molex 63816-1700 Manuale utente
Hydraulic Dieless Crimping Tool
Doc No. TM-638161700 Release Da e: 03-21-14 UNCONTROLLED COPY Page 1 of 29
Revision: D Revision Da e: 05-10-17
Hydraulic Dieless Crimping Tool
With wivel Bench Adapter and Terminal Locator
Operation Manual
Order No. 63816-1700
For Insulated and Non-Insulated Terminal and plices
Descrip ion
Opera ion
Main enance
Hydraulic Dieless Crimping Tool
Doc No. TM-638161700 Release Da e: 03-21-14 UNCONTROLLED COPY Page 2 of 29
Revision: D Revision Da e: 05-10-17
Table of Contents
Contents
Hydraulic Dieless Crimping Tool............................................................................................................................................ 1
afety Warnings and Information ...................................................................................................................................... 3
Sec ion 1 ............................................................................................................................................................................... 6
General Descrip ion .......................................................................................................................................................... 6
Principal Mechanical Par s of he 63816-1700 Dieless Crimping Tool .............................................................................. 7
1.1. Descrip ion ............................................................................................................................................................ 7
1.2. Fea ures ................................................................................................................................................................ 8
1.3. Technical Specifica ion .......................................................................................................................................... 8
1.4. Delivery Check ...................................................................................................................................................... 8
1.5. Tools ...................................................................................................................................................................... 8
Sec ion 2 ............................................................................................................................................................................... 9
Se up and Adjus men s ..................................................................................................................................................... 9
2.1 Se up ................................................................................................................................................................... 10
Air Supply Hook-Up .................................................................................................................................................... 10
Hydraulic Connec ions and Bench Moun ing .............................................................................................................. 10
2.2 Adjus men s ......................................................................................................................................................... 11
2.3 Al erna ive Pump Se ings ................................................................................................................................... 11
Sec ion 3 ............................................................................................................................................................................. 12
Terminal Specifica ions and Crimping Opera ion ............................................................................................................ 12
3.1 Scope .................................................................................................................................................................. 13
3.2 Terminal Char ..................................................................................................................................................... 13
3.3 Crimping Terminals ............................................................................................................................................. 19
3.4 Adjus ing he Pump Release Mechanism ............................................................................................................ 20
Sec ion 4 ............................................................................................................................................................................. 21
4.1 Lubrica ion ........................................................................................................................................................... 22
4.2 Bleeding Air From The Sys em ............................................................................................................................ 22
4.3 Inspec ing The Hydraulic Fluid Level ................................................................................................................... 22
4.4 Draining and Flushing he Reservoir. .................................................................................................................. 22
4.5 Refilling The Bladder ........................................................................................................................................... 22
4.6 Periodic Cleaning ................................................................................................................................................ 23
4.7 Spare Par s ......................................................................................................................................................... 24
4.8 Perishable Par s .................................................................................................................................................. 24
4.9 S orage ................................................................................................................................................................ 24
Sec ion 5 ............................................................................................................................................................................. 25
5.1 Main Par s Lis and Assembly Drawing ............................................................................................................... 26
5.2 Repair Par s ........................................................................................................................................................ 27
5.3 Troubleshoo ing ................................................................................................................................................... 28
Hydraulic Dieless Crimping Tool
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Revision: D Revision Da e: 05-10-17
afety Warnings and Information
Read
and
understand
all of
he ins ruc ions and safe y informa ion in his manual before
opera ing or servicing his ool.
Keep his manual available when using his ool.
Replacemen manuals are available for download a no charge a www.molex.com.
AFETY ALERT YMBOL
This symbol is used o call your a en ion o hazards or unsafe prac ices which could resul in an injury
or proper y damage. The signal word, defined below, indica es he severi y of he hazard. The message
af er he signal word provides informa ion for preven ing or avoiding he hazard.
DANGER
DANGER:
Indica es an imminen ly hazardous si ua ion which, if no avoided, could resul in dea h or serious injury.
WARNING
WARNING:
Indica es a po en ially hazardous si ua ion which, if no avoided, could resul in dea h or serious injury.
CAUTION
CAUTION:
Indica es a po en ially hazardous si ua ion which, if no avoided, may resul in minor or modera e injury.
CAUTION may also be used o aler agains unsafe prac ices associa ed wi h even s ha could lead
o personal injury.
WARNING
WARNING
Always wear proper eye pro ec ion when
Opera ing or servicing his equipmen .
Failure o wear eye pro ec ion could resul
in serious eye injury from flying debris.
Heavy Object
To avoid muscle s rain or back injury, use lif ing
aids and proper lif ing echniques when removing
or replacing.
Failure o observe hese precau ions may resul in
injury or proper y damage.
WARNING
WARNING
Never wear clo hing or jewelery ha is loose or
Tha could po en ially hang in o he equipemen
and ge caugh .
Failure o observe his warning could resul in
Severe Injury or dea h.
Never
ins all or service his machine while
connec ed o any elec rical power source.
Disconnec power by unplugging his ool
from i s power source.
Failure o observe his warning could resul
In severe injury or dea h.
WARNING
WARNING
Never
opera e, service, ins all, or adjus his
machine wi hou proper ins ruc ion and wi hou
firs reading and unders anding he ins ruc ions
in his manual and all applicable ool and/or
wire processing machine.
manuals.
Always wear proper ear pro ec ion
when Opera ing or servicing his applica or.
Failure o observe hese precau ions may resul in
Injury or proper y damage.
Hydraulic Dieless Crimping Tool
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Revision: D Revision Da e: 05-10-17
WARNING
WARNING
Never use his ool wi hou guards or safe y devices
ha are in ended o preven hands from remaining
in he die space.
Failure o observe his warning could resul
In severe injury or dea h.
Do not use
compressed air o clean
his equipmen .
The forces crea ed by compressed
air can force debris in o he ool.
Failure o observe hese precau ions may
resul in injury or proper y damage.
Air
Hydraulic
Pump
WARNING
Pump
WARNING
Hand/Foot Operated
Maximum Capacity: 10,000 P I
Before opera ing he hydraulic pump, all hose
connec ions mus be igh ened wi h proper ools.
Do not over- igh en. Connec ions need only be
igh ened securely and leak-free. Over- igh ening
may cause prema ure hread failure or may cause
high-pressure fi ings o spli a pressures lower
han heir ra ed capaci ies
Should a hydraulic hose ever rup ure, burs , or need
o be disconnec ed, immedia ely shu off he pump
and shif he con rol valve wice o release all pressure.
Never a emp o grasp a leaking hose under pressure
wi h your hands. The force of escaping hydraulic fluid
could cause serious injury.
Do not subjec he hose o po en ial hazard such as fire,
ex reme hea or cold, sharp surfaces, or heavy impac .
Do not allow he hose o kink, wis , curl, or bend so
igh ly ha he oil flow wi hin he hose is blocked or
reduced. Periodically inspec he hose for wear because
any of hese condi ions can damage he hose and
possibly resul in personal injury.
Do not use he hose o move a ached equipmen .
S ress may damage hose and possibly cause personal
injury.
Hose ma erial and coupler seals mus be compa ible
wi h he hydraulic fluid used. Hoses mus no encoun er
corrosive ma erials such as creoso e-impregna ed
objec s and some pain s. Consul he manufac urer
before pain ing a hose.
Never pain he couplers. Hose de eriora ion due o
corrosive ma erials may resul in possible personal injury
Do not exceed he PSI hydraulic ra ing no ed
on he pump namepla e or amper wi h he
in ernal high-pressure relief valve.
Crea ing pressure beyond ra ed capaci ies
may resul in personal injury.
Before replenishing he oil level, re rac he
sys em o preven overfilling he pump reservoir.
An overfill may cause personal injury due
o excess reservoir pressure crea ed when
cylinders are re rac ed.
Cylinder
WARNING
Do not exceed ra ed capaci ies of he cylinders.
Excess pressure may resul in personal injury.
Do not se poorly balanced or off- cen er
loads on a cylinder. The load may ip and
cause personal injury.
Air
upply
WARNING
Shu off and disconnec he air supply when
he pump is no in use or before breaking
any connec ion in he sys em.
Hydraulic Dieless Crimping Tool
Doc No. TM-638161700 Release Da e: 03-21-14 UNCONTROLLED COPY Page 5 of 29
Revision: D Revision Da e: 05-10-17
WARNING
MOLEX CANNOT BE RE PON IBLE FOR DAMAGE OR INJURY RE ULTING FROM UN AFE PRODUCT
U E, LACK OF MAINTENANCE, OR INCORRECT PRODUCT AND Y TEM APPLICATION.
CAUTION
Failure o observe hese precau ions may resul in injury or proper y damage.
CAUTION
Never
perform any service or main enance o her han as described in his manual.
Never modify, al er or misuse he equipmen
Molex crimp specifica ions are valid only when used wi h Molex erminals, applica ors and ooling.
Failure o observe his precau ion may resul in injury and proper y damage.
Tooling Technical Assistance
Molex offers ooling echnical assis ance for cus omers who may need some guidance for ooling adjus men s.
This suppor can be ob ained by calling ei her of he wo numbers lis ed below and asking for he Molex Tooling
Group.
Call Toll Free 1-800-786-6539 (US) 1-630-969-4550 (Global).
This assis ance is limi ed o he opera ion and se -up of a cus omer’s Molex Press Assembly. Ques ions wi h
regard o Molex connec or produc s or how o iden ify he proper ooling and/ or ooling documen a ion should be
direc ed o your local Molex personnel or Cus omer Service Represen a ive.
When calling for service on he ool a copy of he Tooling Manual and Specific Applicator Tooling Specification
Sheet should be presen and a person ha is familiar wi h he applica or should be presen . Be sure he following
informa ion is supplied:
1. Cus omer name
2. Cus omer address
3. Person o con ac such as (name, i le, e-mail, and elephone number
4. Press order number (Lease number also if applicable)
5. Serial number (Lease number also if applicable)
6. Molex Connec or produc order number
7. Urgency of reques
8. Na ure of problem
Application Tooling upport
Phone: +1-402-458-TOOL (8665)
E-Mail: applica ion [email protected]
Website: www.molex.com/applica ion ooling
Molex is a regis ered rademark of Molex, LLC in he Uni ed S a es of America and may be regis ered in o her coun ries; all o her
rademarks lis ed herein belong o heir respec ive owners.
Hydraulic Dieless Crimping Tool
Doc No. TM-638161700 Release Da e: 03-21-14 UNCONTROLLED COPY Page 6 of 29
Revision: D Revision Da e: 05-10-17
ection 1
General Description
1.1. Descrip ion
1.2. Fea ures
1.3. Technical Specifica ions
1.4. Delivery Check
1.5. Tools
Hydraulic Dieless Crimping Tool
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Revision: D Revision Da e: 05-10-17
Figure 1-1
AIR HO E
HYDRAULIC HO E
A EMBLY
FILTER
REGULATOR
GAUGE
HYDRAULIC
CYLINDER
CRIMP HEAD
A EMBLY
FOOT PEDAL
ADJU TABLE
LOCATOR
WIVEL BA E
A EMBLY
AIR / HYD. PUMP
POWER UNIT
Principal Mechanical Parts of the 63816-1700 Dieless Crimping Tool
1.1. Description
( ee Figure 1-1)
The Molex Dieless Crimping Tool is a combina ion Air and Hydraulic crimping sys em which u ilizes four crimp “nibs”
(3 moving and one s a ionary). The hree movable nibs close agains he erminal, which nes s on he four h nib,
crea ing crimp inden a ions from he op, bo om and bo h sides, resul ing in a four sided (quad) crimp.
The opera or adjus s he air pressure hru he air gauge o produce he proper crimp.
This ool is designed o crimp 8 AWG o 500MCM insula ed and uninsula ed erminals and splices.
This ool is also designed o crimp 8 AWG o 500MCM heavy du y compression erminals and connec ors. These
erminals are used for elec rical and indus rial applica ions such as genera ors, swi ch gear, ransformers, mo or
con rols, power dis ribu ion equipmen , welding equipmen , elcommunica ions and u ili ies.
Hydraulic Dieless Crimping Tool
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Revision: D Revision Da e: 05-10-17
1.2. Features
Crimps a wide range of produc s and does no require die se changes, which reduce he overall cos and
provides produc ion flexibili y.
Swivel base and erminal loca or included o provide he opera or wi h a user-friendly ool o increase
produc ivi y.
Comple e ligh weigh sys em ha allows ool o be moved and s ored easily.
1.3. Technical pecification
Pneuma ic:
Supply Pressure: 100 PSI (6.9 Bars)
Air Pressure: 125-PSI max. (8.6 Bars max.)
Cycle Time: 15 seconds
1.4. Delivery Check
Carefully remove he Hydraulic Dieless Crimping Tool from i s shipping con ainer and de ermine ha he
following i ems are included in he package.
Description Quantity
63816-1710 Crimp Head Assembly 1
63916-1711 Hydraulic Hose Assembly 1
63816-1720 Air / Hydraulic Pump
Power Uni wi h hoses 1
19286-0049 Fil er regula or wi h gauge 1
19286-0103 Air Hose Assembly 1
TM-63816-1700 Ins ruc ion Manual 1
1.5. Tools
The following ools are recommended for se up and adjus men s.
Me ric s andard hex wrench se
Adjus able wrench
Wire s ripper / cu er
Hydraulic Dieless Crimping Tool
Doc No. TM-638161700 Release Da e: 03-21-14 UNCONTROLLED COPY Page 9 of 29
Revision: D Revision Da e: 05-10-17
ection 2
etup and Adjustments
2.1. Se up
2.2. Adjus men s
2.3. Al erna ive Pump Se ings
Hydraulic Dieless Crimping Tool
Doc No. TM-638161700 Release Da e: 03-21-14 UNCONTROLLED COPY Page 10 of 29
Revision: D Revision Da e: 05-10-17
2.1 et-Up
Caution: Always disconnect the air pressure until the system is ready to operate.
The principal mechanical par s of he 63816-1700 Dieless Crimping Tool are illus ra ed in Sec ion 5 Assembly
Drawings.
Air upply Hook-Up
1. Selec he 1/4 NPT hreaded fi ings ha are compa ible
wi h your air supply.
2. Nex ins all he fi ings o he fil er, regula or, gauge uni .
The air supply should be 20 CFM (550 L/M) and 100 PSI
(6.9 Bars) o ob ain he ra ed hydraulic ou pu . Air pressure
should be regula ed o a maximum of 125 PSI (8.6 Bars).
See Figure 2-1.
Hydraulic Connections and Bench Mounting
1. Remove he dus cap from he hose where i a aches o
he crimp head.
2. Connec he quick connec coupler on o he cylinder inle
on he crimp head. See figure 2-1.
Figure 2
-
1
AIR UPPLY
CU TOMER
UPPLIED
FILTER, REGULATOR, AND GAUGE
THE LUBRICATOR I OPTIONAL
AIR HO E
DIELE
CRIMPING HEAD
HYDRAULIC
HO E
QUICK
CONNECT
COUPLER
POWER UNIT
WORK BENCH
WIVEL BA E
Figure 2-2
WA HER (4)
HEX NUT (4)
M8 or 5/16
-
18
FLAT HEAD
MACHINE CREW (4)
Indice
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