER
Use the battery crimping tool only with specifically designated battery packs.
When the battery pack is not in use, keep it away from other metal objects like paper clips,
coins, keys, nails, screws or other small metal objects that can make a connection from one
terminal to another. Shorting the battery terminals together may cause burns or a fire.
Under abusive conditions, liquid may be ejected from the battery; avoid contact. If contact
accidentally occurs, flush with water. If liquid contacts eyes, seek medical help. Liquid ejected
from the battery may cause irritations or burns.
Due to the risk of hand or finger injury, never try to reach into the battery crimping tool before
having assured that the battery has been removed.
CAUTION
Do not operate the battery crimping tool before having read and understood all operating
instructions.
Every tool operator must have read and understood this operating instruction. The safety
instructions, warnings and precautions contained in the individual chapters must be strictly
observed by all users and operators when working on or with the battery crimping tool.
Figure 4.5
1

Battery Crimping Tool
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The battery crimping tool may only be set up and operated in perfect technical conditions,
observing all safety regulations and considering any possible dangers.
Before commissioning the tool, it is always important to check whether a Molex-approved
adapter, tool head or die set is installed and is functioning correctly.
The crimp tool is only allowed to be used with a mounted, Molex-approved adapter with tool
head or tool head with die set.
When working with the battery crimping tool, do not wear loose clothing, jewelry or long, loose
hair that can get caught in the mechanism.
Work with caution.
In cases of a tool malfunction, production must be stopped, and the malfunction must be fixed
before continuing work with the battery crimping tool.
Only one person is allowed to work on or with the battery crimping tool at a time.
Only trained personnel are allowed to work on or with the battery crimping tool.
Instructions
1. Remove the battery from the battery crimping tool by
pressing the battery unlocking device.
2. Connect the charger to the power supply.
3. Insert the battery into the charger. The battery
charging time is approximately 40 minutes.
4. When the battery is fully charged, remove it and
reinsert it into the battery crimping tool.
The battery crimping tool is now ready for use.
INFORMATION
Please pay attention that the battery has been removed from the charger if it is not connected
to the power supply. Otherwise, the battery will be completely discharged.
6.2 Battery Charge Level
Press button 1 to check the charge level of the battery. See
Figure 6.2:
100 %
75 %
50 %
25 %
0%
Figure 6.1
Figure 6.2
1

Battery Crimping Tool
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7Commissioning
7.1 Available Adapters, Tool Heads and Die Sets
The following charts show all applications for the battery powered tool. See Figures 7.1 and 7.2:
Figure 7.1 Modular Crimp Head
Figure 7.2 Power Crimp Head
Note: The above modular crimp heads and battery powered crimp adapters are sold separately and are
not included with the 63816-0270 (110V) or 63816-0280 (220V) battery crimping tool.
TYPE 4A
LOCKING
PINS (2)
BATTERY
POWERED TOOL
TYPE 4A
MODULAR
CRIMP HEAD
WITH TOOLING
63816-0600
ADAPTER
LOCKING
PINS (2)
TYPE AT
SLOTTED
SCREWS (2)
BATTERY
POWERED TOOL
TYPE AT
MODULAR
CRIMP HEAD
WITH TOOLING
63816-0900
ADAPTER
LOCKING
PINS (2)
TYPE 2C or TYPE 4C
BATTERY
POWERED
TOOL
TYPE 2C
OR TYPE 4C
POWER CRIMP
HEAD
LOCKING
PINS (2)
TYPE 4D
BATTERY
POWERED
TOOL
TYPE 4D
POWER CRIMP
HEAD
(NO TOOLING
SHOWN)
LOCKING
PINS (2)
LOCKING
PINS (2)
TYPE 4E
POWER CRIMP
HEAD
TYPE 4E
BATTERY
POWERED
TOOL

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7.2 Mounting a Tool Head or Adapter on the Tool
DANGER
Due to the risk of hand or finger injury, never try to reach into the battery crimping tool before
having assured that the battery has been removed.
Remove the battery from the battery crimping tool before mounting or exchanging the adapter,
tool head or die set.
CAUTION
Every tool operator must have read and understood this operating instruction. The safety
instructions, warnings and precautions contained in the individual chapters must be strictly
observed by all users and operators when working on or with the battery crimping tool.
The battery crimping tool may only be set up and operated in perfect technical conditions,
observing all the safety regulations and considering any possible dangers.
Before commissioning the tool, it is always important to check if a Molex-approved adapter, tool
head or die set is installed and is functioning correctly.
The crimp tool is only allowed to be used with the mounted adapter with tool head or tool head
with die set.
When working with the battery crimping tool, do not wear loose clothing, jewelery or long,
loose hair that can get caught in the mechanism.
Work with caution.
In cases of a tool malfunction, production must be stopped, and the malfunction must be fixed
before continuing work with the battery crimping tool.
Only one person is allowed to work on or with the battery crimping tool.
Only trained personnel are allowed to work on or with the battery crimping tool.
Before mounting the tool head or adapter, please pay
attention that the ram of the tool is in the lowest position. If
the ram is in another position, press the trigger until the ram
automatically returns to the lowest position.
Pull out the pins (1) of the holding device.
Install the adapter on the tool from above.
Or
Install the tool head from behind and pay attention that the
ram of the tool head engages correctly into the notch of the
tool ram.
INFORMATION
The tool heads of the 2C or 4C frames supplied as of March 2016 have been optimized
according to the latest guidelines. Due to the spring-guided closing mechanism, the tool heads
are always closed.
1
Figure 7.3
Mounting of Adapter

Battery Crimping Tool
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After having mounted the
adapter or tool head, lock the
pins (1)of the holding
device.
7.3 Turning the LED Light On/Off for Illumination of the Workplace
7.3.1 Turn On the LED
Remove the battery from the battery crimping tool.
Reinsert the battery without pressing the trigger (1).
The LED (2) lights up during and after the crimping process.
7.3.2 Turn Off the LED
Remove the battery from the battery crimping tool.
Press the trigger (1), and keep it pressed while inserting the
battery.
Keep the trigger pressed for some seconds.
The LED (2) is turned off.
1
Figure 7.4
Mounting of Tool Head
1
Figure 7.5
2
1
Figure 7.6

Battery Crimping Tool
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8Normal Operation: Production Cycle
DANGER
Due to the risk of hand or finger injury, never try to reach into the battery crimping tool before
having assured that the battery has been removed.
Remove the battery from the battery crimping tool before mounting or exchanging the adapter,
tool head or die set.
CAUTION
Do not operate the battery crimping tool before having read and understood all operating
instructions.
Every tool operator must have read and understood this operating instruction. The safety
instructions, warnings and precautions contained in the individual chapters must be strictly
observed by all users and operators when working on or with the battery crimping tool.
The battery crimping tool may only be set up and operated in perfect technical conditions,
observing all the safety regulations and considering any possible dangers.
Before commissioning the tool, it is always important to check if a Molex-approved adapter, tool
head or die set is installed and functioning correctly.
The crimp tool is only allowed to be used with mounted adapter with tool head or tool head with
die set.
When working with the battery crimping tool, do not wear loose clothing, jewelery or long,
loose hair that can get caught in the mechanism.
Work with caution.
In cases of a tool malfunction, production must be stopped, and the malfunction must be fixed
before continuing work with the battery crimping tool.
Only one person is allowed to work on or with the battery crimping tool at a time.
Only trained personnel are allowed to work on or with the battery crimping tool.
INFORMATION
If you release the trigger, the crimping process will be interrupted. If you press the trigger
again, the crimping process will continue until its completion.

Battery Crimping Tool
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8.1 Overview
Modular crimp heads, power crimp heads, adapters and dies are easily and quickly interchanged
between the hand crimp tools and the battery powered tools. Refer to the following compatibility
chart:
Battery Powered Crimp Tool and Adapters for Hand Crimp Tools
Type 4A
Type 2C
Type 4C
Type 4D
Type 4E
Type AT
Type RHT
See Note
63816-0600
63816-0300
63816-0300
63816-0800
63816-1600
63816-0900
64005-xx00
+ 63816-0900
Adapter
Head
Head
Head
Head
Adapter
AT Head
+ Adapter
63816-0200
Battery Powered Crimp Tool
NOTE: Untooled AT heads are not available separately. Customers can install RHT tooling into one of their existing AT
heads.
Caution must be taken as the markings on the AT head will not match the tooling from an RHT tool for a different terminal.

Battery Crimping Tool
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63816-0001
LOCKING PINS (2)
TYPE 4A
MODULAR CRIMP
HEAD WITH TOOLING
63816-0600
ADAPTER
Figure 8.1
Application Tooling
8.2 63816-0600 Power Crimp Adapter for Type 4A Hand Crimp Tools
Scope
The 63816-0600 power crimp adapter was created for use with the Type 4A modular crimp heads
when used with the battery powered tool (Order No. 63816-0270 or 63816-0280).
Installation of Type 4A Modular Crimp Heads onto the Power Crimp Adapter
To mount the Type 4A modular crimp heads to the 63816-0600 modular crimp adapter, slide the
locking pins outward until they stop. Then, place the crimp head in the upper slot and align the holes
with the pins. Push the pins inward until they lock. See Figure 8.1.
Installation of Type 4A Power Crimp Adapter to Battery Powered Crimping Tool
To install the 63816-0600 power crimp adapter onto the battery powered tool, refer to Section 7.2.
Operation
1. Load the terminal as described in the Operation section of the Application Tooling Specification
(ATS) sheet for the tool.
2. Cycle the battery powered tool to crimp the terminal to the wire. Hold the trigger until the tool
completes the cycle.
3. Remove the crimped terminal from the terminal locator by pressing down on the wire stop and
gently pulling on the wire. The terminal locator can be in either position.
4. Visually inspect the crimped terminal for proper crimp location.
WARNING: Never place fingers into the tooling nest.
63816-0600
Power Crimp Adapter
Type 4A
WIRE

Battery Crimping Tool
Doc. No: 638160270 Release Date: 05-14-18 UNCONTROLLED COPY Page 18 of 32
Revision: A Revision Date: 05-14-18
Figure 8.3
1
Maintenance
It is recommended that each operator of the tool be made aware of and responsible for the following
maintenance steps:
1. This tool was engineered for durability, but like any fine
piece of equipment, it needs cleaning and lubrication for a
maximum service life of trouble-free crimping.
2. Remove dust, moisture and other contaminants with a
clean brush or a soft, lint-free cloth.
3. Do not use any abrasive materials that could damage the
tool.
4. Make certain all pins, pivot points and bearing surfaces in
the tool head are protected with a thin coat of high-quality
machine oil. Do not oil excessively. Using a light oil such as
SAE 30 weight automotive oil every 5,000 crimps or
monthly will significantly enhance the tool life and ensure a
stable calibration. See Figure 8.2 for lubrication points.
5. Store the tool in a clean and dry area when not in use.
Warranty
This tool is for electrical terminal crimping purposes only. This tool is made of the best quality
materials. All vital components are long-life tested. All tools are warranted to be free of manufacturing
defects for a period of 30 days. Should such a defect occur, Molex 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.
Parts List
Item
Order No.
Description
Quantity
1
63816-0600
Power Crimp Adapter
1
LUBRICATION
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY MONTH
OR
5,000 CRIMPS)
Figure 8.2

Battery Crimping Tool
Doc. No: 638160270 Release Date: 05-14-18 UNCONTROLLED COPY Page 19 of 32
Revision: A Revision Date: 05-14-18
ANVILS
POWER
CRIMP HEAD
Figure 8.4
PUNCHES
M4 X 10 LONG
BHCS
M4 X 18 LONG
BHCS
Application Tooling
8.3 63816-0300 Power Crimp Head for Type 2C and 4C Hand Crimp Tools
Scope
The 63816-0300 power crimp head was created for use with the Type 2C and 4C crimp dies and
locator kits when used with the battery powered tool (Order No. 63816-0270 or 63816-0280).
Installation of Type 2C or 4C Crimp Tool Kit into the Power Crimp Head
Remove the crimp tool kit from the Type 2C or 4C hand crimp tool. To do this, see the instruction
sheet included with the hand crimp tool.
To install the crimp tool kit into the power crimp head, follow the steps below:
1. Insert the anvils into the bottom slots of the nest. The wire size markings face toward the front
of the head, opposite from the locator pivot shaft. Install the M4 x 10 long BHCS, and tighten in
place.
2. Insert the punches into the top slots of the nest with wire size markings to the front. Install the
M4 x 18 long BHCS, and tighten in place. See Figure 8.4.
3. Position the locator with the hole over the brass pivot shaft and snap it into place.
WARNING: Never place fingers into the tooling nest.
Power Crimp Head Installation onto Battery Powered Crimping Tool
To install the 63816-0300 power crimp adapter onto the battery powered tool, refer to Section 7.2.
Operation
1. Load the terminal as described in the Operation section of the Application Tooling Specification
(ATS) sheet for the tool.
63816-0300
Power Crimp Head
Type 2C
Type 4C
WIRE

Battery Crimping Tool
Doc. No: 638160270 Release Date: 05-14-18 UNCONTROLLED COPY Page 20 of 32
Revision: A Revision Date: 05-14-18
2
Figure 8.6
1
M4 X 8 LONG
BHCS (REF)
2. Cycle the battery powered tool to crimp the terminal to the wire. Hold the trigger until the tool
completes the cycle.
3. Remove the crimped terminal from the terminal locator by pressing down on the wire stop and
gently pulling on the wire. The terminal locator can be in either position.
4. Visually inspect the crimped terminal for proper crimp location.
Maintenance
It is recommended that each operator of the tool be made aware of
and responsible for the following maintenance steps:
1. This tool was engineered for durability, but like any fine piece
of equipment, it needs cleaning and lubrication for a maximum
service life of trouble-free crimping.
2. Remove dust, moisture and other contaminants with a clean
brush or a soft, lint-free cloth.
3. Do not use any abrasive materials that could damage the tool.
4. Make certain all pins, pivot points and bearing surfaces in the
tool head are protected with a thin coat of high-quality
machine oil. Do not oil excessively. Using a light oil such as
SAE 30 weight automotive oil every 5,000 crimps or monthly
will significantly enhance the tool life and ensure a stable
calibration. See Figure 8.5 for lubrication points.
5. Store the tool in a clean and dry area when not in use.
Warranty
This tool is for electrical terminal crimping purposes only. This tool is made of the best quality
materials. All vital components are long-life tested. All tools are warranted to be free of manufacturing
defects for a period of 30 days. Should such a defect occur, Molex 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.
Parts List
Item
Order No.
Description
Quantity
1
63816-0300
Power Crimp Head
1
2
63811-4773
Universal Locator Mount
1
WIRE
LUBRICATION
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY MONTH
OR
5,000 CRIMPS)
Figure 8.5