Air Powered Tool AIR POWERED TOOL Operating and Maintenance Instructions Order No: 63816-0100 Optional Bench Adapter with Foot Switch Order No: 63816-0500 Description Operation Maintenance Order No: TM-638160100 Revision: B Release Date: 02-20-08 Revision Date: 05-28-10 UNCONTROLLED COPY Page 1 of 17 Air Powered Tool Table of Contents 1. Safety Warnings and Information 2. General Description 3. Set-Up and Adjustments 4. Preventive Maintenance 5. Parts List, Assembly Drawings and Troubleshooting Order No: TM-638160100 Revision: B Release Date: 02-20-08 Revision Date: 05-28-10 UNCONTROLLED COPY Page 2 of 17 Air Powered Tool Section 1 Safety Warnings and Information Read and understand all of the instructions and safety information in this manual before operating or servicing this tool. Keep this manual available when using this tool. Replacement manuals are available upon request at no charge at www.molex.com. SAFETY ALERT SYMBOL This symbol is used to call your attention to hazards or unsafe practices which could result in an injury or property damage. The signal word, defined below, indicates the severity of the hazard. The message after the signal word provides information for preventing or avoiding the hazard. DANGER WARNING CAUTION DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING: Indicates a potentially hazardous situation which, if not avoided, will result in death or serious injury. CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. CAUTION may also be used to alert against unsafe practices associated with events that could lead to personal injury. WARNING WARNING Wear eye protection when operating or servicing this tool. Pinch points: Keep hands away from the crimping head when crimping. Failure to wear eye protection could result in serious eye injury from flying debris. WARNING Failure to observe this warning could result In severe injury or death. WARNING Wear appropriate ear protection when Inspect tool and dies before use. Replace any worn or damaged parts. operating this tool. A damaged or improperly assembled tool can break and strike someone nearby. Failure to wear ear protection could result in loss of hearing over a period Failure to observe this warning could result in severe injury or death. of time. Order No: TM-638160100 Revision: B Release Date: 02-20-08 Revision Date: 05-28-10 UNCONTROLLED COPY Page 3 of 17 Air Powered Tool 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 SAFELY AT ALL TIMES For Service, Contact Your Local Molex Sales Office Molex Application Tooling Group 2200 Wellington Court Lisle, Illinois 60532 USA Tel: 1-630-969-4550 Fax: 1-630-505-0049 Order No: TM-638160100 Revision: B Release Date: 02-20-08 Revision Date: 05-28-10 UNCONTROLLED COPY Page 4 of 17 Air Powered Tool Section 2 General Description 2.1 Description 2.2 Features 2.3 Technical Specifications 2.4 Delivery Check 2.5 Tools Order No: TM-638160100 Revision: B Release Date: 02-20-08 Revision Date: 05-28-10 UNCONTROLLED COPY Page 5 of 17 Air Powered Tool 2 General Description Principal Mechanical Parts AIR HOSE TRIGGER MAIN UNIT FOOT SWITCH (Optional) AIR POWERED CRIMP ADAPTER BENCH MOUNT CLAMP (Optional) SWIVEL LOCK Figure 2-1 2.1 Description The Molex Air Powered Tool is designed to crimp a variety of insulated and uninsulated terminals and splices. This tool has an automatic retractable system which returns the crimping adapter along with the crimping dies to the starting position when the maximum force is reached. It is equipped with a special brake that will stop the forward motion of the crimping dies when the trigger is released. The crimping head can be rotated 360° for better access in difficult working situations. This unit requires a power unit and a modular crimp tool head. 2.2 Features Light weight tool for high quantities of terminations. Crimps a wide range of products with interchangeable tool heads and tool kits, which reduce the overall cost and provide production flexibility. Modular crimp heads are easily and quickly interchanged to reduce production down time. Operated by hand or foot, stationary unit available. Modular crimp heads can be rotated to at any angle to accommodate the operator. Order No: TM-638160100 Revision: B Release Date: 02-20-08 Revision Date: 05-28-10 UNCONTROLLED COPY Page 6 of 17 Air Powered Tool 2.3 Technical Specifications Dimensions (with tool head adaptor) Length 342.9mm (13.50”) Diameter 65.0mm (2.56“) Weight 1.3kg (2.98lbs) Production Rate 600 cycles per hour maximum, depending on operator skill and tool kit installed. Operating Parameters Cycle Time Air Consumption per Cycle Required pressure of filtered air suppy 1.0 seconds .721 L (.025 cubic feet) 6 to 6.5 bar (87 to 94 psi) 8 bar maximum (116 psi) 2.4 Delivery Check Carefully remove the Pneumatic Crimping Tool from its shipping container and determine that the following items are included in the package. 63816-0100 TM-638160100 Pneumatic Crimping Unit with tooling adaptor Operation Manual 2.5 Tools The following tools are recommended for setup and adjustments to this tool. 1. 2. 3. 4. Metric standard hex wrench set Adjustable wrench Wire stripper / cutter Screwdriver Order No: TM-638160100 Revision: B Release Date: 02-20-08 Revision Date: 05-28-10 UNCONTROLLED COPY Page 7 of 17 Air Powered Tool Section 3 Set-Up and Adjustments 3.1. Set-up 3.2. Installing or Changing Modular Crimp Heads 3.3. Operation 3.4. Terminal Crimping Order No: TM-638160100 Revision: B Release Date: 02-20-08 Revision Date: 05-28-10 UNCONTROLLED COPY Page 8 of 17 Air Powered Tool 3.1 Set-Up 1. Read the following instructions before attempting to operate this tool. 2. Connect an 8mm or 5/16” air hose to the fitting attached to the rear of the tool and to air supply 6 to 6.5 bar (87 to 94 psi). Do not exceed 8 bar (116 psi). May cause injury or damage to the tool. Air supply must be equipped with an air filter regulator (not supplied by Molex). (Available from any industrial supply co.). See Figure 3-1. TRIGGER SAFETY TO AIR SUPPLY TRIGGER AIR HOSE MODULE CRIMP HEAD (REF) FILTER REGULATOR LUBRICATOR (NOT SUPPLIED) Figure 3-1 If changing to the Optional bench adapter, remove the air hose and connect the tubing from the footswitch. See Figure 3-2. SECURE AIR CRIMPING TOOL IN POSITION CONNECT TUBING FROM FOOT SWITCH WITH FITTING TO AIR SUPPLY MODULE CRIMP HEAD (Reference) (NOT SUPPLIED) BENCH ADAPTER (OPTIONAL) FOOT SWITCH (OPTIONAL) FILTER REGULATOR LUBRICATOR (NOT SUPPLIED) Figure 3-2 Order No: TM-638160100 Revision: B Release Date: 02-20-08 Revision Date: 05-28-10 UNCONTROLLED COPY Page 9 of 17 Air Powered Tool 3. Next lock the trigger on the actuator by flipping the safety switch. Push the safety switch all the way down on the end of the trigger to lock. See Figure 3-3. SAFETY (UNLOCKED) SAFETY (LOCKED) TRIGGER Figure 3-3 Note: Always use the safety or disconnect air supply when changing crimping heads. 4. For the proper crimping head see the tool part number on the label of the terminal/connector container. 5. Strip proper wire to minimum length located on label of terminal/connector container or on the air powered crimp tool head specification sheet. 3.2 Installing or Changing Modular Crimp Heads Before starting any work on any electrical applications: 1. Make sure there are no live cables or parts in the immediate area of the user. 2. Make sure the safety is in the locked position before changing heads. WARNING Remove the power source from the crimping tool before installing and removing the modular crimp head. Installing or Changing heads procedure: 1. 2. 3. 4. Remove the locking pins (2) from the air powered crimp adapter on the air powered tool. Pull the modular crimp head out of the adapter head. To replace the modular crimp head, select the correct modular crimp head for the application needed. While holding the air powered tool in one hand, grasp the modular crimp head with the other hand and slide it into the air powered crimp adapter until the holes in the side plates of the crimp head line up with the holes in the adapter. 5. Replace the locking pins (2) making sure that the modular crimp head is secure. The locking pins can be inserted from either side of the adapter. See Figure 3-4. Order No: TM-638160100 Revision: B Release Date: 02-20-08 Revision Date: 05-28-10 UNCONTROLLED COPY Page 10 of 17 Air Powered Tool AIR POWERED CRIMP ADAPTER MODULAR CRIMP HEAD (NOT INCLUDED) LOCKING PINS (2) Figure 3-4 3.3 Operation: To actuate the crimping tool, first lift the safety lock lever on the trigger. See Figure 3-3. The tool can now be actuated by depressing the trigger and holding until the ram is fully extended. After the ram has been extended fully, release the trigger and the ram will return. If using the optional bench mount, lift the safety lock lever as described above. The tool is now actuated by depressing the footswitch. 3.4 Terminal Crimping Specifications and Instructions for crimping are included with the individual Modular Crimp Heads. Order No: TM-638160100 Revision: B Release Date: 02-20-08 Revision Date: 05-28-10 UNCONTROLLED COPY Page 11 of 17 Air Powered Tool Section 4 Preventive Maintenance 4.1 Periodic Cleaning 4.2 Storage 4.3 Warranty 4.4 Maintenance Order No: TM-638160100 Revision: B Release Date: 02-20-08 Revision Date: 05-28-10 UNCONTROLLED COPY Page 12 of 17 Air Powered Tool 4.1 Periodic Cleaning Always clean tool after use and keep moving parts clear of dirt and debris. This tool is maintenance free, only the sliding ram in the crimping head has to be oiled regularly. Before use: 1. Inspect dies for wear or damage such as cracks, gouges, or chips. 2. Inspect the tool for damage or leaks. If damage is detected, contact Molex to have the tool evaluated. After use: 1. Wipe all tool surfaces clean with a damp cloth and mild detergent. Excessive dirt and grit can contribute to the premature wear of the tool’s internal mechanical parts. If this tool becomes dirty with excessive debris it may jam and become damaged during operation. 2. Fully retract the ram. Store in a cool, dry place. WARNING Do not use solvents or flammable liquids to clean the crimping tool. Solvents or flammable liquids could ignite and cause serious injury or property damage. Monthly: 1. Thoroughly clean all surfaces. Annually or After 10,000 Crimps 1. Return the tool to a Molex representative for inspection. A routine should be established to keep the tool as free from dirt as possible. Order No: TM-638160100 Revision: B Release Date: 02-20-08 Revision Date: 05-28-10 UNCONTROLLED COPY Page 13 of 17 Air Powered Tool An example of a maintenance chart is shown below. Copy and use this chart to track the maintenance of this crimping tool or use this as a template to create your own schedule or use your company’s standard chart, if applicable. Preventive Maintenance Chart CHECK SHEET MONTH Week YEAR _________ Daily Use Days of the Week MON TUE WED THU FRI SAT Solution SUN 1 2 3 4 Cleaning Lubrication Daily Sliding ram into crimping head After use Use SAE No. 10 Oil Schedule should be adjusted up or down depending on usage. Molex recommends that a log of preventive maintenance be kept with the tool. 4.2 Storage In order to protect the tool against damages, this tool should be cleaned carefully and stored in a clean and dry location. 4.3 Warranty All tools are warranted free of manufacturing defects for a period of 30 days. Should such a defect occur, we will repair or exchange the tool free of charge. This repair or exchange will not be applicable to altered, misused, or damaged tools. This tool is designed for hand use only. After one year Molex recommends the crimping tool be returned to Molex for inspection. Only the heads of the crimping tool are permitted to be changed by the operator. If seals are damaged the warranty is void. CAUTION: Molex crimp specifications are valid only when used with Molex terminals and tooling. 4.4 Maintenance Crimping nest should be kept free of oil and all foreign particles. Crimp tool head assemblies should be lubricated monthly by placing a few drops of light machine oil on the sliding ram of the crimping tool. Check the lubricator in the air supply and fill with SAE 10W oil as needed. Check the air filter. To clean, remove the bowl and the filter element and clean with denatured alcohol. Order No: TM-638160100 Revision: B Release Date: 02-20-08 Revision Date: 05-28-10 UNCONTROLLED COPY Page 14 of 17 Air Powered Tool Section 5 Parts List, Assembly Drawing and Troubleshooting 5.1. Parts List and Assembly Drawings 5.2. Troubleshooting Order No: TM-638160100 Revision: B Release Date: 02-20-08 Revision Date: 05-28-10 UNCONTROLLED COPY Page 15 of 17 Air Powered Tool 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 (Included) 3 63816-0500 Optional Bench Adapter with Foot Switch (Sold Separately) 3 1 MODULE CRIMP TOOL (Reference) 3 2 3 Figure 5-1 Order No: TM-638160100 Revision: B Release Date: 02-20-08 Revision Date: 05-28-10 UNCONTROLLED COPY Page 16 of 17 Air Powered Tool 5.2 Troubleshooting Symptom Hand Actuated Unit Power unit piston will not extend when actuated. Foot Actuated Unit Cause Power unit not connected to main air supply. Connect power unit to main air supply. Faulty hand switch assembly. Replace switch assembly. Air line connections to power unit reversed. Disconnect main air supply, then reverse the air line connections on crimping unit. Power unit piston will not Faulty foot switch. extend when actuated. Improper lubrication. Loss of power. Internal seals of crimping unit worn or damaged. Americas Headquarters Lisle, Illinois 60532 U.S.A. 1-800-78MOLEX [email protected] Solution Far East North Headquarters Yamato, Kanagawa, Japan 81-462-65-2324 [email protected] Replace switch assembly. Check for lubrication in the main air supply. Replace the seals or contact a Molex Sales Engineer. Far East South Headquarters Jurong, Singapore 65-6-268-6868 [email protected] European Headquarters Munich, Germany 49-89-413092-0 [email protected] Corporate Headquarters 2222 Wellington Ct. Lisle, IL 60532 U.S.A. 630-969-4550 Fax: 630-969-1352 Visit our Web site at http://www.molex.com Order No: TM-638160100 Revision: B Release Date: 02-20-08 Revision Date: 05-28-10 UNCONTROLLED COPY Page 17 of 17