Molex CS 150 User manual

CS 150 Battery Crimping Tool

Doc No: ATS-638160200 Release Date:12-06-07 UNCONTROLLED COPY Page 1 of21

Revision: A Revision Date:12-06-07

BATTERY POWERED CRIMPING TOOL

Instruction Manual

Order No. 63816-0200



Description



Operation



Maintenance

CS 150 Battery Crimping Tool

Doc No: ATS-638160200 Release Date:12-06-07 UNCONTROLLED COPY Page 2 of21

Revision: A Revision Date:12-06-07

Table of Contents

SECTION

1 Safety Warnings and Information

2 General Description

3 Setup and Adjustments

4 Crimping Dies Go-No go

5 Preventive Maintenance

6 Troubleshooting

CS 150 Battery Crimping Tool

Doc No: ATS-638160200 Release Date:12-06-07 UNCONTROLLED COPY Page 3 of21

Revision: A Revision Date:12-06-07

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 requestat 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 signalword provides information for preventing or avoiding the hazard.

DANGER

DANGER:

Indicates an imminently hazardous situation which, if not avoided, will result in

Death or serious injury.

WARNING WARNING:

Indicates a potentially hazardous situation which, if notavoided, will result in

Death or serious injury.

CAUTION

CAUTION:

Indicates a potentially hazardous situation which,ifnot avoided,may resultin

Minor or moderate injury. CAUTION may also be used to alertagainst unsafe

practices associated with events thatcould lead to personal injury.

WARNING WARNING

Electric shock hazard:

This tool is not insulated. When using this

unit near energized electrical lines, use

proper personal protective equipment.

Failure to observe this warning could

Result in severe injury or death.

Wear eye protection when operating

or servicing this tool.

Failure to wear eye protection could

result in serious eye injury from flying

debris or hydraulic oil.

WARNING WARNING

Skin injection hazard:

Do not use hands to check for oil leaks.

High pressure oil easily punctures skin

causing serious injury, gangrene, ordeath.

If injured, seek medical help immediately

to remove oil.

Pinch points:

Keep hands away from the crimping

head when crimping.

Failure to observe this warning could

Result In severe injury or death.

CS 150 Battery Crimping Tool

Doc No: ATS-638160200 Release Date:12-06-07 UNCONTROLLED COPY Page 4 of21

Revision: A Revision Date:12-06-07

WARNING 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.

An incomplete crimp can cause a fire.



Use proper die, connector, and cable combinations.

Improper combinations can result in an

incomplete crimp.



The relief valve will sound to indicate a completed

crimp. If you do not hear the sound of the relief valve,

the crimp is not complete.

Failure to observe these warnings could result in severe

injury or death.

WARNING WARNING

Do not dispose of the battery in a fire. It will vent fumes and may explode.

Failure to observe this warning could result in severe injury from harmful

fumes or burns from flying debris

Inspect tool and dies before use. Replace any worn or

damaged parts. A damaged or improperly assembled

tool can break and strike someone nearby.

Failure to observe this warning could result in severe

injury or death.

CAUTION CAUTION



Do not operate the tool without the dies. Damage to the ram or crimping

head can result.



Do not operate with the crimping head open. Damage to the ram or

seals can result.



This tool is not designed for continuous use. After 100 crimping cycles,

allow the crimping tool to cool down for 15 minutes.



Do not place the tool in a vise. The crimping tool is designed for hand-held

Operation only.



This tool may be used in damp or wet environments; however, we

recommend air-drying the tool before use if it becomes soaked.



Use this tool for the manufacturer’s intended purpose only.

Failure to observe these precautions may result in injury or property damage.



Do not allow anything to contact the battery’s terminals.



Do not immerse the battery in liquid. Liquid may

create a short circuit and damage the battery.

If the battery is immersed, contact your service

center for proper handling.



Do not place the battery into a pocket, tool pouch, or

tool box with conductive objects.



Conductive objects may create a short circuit and

damage the battery.



Do not place a battery on moist ground or grass.

Moisture may create a short circuit and damage the

battery.

Failure to observe these precautions may result in injury

or property damage.

CAUTION CAUTION



Do not store the battery at more than 60 °C (140 °F). Damage to the

battery can result.



Do not use another manufacturer’s charger. Other manufacturers’

chargers may overcharge and damage the battery.



Do not attempt to open the battery. It contains no user-serviceable parts.

Failure to observe these precautions may result in injury or property damage.

Do not perform any service or maintenance other than as

described in this manual.

Failure to observe this precaution may result in injury

and property damage.

For Service, Contact Your Local Molex Sales Office

Molex Application Tooling Group

2200 Wellington Court

Lisle, Illinois 60532

Tel: 630-969-4550

Fax: 630-505-0049

CS 150 Battery Crimping Tool

Doc No: ATS-638160200 Release Date:12-06-07 UNCONTROLLED COPY Page 5 of21

Revision: A Revision Date:12-06-07

Section 2

General Description

2.1 Description

2.2 Features

2.3 Technical Specifications

2.4 Delivery Check

2.5 Tools

CS 150 Battery Crimping Tool

Doc No: ATS-638160200 Release Date:12-06-07 UNCONTROLLED COPY Page 6 of21

Revision: A Revision Date:12-06-07

Figure 2

-1

LOCKING

PINS (2)

TRIGGER

CRIMPING

HEAD

ADAPTER

RECHARGEABLE

(NiCad 9.6V) BATTERY

UNLOCKING

SWITCH

RETRACT

SLIDE

2General Description

Principal MechanicalParts of the 63816-0200 (Battery charger not shown)

2.1 Description

The Molex Battery Crimping Tool is designed to crimp 8 to4/0 AWG 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 maximumforce is reached. Itis equipped with a special brake

thatwill stop the forward motion ofthe crimping dies when the trigger is released. The crimping head can be

rotated 360ofor better access in difficult working situations.

2.2 Features



Crimps a wide range ofproducts with interchangeable tool heads and tool kits, which reduce the overallcost

and provide production flexibility.



Crimping heads and dies are easily and quickly interchanged to reduce production down time.



Complete portable system thatallows toolto be moved and stored easily.

CS 150 Battery Crimping Tool

Doc No: ATS-638160200 Release Date:12-06-07 UNCONTROLLED COPY Page 7 of21

Revision: A Revision Date:12-06-07

2.3 Technical Specification

Dimensions (with battery)

Length 292.1mm (11.50”)

Width 76.2mm (3.00“)

Depth 50.8mm (2.00“)

Unpacked Weight 1.5kg (3.31lbs)

Production Rate

250 cycles per hour maximum,depending on operator skill and tool kitinstalled.

Battery

Voltage 9.6V

Capacity 1.3 Ah

Charging Time: Approximately 40 Minutes, about15 minutes with fast-charger

Crimps/battery-charge 150 at 10mm2

Operating Parameters

MaximumForce 15kN (1.7 tons)

Cycle Time 2.0 seconds

Stroke Length 9.0mm (.354”)

AmbientTemperature -20oC to +40oC

Sound Level 75dB (A) in a distance of1.0m

Vibrations <2.5m/s2

2.4 Delivery Check

Carefully remove the CS150 Battery Crimping Tool from its shipping container and determine thatthe

following items are included in the package.

CS 150 Battery Crimping Tool with battery

Battery Charger

Carrying Case

63816-0200 Instruction Manual

CS 150 Battery Crimping Tool

Doc No: ATS-638160200 Release Date:12-06-07 UNCONTROLLED COPY Page 8 of21

Revision: A Revision Date:12-06-07

Section 3

Set-Up and Adjustments

3.1. Setup

3.2. Operation

3.3. Installation of Tool Kits



CS 150 Battery Crimping Tool

Doc No: ATS-638160200 Release Date:12-06-07 UNCONTROLLED COPY Page 9 of21

Revision: A Revision Date:12-06-07

3.1 Set-Up

Before starting any work on electrical applications make sure there are no

live cables or parts in the immediate area ofthe user.

WARNING

Remove the battery from the crimping toolbefore

installing and removing dies inthe crimp head.

1. Select the appropriate crimping head with the proper tooling kit

inserted for the application needed.

2. Remove the locking pins (2) fromthe adapter plate on the crimping

tool.

3. Place the crimping head into the adapter and push down until it

engages into the slot ofthe adapter.

4. Replace the locking pins (2) making sure the crimping head is secure.

The locking pins can be inserted fromeither side ofthe adapter plate.

See Figure 3-1.

WARNING

Electric shock hazard:

This tool is not insulated. When usingthis

unit near energized electrical lines, use

proper personal protective equipment.

Failure to observe this warning could

Result in severe injury or death.

WARNING

Wear eye protection when operating

or servicing this tool.

Failure to wear eye protection could

result in serious eye injury from flying

debris or hydraulic oil.

3.2 Operation

1. Insert the proper terminal or connector into the tooling nest and push on the

trigger in the handle just enough so the dies contact the terminal or connector

securely. Release the trigger. This allows the operator to make adjustments

to the connector before the final termination.

2. Insert the wire or cable into the terminal. Push on the wire or cable to assure itis fully seated in the

terminal.

3. Hold the trigger down again until the crimping tool achieves pressure relief,which is accompanied by an

audible “pop”.

Figure 3-2

WITH LOCATOR

HOLD

TRIGGER

DOWN

TERMINAL

AND WIRE

IN PLACE

Figure 3-1

LOCKING

PINS (2)

CRIMPING

TOOL

CRIMPING

HEAD

ADAPTER

CRIMPING

HEAD WITH

TOOLING

ADAPTER

PLATES

LOCKING

LATCH

RETRACT

SLIDE

CS 150 Battery Crimping Tool

Doc No: ATS-638160200 Release Date:12-06-07 UNCONTROLLED COPY Page 10 of21

Revision: A Revision Date:12-06-07

The crimping operation can be interrupted atany time during the cycle by releasing the trigger.

4. The crimping cycle is complete when the dies are completely closed and the maximum crimping force is

reached. The dies will automatically release and will go back to their original position.

Note: In case ofan error or emergency, the ramcan be retracted before the crimping cycle is complete. Todo

this push the retractor slide towards the battery. See Figure 3-1.

Warning: DO NOT crimp copper and AIconducting material together or special connecting material. If

a different conducting material has to be crimped, please contactthe manufacturer.

WARNING

An incomplete crimp can cause a fire.



Use proper die, connector, and cable combinations. Improper combinations can result in an incomplete crimp.



The relief valve will sound to indicate a completed crimp. If you do not hear the sound of the relief valve,

the crimp is not complete.

Failure to observe these warnings could resultin severe injury or death.

3.3 Preventive Instructions

WARNING

Do not dispose of the battery in a fire. It will vent fumes and may explode.

Failure to observe this warning could resultin severe injury from harmfulfumes orburns fromflyingdebris.

WARNING

Inspect tool and dies before use. Replace any worn or damaged parts. A damaged or improperly

assembled toolcan break and strike someone nearby.

Failure to observe this warning could resultin severe injury or death.

CAUTION



Do not operate the tool without the dies. Damage to the ram or crimping head can result.



Do not operate withthe crimping head open. Damage to the ram or seals can result.



This tool is notdesigned for continuous use. After 100 crimping cycles,allow the crimping tool to

cool down for 15 minutes.



Do not place the tool in a vise. The crimping tool is designed for hand-held operation only.



This tool may be used in damp or wet environments;however, we recommend air-drying the tool

before use ifit becomes soaked.



Use this tool for the manufacturer’s intended purpose only.

Failure to observe these precautions may resultininjury or property damage.

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