Hydraulic Dieless Crimping Tool
Hydraulic Dieless Crimping Tool
With Swivel Bench Adapter and Terminal Locator
Operation Manual
Order No. 63816-1700
For Insulated and Non-Insulated Terminal and Splices
Description
Operation
Maintenance
Doc No. TM-638161700 Release Date: 03-21-14
Revision: D
Revision Date: 05-10-17
UNCONTROLLED COPY
Page 1 of 29
Hydraulic Dieless Crimping Tool
Table of Contents
Contents
Hydraulic Dieless Crimping Tool............................................................................................................................................ 1
Safety Warnings and Information ...................................................................................................................................... 3
Section 1 ............................................................................................................................................................................... 6
General Description .......................................................................................................................................................... 6
Principal Mechanical Parts of the 63816-1700 Dieless Crimping Tool .............................................................................. 7
1.1. Description ............................................................................................................................................................ 7
1.2. Features ................................................................................................................................................................ 8
1.3. Technical Specification .......................................................................................................................................... 8
1.4. Delivery Check ...................................................................................................................................................... 8
1.5. Tools...................................................................................................................................................................... 8
Section 2 ............................................................................................................................................................................... 9
Setup and Adjustments ..................................................................................................................................................... 9
2.1
Setup ................................................................................................................................................................... 10
Air Supply Hook-Up .................................................................................................................................................... 10
Hydraulic Connections and Bench Mounting .............................................................................................................. 10
2.2
Adjustments......................................................................................................................................................... 11
2.3
Alternative Pump Settings ................................................................................................................................... 11
Section 3 ............................................................................................................................................................................. 12
Terminal Specifications and Crimping Operation ............................................................................................................ 12
3.1
Scope .................................................................................................................................................................. 13
3.2
Terminal Chart ..................................................................................................................................................... 13
3.3
Crimping Terminals ............................................................................................................................................. 19
3.4
Adjusting the Pump Release Mechanism ............................................................................................................ 20
Section 4 ............................................................................................................................................................................. 21
4.1
Lubrication ........................................................................................................................................................... 22
4.2
Bleeding Air From The System ............................................................................................................................ 22
4.3
Inspecting The Hydraulic Fluid Level ................................................................................................................... 22
4.4
Draining and Flushing the Reservoir. .................................................................................................................. 22
4.5
Refilling The Bladder ........................................................................................................................................... 22
4.6
Periodic Cleaning ................................................................................................................................................ 23
4.7
Spare Parts ......................................................................................................................................................... 24
4.8
Perishable Parts .................................................................................................................................................. 24
4.9
Storage ................................................................................................................................................................ 24
Section 5 ............................................................................................................................................................................. 25
5.1
Main Parts List and Assembly Drawing ............................................................................................................... 26
5.2
Repair Parts ........................................................................................................................................................ 27
5.3
Troubleshooting ................................................................................................................................................... 28
Doc No. TM-638161700 Release Date: 03-21-14
Revision: D
Revision Date: 05-10-17
UNCONTROLLED COPY
Page 2 of 29
Hydraulic Dieless Crimping Tool
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 for download 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:
DANGER
Indicates an imminently hazardous situation which, if not avoided, could result in death or serious injury.
WARNING:
WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION:
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
Always wear proper eye protection when
Operating or servicing this equipment.
Failure to wear eye protection could result
in serious eye injury from flying debris.
WARNING
Never wear clothing or jewelery that is loose or
That could potentially hang into the equipement
and get caught.
Failure to observe this warning could result in
Severe Injury or death.
WARNING
Never operate, service, install, or adjust this
machine without proper instruction and without
first reading and understanding the instructions
in this manual and all applicable tool and/or
wire processing machine.
manuals.
Doc No. TM-638161700 Release Date: 03-21-14
Revision: D
Revision Date: 05-10-17
WARNING
Heavy Object
To avoid muscle strain or back injury, use lifting
aids and proper lifting techniques when removing
or replacing.
Failure to observe these precautions may result in
injury or property damage.
WARNING
Never install or service this machine while
connected to any electrical power source.
Disconnect power by unplugging this tool
from its power source.
Failure to observe this warning could result
In severe injury or death.
WARNING
Always wear proper ear protection
when Operating or servicing this applicator.
Failure to observe these precautions may result in
Injury or property damage.
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Page 3 of 29
Hydraulic Dieless Crimping Tool
WARNING
WARNING
Do not use compressed air to clean
this equipment.
The forces created by compressed
air can force debris into the tool.
Never use this tool without guards or safety devices
that are intended to prevent hands from remaining
in the die space.
Failure to observe this warning could result
In severe injury or death.
Failure to observe these precautions may
result in injury or property damage.
WARNING
WARNING
Hand/Foot Operated
Maximum Capacity: 10,000 PSI
Do not exceed the PSI hydraulic rating noted
on the pump nameplate or tamper with the
internal high-pressure relief valve.
Before operating the hydraulic pump, all hose
connections must be tightened with proper tools.
Do not over-tighten. Connections need only be
tightened securely and leak-free. Over-tightening
may cause premature thread failure or may cause
high-pressure fittings to split at pressures lower
than their rated capacities
Pump
Before replenishing the oil level, retract the
system to prevent overfilling the pump reservoir.
An overfill may cause personal injury due
to excess reservoir pressure created when
cylinders are retracted.
Should a hydraulic hose ever rupture, burst, or need
to be disconnected, immediately shut off the pump
and shift the control valve twice to release all pressure.
WARNING
Never attempt to grasp a leaking hose under pressure
with your hands. The force of escaping hydraulic fluid
could cause serious injury.
Air
Hydraulic
Do not subject the hose to potential hazard such as fire,
Pump
extreme heat or cold, sharp surfaces, or heavy impact.
Do not allow the hose to kink, twist, curl, or bend so
tightly that the oil flow within the hose is blocked or
reduced. Periodically inspect the hose for wear because
any of these conditions can damage the hose and
possibly result in personal injury.
Cylinder
Do not exceed rated capacities of the cylinders.
Excess pressure may result in personal injury.
Do not set poorly balanced or off- center
loads on a cylinder. The load may tip and
cause personal injury.
Do not use the hose to move attached equipment.
Stress may damage hose and possibly cause personal
injury.
Hose material and coupler seals must be compatible
with the hydraulic fluid used. Hoses must not encounter
corrosive materials such as creosote-impregnated
objects and some paints. Consult the manufacturer
before painting a hose.
Creating pressure beyond rated capacities
may result in personal injury.
WARNING
Air
Supply
Shut off and disconnect the air supply when
the pump is not in use or before breaking
any connection in the system.
Never paint the couplers. Hose deterioration due to
corrosive materials may result in possible personal injury
Doc No. TM-638161700 Release Date: 03-21-14
Revision: D
Revision Date: 05-10-17
UNCONTROLLED COPY
Page 4 of 29
Hydraulic Dieless Crimping Tool
WARNING
MOLEX CANNOT BE RESPONSIBLE FOR DAMAGE OR INJURY RESULTING FROM UNSAFE PRODUCT
USE, LACK OF MAINTENANCE, OR INCORRECT PRODUCT AND SYSTEM APPLICATION.
CAUTION
Failure to observe these precautions may result in injury or property damage.
CAUTION
Never perform any service or maintenance other than as described in this manual.
Never modify, alter or misuse the equipment
Molex crimp specifications are valid only when used with Molex terminals, applicators and tooling.
Failure to observe this precaution may result in injury and property damage.
Tooling Technical Assistance
Molex offers tooling technical assistance for customers who may need some guidance for tooling adjustments.
This support can be obtained by calling either of the two numbers listed below and asking for the Molex Tooling
Group.
Call Toll Free 1-800-786-6539 (US) 1-630-969-4550 (Global).
This assistance is limited to the operation and set-up of a customer’s Molex Press Assembly. Questions with
regard to Molex connector products or how to identify the proper tooling and/ or tooling documentation should be
directed to your local Molex personnel or Customer Service Representative.
When calling for service on the tool a copy of the Tooling Manual and Specific Applicator Tooling Specification
Sheet should be present and a person that is familiar with the applicator should be present. Be sure the following
information is supplied:
1.
2.
3.
4.
5.
6.
7.
8.
Customer name
Customer address
Person to contact such as (name, title, e-mail, and telephone number
Press order number (Lease number also if applicable)
Serial number (Lease number also if applicable)
Molex Connector product order number
Urgency of request
Nature of problem
Application Tooling Support
Phone: +1-402-458-TOOL (8665)
E-Mail: applicationtooling@molex.com
Website: www.molex.com/applicationtooling
Molex is a registered trademark of Molex, LLC in the United States of America and may be registered in other countries; all other
trademarks listed herein belong to their respective owners.
Doc No. TM-638161700 Release Date: 03-21-14
Revision: D
Revision Date: 05-10-17
UNCONTROLLED COPY
Page 5 of 29
Hydraulic Dieless Crimping Tool
Section 1
General Description
1.1.
Description
1.2.
Features
1.3.
Technical Specifications
1.4.
Delivery Check
1.5.
Tools
Doc No. TM-638161700 Release Date: 03-21-14
Revision: D
Revision Date: 05-10-17
UNCONTROLLED COPY
Page 6 of 29
Hydraulic Dieless Crimping Tool
Principal Mechanical Parts of the 63816-1700 Dieless Crimping Tool
HYDRAULIC HOSE
ASSEMBLY
FILTER
REGULATOR
GAUGE
AIR HOSE
HYDRAULIC
CYLINDER
FOOT PEDAL
CRIMP HEAD
ASSEMBLY
AIR / HYD. PUMP
POWER UNIT
ADJUSTABLE
LOCATOR
Figure 1-1
SWIVEL BASE
ASSEMBLY
1.1. Description
(See Figure 1-1)
The Molex Dieless Crimping Tool is a combination Air and Hydraulic crimping system which utilizes four crimp “nibs”
(3 moving and one stationary). The three movable nibs close against the terminal, which nests on the fourth nib,
creating crimp indentations from the top, bottom and both sides, resulting in a four sided (quad) crimp.
The operator adjusts the air pressure thru the air gauge to produce the proper crimp.
This tool is designed to crimp 8 AWG to 500MCM insulated and uninsulated terminals and splices.
This tool is also designed to crimp 8 AWG to 500MCM heavy duty compression terminals and connectors. These
terminals are used for electrical and industrial applications such as generators, switch gear, transformers, motor
controls, power distribution equipment, welding equipment, telcommunications and utilities.
Doc No. TM-638161700 Release Date: 03-21-14
Revision: D
Revision Date: 05-10-17
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Hydraulic Dieless Crimping Tool
1.2. Features
Crimps a wide range of products and does not require die set changes, which reduce the overall cost and
provides production flexibility.
Swivel base and terminal locator included to provide the operator with a user-friendly tool to increase
productivity.
Complete lightweight system that allows tool to be moved and stored easily.
1.3. Technical Specification
Pneumatic:
Supply Pressure:
Air Pressure:
Cycle Time:
100 PSI (6.9 Bars)
125-PSI max. (8.6 Bars max.)
15 seconds
1.4. Delivery Check
Carefully remove the Hydraulic Dieless Crimping Tool from its shipping container and determine that the
following items are included in the package.
Description
Quantity
63816-1710 Crimp Head Assembly
63916-1711 Hydraulic Hose Assembly
63816-1720 Air / Hydraulic Pump
Power Unit with hoses
19286-0049 Filter regulator with gauge
19286-0103 Air Hose Assembly
TM-63816-1700
Instruction Manual
1
1
1
1
1
1
1.5. Tools
The following tools are recommended for setup and adjustments.
Metric standard hex wrench set
Adjustable wrench
Wire stripper / cutter
Doc No. TM-638161700 Release Date: 03-21-14
Revision: D
Revision Date: 05-10-17
UNCONTROLLED COPY
Page 8 of 29
Hydraulic Dieless Crimping Tool
Section 2
Setup and Adjustments
2.1.
Setup
2.2.
Adjustments
2.3.
Alternative Pump Settings
Doc No. TM-638161700 Release Date: 03-21-14
Revision: D
Revision Date: 05-10-17
UNCONTROLLED COPY
Page 9 of 29
Hydraulic Dieless Crimping Tool
2.1 Set-Up
Caution: Always disconnect the air pressure until the system is ready to operate.
The principal mechanical parts of the 63816-1700 Dieless Crimping Tool are illustrated in Section 5 Assembly
Drawings.
Air Supply Hook-Up
AIR SUPPLY
CUSTOMER
SUPPLIED
FILTER, REGULATOR, AND GAUGE
THE LUBRICATOR IS OPTIONAL
QUICK
CONNECT
COUPLER
HYDRAULIC
HOSE
AIR HOSE
POWER UNIT
DIELESS
CRIMPING HEAD
Figure 2-1
M8 or 5/16-18
FLAT HEAD
MACHINE SCREW (4)
1. Select the 1/4 NPT threaded fittings that are compatible
with your air supply.
2. Next install the fittings to the filter, regulator, gauge unit.
The air supply should be 20 CFM (550 L/M) and 100 PSI
(6.9 Bars) to obtain the rated hydraulic output. Air pressure
should be regulated to a maximum of 125 PSI (8.6 Bars).
See Figure 2-1.
Hydraulic Connections and Bench Mounting
1. Remove the dust cap from the hose where it attaches to
the crimp head.
2. Connect the quick connect coupler onto the cylinder inlet
on the crimp head. See figure 2-1.
WORK BENCH
WASHER (4)
HEX NUT (4)
SWIVEL BASE
Figure 2-2
Doc No. TM-638161700 Release Date: 03-21-14
Revision: D
Revision Date: 05-10-17
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Page 10 of 29
Hydraulic Dieless Crimping Tool
3. Before attempting to crimp any terminals, be sure the Swivel Base is securely fastened to a clean, sturdy work
bench or table in a well-lighted area. Fasten the base with four M8 or 5/16-18 flat head machine screws, nuts
and washers of sufficient length for the table top. (Not supplied). See Figure 2-2.
WARNING: Seal all external pipe connections with a high quality, non-hardening pipe sealant. Teflon tape
may also be used to seal hydraulic connections if only one layer of tape is used.
2.2
Adjustments
Recommended air pressure gauge settings to obtain proper crimp on noninsulated and insulated terminals and
splices.
Wire Size (AWG)
*SPX Power Team Pump
8
6
4
2
1
1/0
2/0
3/0
4/0
250 MCM
300 MCM
350 MCM
400 MCM
500 MCM
40 PSI
45 PSI
50 PSI
55 PSI
65 PSI
65 PSI
70 PSI
75 PSI
75 PSI
85 PSI
90 PSI
90 PSI
100 PSI
100 PSI
Pump Output
Hydraulic Pressure (Ref.)
4000 PSI
4500 PSI
5000 PSI
5500 PSI
6500 PSI
6500 PSI
7000 PSI
7500 PSI
7500 PSI
8500 PSI
9000 PSI
9000 PSI
10,000 PSI
10,000 PSI
DLH Head
Crimp Pressure (Ref.)
4960 PSI
5580 PSI
6200 PSI
6820 PSI
8060 PSI
8060 PSI
8680 PSI
9300 PSI
9300 PSI
10,540 PSI
11,160 PSI
11,160 PSI
12,400 PSI
12,400 PSI
*The SPX Power Team model PA9 air / hydraulic pump is currently shipped with the 63816-1700 tool. This pump
has a 100:1 oil / air pressure ratio at the outlet hose with a 10,000 max. safety, regardless of air input. The
pressure ratio at the crimp dies is 124:1 (6.2 ton max.)
2.3
Alternative Pump Settings
The following chart shows the pressure settings for other equivalent pumps. (Ref. only)
Wire Size (AWG)
8
6
4
2
1
1/0
2/0
3/0
4/0
250 MCM
300 MCM
350 MCM
400 MCM
500 MCM
Doc No. TM-638161700 Release Date: 03-21-14
Revision: D
Revision Date: 05-10-17
OTC Pump
30 PSI
35 PSI
40 PSI
45 PSI
60 PSI
60 PSI
65 PSI
70 PSI
70 PSI
Enerpac Turbo Pump
21 PSI
25 PSI
28 PSI
32 PSI
42 PSI
42 PSI
46 PSI
50 PSI
50 PSI
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Page 11 of 29
Hydraulic Dieless Crimping Tool
Section 3
Terminal Specifications and Crimping Operation
3.2
Scope
3.3
Terminal Specifications Chart
3.4
Crimping Terminals
3.5
Adjusting the Pump Release Mechanism
Doc No. TM-638161700 Release Date: 03-21-14
Revision: D
Revision Date: 05-10-17
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Page 12 of 29
Hydraulic Dieless Crimping Tool
3.1 Scope
Heavy Duty Compression Terminals and Connectors 8 AWG to 500 MCM. Standard and Long Barrel with one to
two holes for copper conductors only.
Testing
Mechanical
The tensile test, or pull test, is a means of evaluating the mechanical properties of the crimped connections.
The following charts show the UL specifications for various wire sizes. The tensile strength is shown in pounds,
which indicates the minimum acceptable force to break or separate the terminal from the conductor.
Wire Size (AWG)
8
6
4
2
1
1/0
2/0
3/0
4/0
250 MCM
300 MCM
350 MCM
400 MCM
500 MCM
Color Code
Red
Blue
Gray
Brown
Green
Pink
Black
Orange
Purple
Yellow
White
Red
Blue
Brown
*UL – 486A
90
100
140
180
200
250
300
350
450
*UL – 486A – Terminals (Copper Conductors Only)
The following is a partial list of the product part numbers and their specifications that this tool is designed to run.
We will be adding to this list and an up to date copy is available on www.molex.com.
3.2 Terminal Chart
Wire Size: 8 AWG
Terminal
No.
Terminal
Eng No. (REF)
19063-0006
19063-0009
19063-0012
19063-0019
19063-0021
19063-0025
19063-0026
19063-0028
19063-0029
19063-0031
19063-0032
19063-0033
19063-0035
19063-0036
19063-0038
19063-0040
19063-0042
19063-0044
D-750-10
D-750-14
D-750-56
D-750-38
D-750-56
D-752-10
D-752-12
D-752-14
D-752-38
D-752-58
D-752-78
D-753-12
D-753-34
D-753-38
D-753-58
D-756-06
D-756-08
D-756-10
8.50mm²
Wire Strip Length
In
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
mm
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
Wire Size: 8 AWG
Insulation Diameter
Maximum
In
mm
.265
6.73
.265
6.73
.265
6.73
.265
6.73
.265
6.73
.265
6.73
.265
6.73
.265
6.73
.265
6.73
.265
6.73
.265
6.73
.265
6.73
.265
6.73
.265
6.73
.265
6.73
.265
6.73
.265
6.73
.265
6.73
Doc No. TM-638161700 Release Date: 03-21-14
Revision: D
Revision Date: 05-10-17
Terminal
No.
Terminal
Eng No. (REF)
19063-0046
19067-0001
19067-0003
19067-0006
19067-0008
19067-0012
19067-0016
19067-0018
19067-0022
19067-0025
19067-0028
19067-0030
19067-0031
19067-0032
19067-0033
19067-0034
19067-0035
19067-0037
D-756-14
D-950-06
D-950-08
D-950-10
D-950-14
D-950-56
D-951-10
D-951-14
D-951-38
D-951-56
D-952-12
D-952-38
D-952-76
D-953-12
D-953-34
D-953-58
D-956-06
D-956-08
8.50mm²
Wire Strip Length
In
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
UNCONTROLLED COPY
mm
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
Insulation Diameter
Maximum
In
mm
.265
6.73
.350
8.89
.350
8.89
.350
8.89
.350
8.89
.350
8.89
.350
8.89
.350
8.89
.350
8.89
.350
8.89
.350
8.89
.350
8.89
.350
8.89
.350
8.89
.350
8.89
.350
8.89
.350
8.89
.350
8.89
Page 13 of 29
Hydraulic Dieless Crimping Tool
Wire Size: 8 AWG
Terminal
No.
Terminal
Eng No. (REF)
19067-0039
19067-0041
19067-0128
19067-0129
19071-0132
19071-0134
19071-0136
19071-0140
19071-0144
19071-0146
19071-0148
19071-0150
19071-0153
19071-0156
19071-0158
19071-0161
19071-0162
19071-0163
19071-0164
19071-0166
19071-0168
19071-0169
19071-0170
19071-0171
19071-0172
19071-0173
19071-0174
19071-0176
19071-0178
19071-0180
19071-0182
19071-0334
19154-0041
19193-0143
19193-0146
19193-0149
19193-0152
19193-0157
19193-0159
19193-0163
19193-0167
19193-0171
19193-0175
19193-0178
19193-0179
19193-0182
19193-0184
19193-0185
19193-0186
19193-0187
19193-0190
19193-0191
19193-0192
19193-0193
19193-0194
19193-0195
19193-0196
19193-0198
19193-0200
19193-0202
19193-0204
19202-0054
19205-0004
19215-0034
19221-0167
D-956-10
D-956-14
D-951-76
D-952-58
D-650-06X
D-650-08X
D-650-10X
D-650-14X
D-650-56X
D-651-10X
D-651-14X
D-651-38X
D-651-56X
D-651-76X
D-652-10X
D-652-14X
D-652-38X
D-652-56X
D-652-58X
D-652-76X
D-653-12X
D-653-14X
D-653-34X
D-653-38X
D-653-56X
D-653-58X
D-653-76X
D-656-06X
D-656-08X
D-656-10X
D-656-14X
D-652-12X
D-654X
D-350-06
D-350-08
D-350-10
D-350-14
D-350-56
D-351-10
D-351-14
D-351-38
D-351-56
D-351-76
D-352-10
D-352-12
D-352-14
D-352-38
D-352-56
D-352-58
D-352-76
D-353-12
D-353-14
D-353-34
D-353-38
D-353-56
D-353-58
D-353-76
D-356-06
D-356-08
D-356-10
D-356-14
D-754
D-355
D-354
HDC-8102-CC
8.50mm²
Wire Strip Length
In
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.375
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.438
.375
.312
.375
.610
mm
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
9.53
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
11.11
9.53
7.92
9.53
15.49
Wire Size: 8 AWG
Insulation Diameter
Maximum
In
mm
.350
8.89
.350
8.89
.350
8.89
.350
8.89
.385
9.77
.385
9.77
.385
9.77
.385
9.77
.385
9.77
.385
9.77
.385
9.77
.385
9.77
.385
9.77
.385
9.77
.385
9.78
.385
9.78
.385
9.78
.385
9.78
.385
9.78
.385
9.78
.385
9.78
.385
9.78
.385
9.78
.385
9.78
.385
9.78
.385
9.78
.385
9.78
.385
9.78
.385
9.78
.385
9.78
.385
9.78
.385
9.78
.385
9.78
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
.265
6.73
N/A
N/A
.170
4.32
N/A
N/A
Doc No. TM-638161700 Release Date: 03-21-14
Revision: D
Revision Date: 05-10-17
Terminal
No.
Terminal
Eng No. (REF)
19221-0212
19221-0223
19221-0224
19221-0225
19221-0226
19221-0290
19221-0315
HDC-810-CC
BCL-810-PL
BCL-814-PL
BCL-8516-PL
BCL-838-WP-PL
HDCL-8102-CC
HDCL-810-CC
Wire Strip Length
In
.516
.438
.438
.438
.438
.915
.984
Wire Size: 6 AWG
Terminal
No.
Terminal
Eng No. (REF)
19063-0048
19063-0050
19063-0052
19063-0054
19063-0056
19063-0059
19063-0061
19063-0062
19063-0063
19063-0064
19063-0065
19063-0066
19063-0067
19063-0069
19063-0071
19063-0073
19063-0076
19067-0043
19067-0045
19067-0047
19067-0052
19067-0055
19067-0059
19067-0061
19067-0062
19067-0063
19067-0064
19067-0065
19067-0067
19067-0069
19067-0071
19067-0073
19071-0185
19071-0188
19071-0190
19071-0193
19071-0196
19071-0200
19071-0201
19071-0203
19071-0204
19071-0206
19071-0207
19071-0208
19071-0218
19071-0221
19071-0225
19071-0229
19154-0045
19193-0206
19193-0209
19193-0212
19193-0216
E-757-08
E-757-10
E-757-14
E-757-38
E-757-56
E-757-76
E-758-10
E-758-12
E-758-14
E-758-38
E-758-56
E-758-58
E-758-76
E-760-08
E-760-10
E-760-14
E-760-56
E-957-08
E-957-10
E-957-14
E-957-38
E-957-56
E-957-76
E-958-12
E-958-14
E-958-38
E-958-58
E-958-76
E-960-08
E-960-10
E-960-14
E-960-56
E-657-08X
E-657-10X
E-657-14X
E-657-38X
E-657-56X
E-658-10X
E-658-12X
E-658-14X
E-658-38X
E-658-56X
E-658-58X
E-658-76X
E-660-08X
E-660-10X
E-660-14X
E-660-56X
E-662X
E-357-08
E-357-10
E-357-14
E-357-38
8.50mm²
mm
13.11
11.11
11.11
11.11
11.11
23.24
24.99
Insulation Diameter
Maximum
In
mm
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
16.50mm²
Wire Strip Length
In
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.438
.468
.468
.468
.468
UNCONTROLLED COPY
mm
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.11
11.88
11.88
11.88
11.88
Insulation Diameter
Maximum
In
mm
.350
8.89
.350
8.89
.350
8.89
.350
8.89
.350
8.89
.350
8.89
.350
8.89
.350
8.89
.350
8.89
.350
8.89
.350
8.89
.350
8.89
.350
8.89
.350
8.89
.350
8.89
.350
8.89
.350
8.89
.428
10.87
.428
10.87
.428
10.87
.428
10.87
.428
10.87
.428
10.87
.428
10.87
.428
10.87
.428
10.87
.428
10.87
.428
10.87
.428
10.87
.428
10.87
.428
10.87
.428
10.87
.440
11.17
.440
11.17
.440
11.17
.440
11.17
.440
11.17
.440
11.17
.440
11.17
.440
11.17
.440
11.17
.440
11.17
.440
11.17
.440
11.17
.440
11.17
.440
11.17
.440
11.17
.440
11.17
.440
11.17
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Page 14 of 29
Hydraulic Dieless Crimping Tool
Wire Size: 6 AWG
Terminal
No.
Terminal
Eng No. (REF)
19193-0219
19193-0225
19193-0226
19193-0229
19193-0230
19193-0232
19193-0233
19193-0234
19193-0236
19193-0237
19193-0238
19193-0239
19193-0240
19193-0241
19193-0242
19193-0243
19193-0245
19193-0248
19193-0251
19193-0252
19202-0055
19205-0006
19215-0040
19221-0168
19221-0213
19221-0215
19221-0227
19221-0228
19221-0229
19221-0291
19221-0316
E-357-56
E-358-10
E-358-12
E-358-14
E-358-38
E-358-56
E-358-58
E-358-76
E-359-12
E-359-14
E-359-34
E-359-34
E-359-56
E-359-58
E-359-76
E-360-08
E-360-10
E-360-14
E-360-56
E-360-56R90
E-762
E-361
E-362
HDC-6142-CC
HDC-614-CC
HDC-610-CC
BCL-614-WP-PL
BCL-6516-WP-PL
BCL-638-WP-PL
HDCL-6142-CC
HDCL-614-CC
Wire Strip Length
In
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.468
.438
.375
.438
.540
.547
.547
.468
.468
.468
.670
1.047
Wire Size: 4 AWG
Terminal
No.
Terminal
Eng No. (REF)
19063-0078
19063-0079
19063-0080
19063-0081
19063-0082
19063-0083
19063-0084
19063-0085
19063-0086
19063-0087
19063-0088
19063-0089
19063-0090
19063-0091
19063-0092
19067-0075
19067-0076
19067-0077
19067-0078
19067-0079
19067-0080
19067-0081
19067-0082
19067-0084
19067-0085
19067-0086
19067-0087
19067-0088
19067-0089
F-766-10
F-766-12
F-766-14
F-766-38
F-766-56
F-766-76
F-767-10
F-767-14
F-767-56
F-770-12
F-770-14
F-770-34
F-770-38
F-770-56
F-770-76
F-966-10
F-966-12
F-966-14
F-966-38
F-966-56
F-966-76
F-967-10
F-967-14
F-967-56
F-969-12
F-969-38
F-969-58
F-970-34
F-970-58
16.50mm²
mm
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.88
11.11
9.52
11.11
13.71
13.90
13.90
11.88
11.88
11.88
17.02
26.59
25.00mm²
Wire Strip Length
In
.531
.531
.531
.531
.531
.531
.531
.531
.531
.531
.531
.531
.531
.531
.531
.531
.531
.531
.531
.531
.531
.531
.531
.531
.531
.531
.531
.531
.531
Wire Size: 4 AWG
Insulation Diameter
Maximum
In
mm
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
.342
8.68
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
mm
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
Insulation Diameter
Maximum
In
mm
.432
10.97
.432
10.97
.432
10.97
.432
10.97
.432
10.97
.432
10.97
.432
10.97
.432
10.97
.432
10.97
.432
10.97
.432
10.97
.432
10.97
.432
10.97
.432
10.97
.432
10.97
.520
13.20
.520
13.20
.520
13.20
.520
13.20
.520
13.20
.520
13.20
.520
13.20
.520
13.20
.520
13.20
.520
13.20
.520
13.20
.520
13.20
.520
13.20
.520
13.20
Doc No. TM-638161700 Release Date: 03-21-14
Revision: D
Revision Date: 05-10-17
Terminal
No.
Terminal
Eng No. (REF)
19071-0231
19071-0234
19071-0237
19071-0240
19071-0243
19071-0247
19071-0250
19071-0253
19071-0255
19154-0082
19193-0254
19193-0258
19193-0261
19193-0264
19193-0267
19193-0270
19193-0273
19193-0275
19193-0278
19193-0281
19193-0282
19193-0283
19193-0284
19193-0285
19193-0286
19193-0287
19193-0288
19193-0289
19193-0291
19193-0292
19193-0293
19193-0294
19202-0085
19205-0086
19215-0089
19221-0169
19221-0170
19221-0214
19221-0216
19221-0217
19221-0230
19221-0231
19221-0232
19221-0292
19221-0317
F-666-10X
F-666-12X
F-666-14X
F-666-38X
F-666-56X
F-666-76X
F-667-10X
F-667-14X
F-667-56X
F-664X
F-366-10
F-366-12
F-366-14
F-366-38
F-366-56
F-366-76
F-367-10
F-367-14
F-367-56
F-369-12
F-369-14
F-369-38
F-369-56
F-369-58
F-369-76
F-370-12
F-370-14
F-370-34
F-370-38
F-370-56
F-370-58
F-370-76
F-764
F-365
F-364
HDC-4142-CC
HDC-45162-CC
HDC-414-CC
HDC-410-CC
HDC-4516-CC
BCL-414-PL
BCL-4516-PL
BCL-438-PL
HDCL-4142-CC
HDCL-414-CC
Wire Strip Length
In
.531
.531
.531
.531
.531
.531
.531
.531
.531
.453
.531
.531
.531
.531
.531
.531
.531
.531
.531
.531
.531
.531
.531
.531
.531
.531
.531
.531
.531
.531
.531
.531
.531
.531
.531
.610
.610
.594
.594
.610
.500
.500
.500
1.047
1.047
Wire Size: 2 AWG
Terminal
No.
Terminal
Eng No. (REF)
19063-0093
19063-0094
19063-0095
19063-0096
19063-0097
19063-0098
19063-0099
19063-0100
19063-0101
19063-0102
19063-0103
19063-0104
19063-0111
19063-0112
19063-0113
G-774-12
G-774-14
G-774-38
G-774-56
G-774-58
G-774-76
G-775-12
G-775-14
G-775-38
G-775-56
G-775-58
G-775-76
G-777-12
G-777-14
G-777-34
25.00mm²
mm
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
11.50
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
13.48
15.49
15.49
15.09
15.09
15.49
12.70
12.70
12.70
26.58
26.59
Insulation Diameter
Maximum
In
mm
.515
13.08
.515
13.08
.515
13.08
.515
13.08
.515
13.08
.515
13.08
.515
13.08
.515
13.08
.515
13.08
.605
15.36
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
.429
10.89
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
35.00mm²
Wire Strip Length
In
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
UNCONTROLLED COPY
mm
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
Insulation Diameter
Maximum
In
mm
.525
13.33
.525
13.33
.525
13.33
.525
13.33
.525
13.33
.525
13.33
.525
13.33
.525
13.33
.525
13.33
.525
13.33
.525
13.33
.525
13.33
.525
13.33
.525
13.33
.525
13.33
Page 15 of 29
Hydraulic Dieless Crimping Tool
Wire Size: 2 AWG
Terminal
No.
Terminal
Eng No. (REF)
19063-0114
19063-0115
19063-0116
19063-0117
19067-0090
19067-0091
19067-0092
19067-0093
19067-0094
19067-0095
19067-0096
19067-0097
19067-0098
19067-0099
19067-0100
19067-0105
19067-0106
19067-0107
19067-0108
19067-0109
19067-0110
19067-0130
19071-0272
19071-0273
19071-0275
19071-0276
19071-0277
19071-0278
19071-0279
19071-0281
19071-0283
19071-0285
19071-0287
19071-0289
19071-0290
19071-0291
19071-0292
19071-0293
19071-0294
19071-0295
19071-0296
19071-0297
19071-0298
19071-0299
19071-0300
19071-0301
19154-0049
19193-0296
19193-0297
19193-0298
19193-0299
19193-0301
19193-0302
19193-0303
19193-0305
19193-0307
19193-0309
19193-0311
19193-0318
19193-0319
19193-0320
19193-0321
19193-0322
19193-0324
19193-0611
G-777-38
G-777-56
G-777-58
G-777-76
G-974-12
G-974-14
G-974-38
G-974-56
G-974-76
G-975-10
G-975-14
G-975-38
G-975-56
G-977-34
G-977-58
G-776-12
G-776-14
G-776-38
G-776-56
G-776-58
G-776-76
G-974-58
G-674-12X
G-674-14X
G-674-38X
G-674-56X
G-674-58X
G-674-76X
G-675-10X
G-675-14X
G-675-38X
G-675-56X
G-675-76X
G-676-12X
G-676-14X
G-676-38X
G-676-56X
G-676-58X
G-676-76X
G-677-12X
G-677-14X
G-677-34X
G-677-38X
G-677-56X
G-677-58X
G-677-76X
G-672X
G-374-12
G-374-14
G-374-38
G-374-56
G-374-58
G-374-76
G-375-10
G-375-14
G-375-38
G-375-56
G-375-76
G-377-12
G-377-14
G-377-34
G-377-38
G-377-56
G-377-76
G-377-76
35.00mm²
Wire Strip Length
In
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.531
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
.578
mm
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
13.48
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
14.68
Wire Size: 2 AWG
Insulation Diameter
Maximum
In
mm
.525
13.33
.525
13.33
.525
13.33
.525
13.33
.600
15.24
.600
15.24
.600
15.24
.600
15.24
.600
15.24
.600
15.24
.600
15.24
.600
15.24
.600
15.24
.525
.525
.525
.525
.525
.525
.600
.655
.655
.655
.655
.655
.655
.655
.655
.655
.655
.655
.655
.655
.655
.655
.655
.655
.655
.655
.655
.655
.655
.655
.655
.650
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
13.33
13.33
13.33
13.33
13.33
13.33
15.24
16.63
16.63
16.63
16.63
16.63
16.63
16.63
16.63
16.63
16.63
16.63
16.63
16.63
16.63
16.63
16.63
16.63
16.63
16.63
16.63
16.63
16.63
16.63
16.63
16.51
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Doc No. TM-638161700 Release Date: 03-21-14
Revision: D
Revision Date: 05-10-17
Terminal
No.
Terminal
Eng No. (REF)
19202-0057
19205-0008
19215-0046
19221-0171
19221-0172
19221-0218
19221-0219
19221-0220
19221-0233
19221-0235
19221-0236
19221-0293
19221-0294
19221-0323
19221-0324
G-772
G-373
G-372
HDC-2142-CC
HDC-25162-CC
HDC-214-CC
HDC-2516-CC
HDC-238-CC
BCL-2516-PL
BCL-238-PL
BCL-212-WP-PL
HDCL-2142-CC
HDCL-25162-CC
HDCL-214-CC
HDCL-2516-CC
35.00mm²
Wire Strip Length
In
.531
.578
.531
mm
13.48
14.68
13.48
.780
.547
.547
.657
.593
.593
.593
1.052
1.052
1.266
1.266
19.81
13.90
13.90
16.69
15.06
15.06
15.06
26.72
26.72
32.16
32.16
Wire Size: 1 AWG
Terminal
No.
Terminal
Eng No. (REF)
19221-0173
19221-0174
19221-0221
19221-0237
19221-0238
19221-0239
19221-0271
19221-0272
19221-0273
19221-0295
19221-0296
19221-0334
19221-0335
HDC-1142-CC
HDC-15162-CC
HDC-114-CC
BCL-1516-PL
BCL-138-PL
BCL-112-PL
HDC-1516-CC
HDC-138-CC
HDC-112-CC
HDCL-1142-CC
HDCL-15162-CC
HDCL-114-CC
HDCL-1516-CC
Wire Size: 1/0 AWG
Terminal
No.
Terminal
Eng No. (REF)
19063-0118
19063-0119
19063-0120
19063-0121
19063-0122
19063-0123
19063-0124
19063-0125
19063-0126
19063-0127
19063-0128
19067-0101
19067-0102
19067-0315
19071-0302
19071-0303
19071-0305
19071-0306
19071-0308
19071-0336
19071-0337
19071-0338
19193-0325
19193-0326
19193-0327
19193-0328
19193-0329
H-780-12
H-780-14
H-780-38
H-780-56
H-780-76
H-781-14
H-781-38
H-781-56
H-782-14
H-782-38
H-782-56
H-980-38
H-980-76
H-980-12
H-680-76X
H-681-14X
H-681-38X
H-681-56X
H-682-12X
H-682-34X
H-682-38X
H-682-58X
H-380-12
H-380-14
H-380-38
H-380-56
H-380-76
42.5mm²
Wire Strip Length
In
.420
.770
.750
.656
.656
.656
.750
.750
.750
1.410
1.410
mm
10.67
19.56
19.05
16.66
16.66
16.66
19.05
19.05
19.05
35.81
35.81
UNCONTROLLED COPY
Insulation Diameter
Maximum
In
mm
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
50.00mm²
Wire Strip Length
In
.765
.765
.765
.765
.765
.765
.765
.765
.765
.765
.765
.765
.765
.765
.765
.765
.765
.765
.765
.765
.765
.765
.765
.765
.765
.765
.765
Insulation Diameter
Maximum
In
mm
.509
12.92
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
mm
19.43
19.43
19.43
19.43
19.43
19.43
19.43
19.43
19.43
19.43
19.43
19.43
19.43
19.43
19.43
19.43
19.43
19.43
19.43
19.43
19.43
19.43
19.43
19.43
19.43
19.43
19.43
Insulation Diameter
Maximum
In
mm
.595
15.11
.595
15.11
.595
15.11
.595
15.11
.595
15.11
.595
15.11
.595
15.11
.595
15.11
.595
15.11
.595
15.11
.595
15.11
.680
17.27
.680
17.27
.680
17.27
.680
17.27
.680
17.27
.680
17.27
.680
17.27
.680
17.27
.680
17.27
.680
17.27
.680
17.27
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Page 16 of 29
Hydraulic Dieless Crimping Tool
Wire Size: 1/0 AWG
Terminal
No.
Terminal
Eng No. (REF)
19193-0330
19193-0331
19193-0333
19193-0556
19202-0058
19205-0009
19215-0047
19221-0176
19221-0242
19221-0240
19221-0241
19221-0274
19221-0275
19221-0276
19221-0277
19221-0297
19221-0298
19221-0336
19221-0337
19221-0353
19221-0377
19221-0393
19221-0394
19221-0422
19221-0423
19221-0436
19221-0437
19221-0440
19221-0441
19221-0847
H-381-14
H-381-38
H-381-56
H-381-12
H-783
H-384
H-383
HDC-10382-CC
BCL-1012-PL
BCL-10516-PL
BCL-1038-PL
HDC-1014-CC
HDC-10516-CC
HDC-1038-CC
HDC-1012-CC
HDCL-105162-CC
HDCL-10382-CC
HDCL-10516-CC
HDCL-1038-CC
HDCL-105162-CC
BCL-1038
BCL-1012
BCL-10516
BCL-1014-PL
BCL-1014
BCL-1012-WP-PL
BCL-1012-PL
BCL-1038-WP-PL
BCL-1038-WP
BCL-1010MM-PL
50.00mm²
Wire Strip Length
In
.765
.765
.765
.765
.578
.718
.625
1.070
.703
.703
.703
.875
.875
.875
.875
1.520
1.520
1.406
1.406
.860
.703
.703
.703
.703
.703
.703
.703
.703
.703
.703
mm
19.43
19.43
19.43
19.43
14.68
18.23
15.88
27.18
17.85
17.85
17.85
22.23
22.23
22.23
22.23
38.61
38.61
35.71
35.71
21.84
17.85
17.85
17.85
17.85
17.85
17.85
17.85
17.85
17.85
17.85
Wire Size: 2/0 AWG
Insulation Diameter
Maximum
In
mm
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
.590
14.98
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Terminal
No.
Terminal
Eng No. (REF)
19193-0350
19193-0351
19193-0352
19193-0353
19202-0059
19205-0010
19215-0048
19221-0105
19221-0106
19221-0107
19221-0178
19221-0179
19221-0195
19221-0234
19221-0243
19221-0244
19221-0245
19221-0249
19221-0278
19221-0299
19221-0300
19221-0338
19221-0339
19221-0379
19221-0397
19221-0398
19221-0597
19221-0598
19221-0848
J-387-12
J-387-34
J-387-58
J-387-78
J-788
J-389
J-388
HDC-20516-CC
HDC-2038-CC
HDC-2012-CC
HDC-20382-CC
HDC-20122-CC
HDC-205162-CC
BCL-2014-PL
BCL-20516-PL
BCL-2038-PL
BCL-2012-PL
BCL-2014
HDC-2014-CC
HDCL-20382-CC
HDCL-20122-CC
HDCL-2038-CC
HDCL-2012-CC
BCL-2038
BCL-2012
BCL-20516
BCL-2058
BCL-2058-PL
BCL-2010MM-PL
Terminal
No.
Terminal
Eng No. (REF)
19202-0060
19205-0012
19215-0049
19221-0108
19221-0109
19221-0110
19221-0180
19221-0181
19221-0182
19221-0246
19221-0247
19221-0248
19221-0301
19221-0302
19221-0325
19221-0326
19221-0355
19221-0381
19221-0401
19221-0402
19221-0478
19221-0570
19221-0862
K-793
K-393
K-394
HDC-3014-CC
HDC-30516-CC
HDC-3038-CC
HDC-305162-CC
HDC-30382-CC
HDC-30122-CC
BCL-30516-PL
BCL-3038-PL
BCL-3012-PL
HDCL-30382-CC
HDCL-30122-CC
HDCL-3038-CC
HDCL-3012-CC
HDC-3012-CC
BCL-3038
BCL-3012
BCL-30516
BCL-3014
BCL-3014-PL
BCL-3010MM-PL
70.00mm²
Wire Strip Length
In
.781
.781
.781
.781
.688
.718
.640
.985
.985
.985
.980
.980
.980
.750
.750
.750
.750
.750
.985
1.690
1.690
1.422
1.422
.750
.750
.750
.750
.750
.750
mm
19.83
19.83
19.83
19.83
17.47
18.23
16.25
25.02
25.02
25.02
24.90
24.90
24.90
19.05
19.05
19.05
19.05
19.05
25.02
42.93
42.93
36.12
36.12
19.05
19.05
19.05
19.05
19.05
19.05
Wire Size: 3/0 AWG
Wire Size: 2/0 AWG
Terminal
No.
Terminal
Eng No. (REF)
19063-0129
19063-0130
19063-0131
19063-0132
19063-0133
19063-0134
19063-0135
19063-0136
19063-0137
19067-0109
19067-0110
19067-0111
19067-0112
19067-0113
19067-0114
19067-0115
19067-0116
19071-0309
19071-0310
19071-0311
19071-0312
19071-0313
19071-0314
19071-0339
19071-0340
19193-0341
19193-0342
19193-0345
19193-0346
19193-0348
J-785-12
J-785-14
J-785-38
J-785-56
J-785-76
J-787-12
J-787-34
J-787-58
J-787-78
J-985-12
J-985-14
J-985-38
J-985-56
J-985-76
J-987-12
J-987-34
J-987-58
J-685-12X
J-685-14X
J-685-38X
J-685-56X
J-685-76X
J-687-12X
J-687-34X
J-687-58X
J-385-12
J-385-14
J-385-38
J-385-56
J-385-76
70.00mm²
Wire Strip Length
In
.781
.781
.781
.781
.781
.781
.781
.781
.781
.781
.781
.781
.781
.781
.781
.781
.781
.781
.781
.781
.781
.781
.781
.781
.781
.781
.781
.781
.781
.781
mm
19.83
19.83
19.83
19.83
19.83
19.83
19.83
19.83
19.83
19.83
19.83
19.83
19.83
19.83
19.83
19.83
19.83
19.83
19.83
19.83
19.83
19.83
19.83
19.83
19.83
19.83
19.83
19.83
19.83
19.83
Insulation Diameter
Maximum
In
mm
.675
17.14
.675
17.14
.675
17.14
.675
17.14
.675
17.14
.675
17.14
.675
17.14
.675
17.14
.675
17.14
.765
19.43
.765
19.43
.765
19.43
.765
19.43
.765
19.43
.765
19.43
.765
19.43
.765
19.43
.735
18.66
.735
18.66
.735
18.66
.735
18.66
.735
18.66
.675
17.14
.675
17.14
.675
17.14
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Doc No. TM-638161700 Release Date: 03-21-14
Revision: D
Revision Date: 05-10-17
Terminal
No.
Terminal
Eng No. (REF)
19202-0061
19205-0013
L-778
L-378
95.00mm²
Wire Strip Length
In
.640
.672
.672
1.110
1.110
1.110
1.100
1.100
1.100
.812
.812
.812
1.650
1.650
1.547
1.547
1.110
.812
.812
.812
.812
.812
.750
Wire Size: 4/0 AWG
Insulation Diameter
Maximum
In
mm
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
.670
17.02
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
mm
16.25
17.06
17.06
28.19
28.19
28.19
27.94
27.94
27.94
20.63
20.63
20.63
41.91
41.91
39.29
39.29
28.19
20.63
20.63
20.63
20.63
20.63
19.05
Insulation Diameter
Maximum
In
mm
.731
18.56
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
120.00mm²
Wire Strip Length
In
.750
.750
UNCONTROLLED COPY
mm
19.05
19.05
Insulation Diameter
Maximum
In
mm
.831
21.10
N/A
N/A
Page 17 of 29
Hydraulic Dieless Crimping Tool
Wire Size: 4/0 AWG
Terminal
No.
Terminal
Eng No. (REF)
19215-0050
19221-0183
19221-0184
19221-0250
19221-0251
19221-0303
19221-0304
19221-0327
19221-0328
19221-0356
19221-0357
19221-0358
19221-0359
19221-0371
19221-0372
19221-0373
19221-0374
19221-0375
19221-0376
19221-0382
19221-0403
19221-0412
19221-0413
19221-0502
19221-0503
19221-0648
19221-0652
L-379
HDC-40382-CC
HDC-40122-CC
BCL-4038-PL
BCL-4012-PL
HDCL-40382-CC
HDCL-40122-CC
HDCL-4038-CC
HDCL-4012-CC
HDC-4014-CC
HDC-40516-CC
HDC-4038-CC
HDC-4012-CC
BCL-4038-PL (.625)
BCL-4012-PL (.625)
BCL-4058-PL (.625)
BCL-4038 (.625)
BCL-4012 (.625)
BCL-4058 (.625)
BCL-4038
BCL-4012
BCL-40516-PL
BCL-40516
BCL-40516
BCL-40516-PL
BCL-4014-PL
BCL-4014
120.00mm²
Wire Strip Length
In
.750
1.210
1.210
1.159
1.159
1.880
1.880
1.843
1.843
1.220
1.220
1.220
1.220
.859
.859
.859
.859
.859
.859
.859
.859
.859
.859
.859
.859
.859
.859
mm
19.05
30.73
30.73
29.44
29.44
47.75
47.75
46.81
46.81
30.99
30.99
30.99
30.99
21.8
21.8
21.8
21.8
21.8
21.8
21.8
21.8
21.8
21.8
21.8
21.8
21.8
21.8
Wire Size: 300 MCM AWG
Insulation Diameter
Maximum
In
mm
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Wire Size: 250 MCM AWG 127.00mm²
Terminal
No.
Terminal
Eng No. (REF)
19221-0185
19221-0186
19221-0305
19221-0306
19221-0329
19221-0330
19221-0360
19221-0361
19221-0446
19221-0447
HDC-250382-CC
HDC-250122-CC
HDCL-250382-CC
HDCL-250122-CC
HDCL-25038-CC
HDCL-25012-CC
HDC-25038-CC
HDC-25012-CC
BCL-25038
BCL-25038-PL
Wire Strip Length
In
1.270
1.270
1.870
1.870
2.093
2.093
1.282
1.282
.859
.859
mm
32.26
32.26
47.50
47.50
53.16
53.16
32.56
32.56
21.8
21.8
Insulation Diameter
Maximum
In
mm
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Wire Size: 300 MCM AWG
Terminal
No.
Terminal
Eng No. (REF)
19221-0187
19221-0188
HDC-300382-CC
HDC-300122-CC
152.00mm²
Insulation Diameter
Wire Strip Length
Maximum
In
mm
In
mm
1.330
33.78
N/A
N/A
1.330
33.78
N/A
N/A
Doc No. TM-638161700 Release Date: 03-21-14
Revision: D
Revision Date: 05-10-17
Terminal
No.
Terminal
Eng No. (REF)
19221-0307
19221-0308
19221-0331
19221-0332
19221-0362
19221-0363
19221-0364
HDCL-300382-CC
HDCL-300122-CC
HDCL-30038-CC
HDCL-30012-CC
HDC-30038-CC
HDC-30012-CC
HDC-30058-CC
152.00mm²
Insulation Diameter
Wire Strip Length
Maximum
In
mm
In
mm
2.060
52.32
N/A
N/A
2.060
52.32
N/A
N/A
2.235
56.77
N/A
N/A
2.235
56.77
N/A
N/A
1.407
35.74
N/A
N/A
1.407
35.74
N/A
N/A
1.407
35.74
N/A
N/A
Wire Size: 350 MCM AWG
Terminal
No.
Terminal
Eng No. (REF)
19221-0189
19221-0190
19221-0309
19221-0310
19221-0333
19221-0340
19221-0365
19221-0366
HDC-350382-CC
HDC-350122-CC
HDCL-350382-CC
HDCL-350122-CC
HDCL-35038-CC
HDCL-35012-CC
HDC-35012-CC
HDC-35058-CC
177.30mm²
Insulation Diameter
Wire Strip Length
Maximum
In
mm
In
mm
1.540
39.12
N/A
N/A
1.540
39.12
N/A
N/A
2.210
56.13
N/A
N/A
2.210
56.13
N/A
N/A
2.931
74.45
N/A
N/A
2.931
47.45
N/A
N/A
1.531
38.89
N/A
N/A
1.531
38.89
N/A
N/A
Wire Size: 400 MCM AWG
Terminal
No.
Terminal
Eng No. (REF)
19221-0191
19221-0192
19221-0311
19221-0312
19221-0341
19221-0342
19221-0367
19221-0368
HDC-400382-CC
HDC-400122-CC
HDCL-400382-CC
HDCL-400122-CC
HDCL-40038-CC
HDCL-40012-CC
HDC-40012-CC
HDC-40058-CC
202.70 mm²
Insulation Diameter
Wire Strip Length
Maximum
In
mm
In
mm
1.590
40.37
N/A
N/A
1.590
40.37
N/A
N/A
2.280
57.91
N/A
N/A
2.280
57.91
N/A
N/A
2.469
62.71
N/A
N/A
2.469
62.71
N/A
N/A
1.594
40.49
N/A
N/A
1.594
40.49
N/A
N/A
Wire Size: 500 MCM AWG
Terminal
No.
Terminal
Eng No. (REF)
19221-0193
19221-0194
19221-0313
19221-0314
19221-0343
19221-0344
19221-0369
19221-0370
HDC-500382-CC
HDC-500122-CC
HDCL-500382-CC
HDCL-500122-CC
HDCL-50038-CC
HDCL-50012-CC
HDC-50012-CC
HDC-50058-CC
253.40 mm²
Insulation Diameter
Wire Strip Length
Maximum
In
mm
In
mm
1.810
45.97
N/A
N/A
1.810
45.97
N/A
N/A
2.860
72.64
N/A
N/A
2.860
72.64
N/A
N/A
3.063
77.80
N/A
N/A
3.063
77.80
N/A
N/A
1.907
48.44
N/A
N/A
1.797
45.64
N/A
N/A
UNCONTROLLED COPY
Page 18 of 29
Hydraulic Dieless Crimping Tool
3.3 Crimping Terminals
INDENTOR
NIB
Before crimping, set the recommended air pressure gauge
to obtain the proper crimp . See Section 2.2 (Adjustments).
WIRE STOP
1. Adjust wire stop to position terminal barrel centered on
the Indentor nibs. See Figure 3-.1
2. Adjust wire stop so conductor is visible beyond
terminal barrel but not so far that it effects use of
terminal.
3. Position the terminal in the locator as shown in Figure
3-2 and 3-3. Insert the properly stripped wire into the
terminal barrel. The wire ends should butt up against
the wire stop of the locator.
WIRE
INDENTOR NIB
MOVABLE
JAWS (NIBBS)
ADJUSTABLE
WIRE STOP
CENTER BARREL
BETWEEN NIBS
Figure 3-1
ADJUSTABLE
WIRE STOP
MOVABLE
JAW (NIBB)
TERMINAL
Figure 3-2
Figure 3-3
TERMINAL
4. If the terminal is to big or the barrel of the terminal has a closed
end, take off the locators and the wire stop. Position the
terminal in the center of the jaws. Insert the properly stripped
wire visually into the terminal barrel. as shown in Figure 3-4.
5. Depress the pedal on the Air / Hydraulic pump to activate the
jaws. The crimping process is done in small increments
gradually allowing the press to fully crimp the terminal onto the
wire.
6. After the terminal is fully crimped, depress the elevated portion
of the pedal to release the pump. This will allow the jaws to
release.
7. Remove the crimped terminal and inspect for proper crimp
location.
Doc No. TM-638161700 Release Date: 03-21-14
Revision: D
Revision Date: 05-10-17
UNCONTROLLED COPY
TIGHTEN TO
SECURE THE
WIRE STOP
REMOVE WIRE
STOP AND
LOCATORS
HEAVY DUTY
TERMINAL
Figure 3-4
Page 19 of 29
Hydraulic Dieless Crimping Tool
3.4 Adjusting the Pump Release Mechanism
(See Figure 3-5)
1. Loosen the Adjusting Screw.
2. Verify that the Adjusting Plate is free.
3. Depress the Air Inlet Stem with the Foot
Pedal. The pump will now run and
build pressure.
4. Release the Foot Pedal. The pump will stop
running, but the hydraulic pressure will
be held.
5. With the Foot Pedal resting on the Air Inlet
Stem rotate the Adjusting Plate clockwise
until a stop is felt.
AIR INLET
STEM
FOOT PEDAL
Figure 3-5
ADJUSTING
ADJUSTING PLATE
SCREW
HEX STEM
Note: If the end of the slot in the Adjusting Plate is met before a stop is f elt, the Adjusting Plate
must be repositioned one step counter-clockwise on the Hex Stem, then repeat step 5.
6. Tighten the Adjusting Screw. The release mechanism is now properly set.
Doc No. TM-638161700 Release Date: 03-21-14
Revision: D
Revision Date: 05-10-17
UNCONTROLLED COPY
Page 20 of 29
Hydraulic Dieless Crimping Tool
Section 4
Maintenance
4.1
Lubrication
4.2
Bleeding Air From the System
4.3
Inspecting the Hydraulic Fluid Level
4.4
Draining and Flushing the Reservoir
4.5
Refilling the Bladder
4.6
Periodic Cleaning
4.7
Spare Parts
4.8
Perishable Parts
4.9
Storage
Doc No. TM-638161700 Release Date: 03-21-14
Revision: D
Revision Date: 05-10-17
UNCONTROLLED COPY
Page 21 of 29
Hydraulic Dieless Crimping Tool
4.1
Lubrication
WARNING: Any repair or servicing, which requires dismantling the pump must be performed in a dirtfree environment by a qualified technician.
CAUTION: Always disconnect the air supply before all maintenance
If the pump is operated on a continuous duty cycle for extended periods, the manufacturer recommends an
automatic air line oiler be installed in the air inlet as close to the pumping unit as possible.
Set the unit to feed approximately 1 drop of oil per minute into the system. Use SAE grade oil (5W to 30W).
4.2 Bleeding Air From The System
During the initial moments of activation or after prolonged use, a significant amount of air may accummulate
within the hydraulic system. This entrapped air may cause the cylinder to respond slowly or behave in an
unstable manner.
To remove the air, run the system through several cycles (extending and retracting the ram) free of any load.
The rams must be at a lower level than the pump to allow air to be released through the pump bladder.
4.3 Inspecting The Hydraulic Fluid Level
CAUTION: Always disconnect the air supply before all maintenance
1. Check the oil level in the bladder after every 10 hours of use.
2. Drain and replenish the bladder with Power Team hydraulic oil after every 300 hours of use.
Hoses: Hydraulic hoses on this unit carry a rating of 10,000 PSI.
Replacement hoses must carry the same rating.
4.4 Draining and Flushing the Reservoir.
IMPORTANT: Wipe the pump exterior completely clean before attempting this procedure!
1.
2.
3.
4.
Drain the bladder of all oil and refill half full with clean hydraulic oil. Rinse the filter clean.
Run the unit for serveral minutes.
Drain and clean the bladder once more.
Refill the bladder with Power Team hydraulic oil.
IMPORTANT: Drain and clean the other hydraulic system components such as the hoses, cylinders, etc.
before reconnecting them to the pump. This will prevent contaminated fluid from entering the pump again.
4.5 Refilling The Bladder
CAUTION: Always disconnect the air supply before all maintenance
1. If additional oil must be added to the reservoir, use only an approved high grade hydraulic oil such as
Power Team (215 SSU @ 100° F(38°C)).
Doc No. TM-638161700 Release Date: 03-21-14
Revision: D
Revision Date: 05-10-17
UNCONTROLLED COPY
Page 22 of 29
Hydraulic Dieless Crimping Tool
2.
3.
4.
5.
Clean the entire area around the filler cap before adding oil to the bladder.
Position the pump with the filler in the upright position.
Remove the filler cap and insert a clean funnel with filter.
The ram must be fully retracted and the air supply disconnected when adding the oil to the bladder.
4.6 Periodic Cleaning
CAUTION: Always disconnect the air supply before all maintenance
A routine should be established to keep the pump as free from dirt as possible.
1.
2.
3.
4.
All unused couplers should be sealed with thread protectors.
All hose connections must be free of grit and grime.
Any equipment hooked up to the pump should also be kept clean.
Use only an approved, clean hydraulic oil in this unit and change as recommended (every 300 hours).
An example of a maintenance chart is shown below. Copy and use this chart to track the maintenance of
your 63816-1700 Dieless 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
Daily: Clean. See Section 3.5.
As Required: Lubricate. See Section 3.1.
CHECK SHEET MONTH
Week
Daily Use
YEAR _________
Days of the Week
MON
TUE
WED
THU
FRI
SAT
Solution
SUN
1
2
3
4
Lubrication
Change Hydraulic
oil
Bleeding Air From
the System
1 drop per minute
into the system
300 Hours
After prolong use
Refilling Reservoir
10 hours or when needed
Cleaning
Hose connections free of grit
and dirt. Pump kept clean
Use SAE No. 10 Oil
Hydraulic oil
215 SSU @ 100° F(38°C)
Run the system thru
several cycles.
Hydraulic oil
215 SSU @ 100° F(38°C)
Use soft cloth
Schedule should be adjusted up or down depending on usage. Molex recommends that a log of preventive
maintenance be kept with the tool.
Doc No. TM-638161700 Release Date: 03-21-14
Revision: D
Revision Date: 05-10-17
UNCONTROLLED COPY
Page 23 of 29
Hydraulic Dieless Crimping Tool
4.7 Spare Parts
Customers are responsible for maintaining the tool. Spare parts are available from Molex. Moving and
functioning parts can be damaged or wear out over time and will require replacement. Molex recommends that
the customer keep some or all of them in stock to reduce production down time. These parts are identified in the
Repair Parts List. See Section 5.2.
4.8 Perishable Parts
Customers are responsible for maintaining the 63816-1700 Dieless Crimping Tool. Perishable parts are
those parts that come in contact with the product and will wear out over time. Molex recommends that all
customers keep at least one set of the perishable tooling in stock at all times. This will reduce the amount of
production down time.
4.9 Storage
When storing the 63816-1700 assembly, disconnect the air supply and store in a dry location. If the pump is
disconnected from the dieless crimping Tool, reinstall the dust cap on the cylinder inlet. When transporting,
reinstall the red-vented cap on the pump reservoir.
Doc No. TM-638161700 Release Date: 03-21-14
Revision: D
Revision Date: 05-10-17
UNCONTROLLED COPY
Page 24 of 29
Hydraulic Dieless Crimping Tool
Section 5
5.1
Parts Lists and Assembly Drawings
5.2
Troubleshooting
Doc No. TM-638161700 Release Date: 03-21-14
Revision: D
Revision Date: 05-10-17
UNCONTROLLED COPY
Page 25 of 29
Hydraulic Dieless Crimping Tool
5.1 Main Parts List and Assembly Drawing
Item
1
2
3
4
5
63816-1700 Main Assembly - Figure 5-1
Order No.
Description
63816-1710
Crimp Head Assembly
63816-1711
Hydraulic Hose Assembly – 10 ft.
63816-1720
Air / Hydraulic Pump Power Unit
19286-0049
Filter Regulator with Gauge
19286-0103
Air Hose 1/4 NPT Male Fitting-10 Feet
Qty
1
1
1
1
1
4
5
2
3
1
Figure 5-1
Doc No. TM-638161700 Release Date: 03-21-14
Revision: D
Revision Date: 05-10-17
UNCONTROLLED COPY
Page 26 of 29
Hydraulic Dieless Crimping Tool
5.2 Repair Parts
The following is a list of spare and perishable parts that are available:
63816-1710 Repair Parts - Figure 5-2
Item
Order No.
Description
1
63816-1712
Hydraulic Cylinder
2
63816-1713
Main Seal for Item 1
3
63816-1714
Retract Spring for Item 1
4
63816-1715
Indenter, large
5
63816-1716
Indenter, small
6
63816-1717
Base and locator assembly
Qty
1 Ref (Repair Part)
1 Ref (Repair Part)
1 Ref (Repair Part)
2 Ref (Repair Part)
2 Ref (Repair Part)
Ref
1
2
Figure 5-2
3
5
4
6
5
4
Doc No. TM-638161700 Release Date: 03-21-14
Revision: D
Revision Date: 05-10-17
UNCONTROLLED COPY
Page 27 of 29
Hydraulic Dieless Crimping Tool
5.3 Troubleshooting
Symptom
Pump reciprocates
but no oil delivery.
(Ram will not extend)
Low oil delivery.
(Ram extends
slowly)
Cause
Low oil level.
Release improperly adjusted.
Inadequate air supply.
1. Check air input supply.
2. Contamination,
check air side of the pump.
Hydraulic failure.
Air in hydraulic system.
Release improperly adjusted.
Pump will not build to
maximum pressure.
(No visible leakage)
Pump builds pressure
but will not hold
system pressure.
Solution
1. Add oil see Refilling The Bladder Section 4-5.
2. See Adjusting the Pump Release Mechanism
Section 3.4.
1. Should be 20 CFM mininum.
2. Clean and reassemble. Thoroughly inspect the
slot inthe air cylinder tube.
Check the oil filter for contamination. Clean and
reinstall.
See Bleeding Air From The System Section 4-2.
See Adjusting the Pump Release Mechanism
Section 3.4.
Check the air supply.
100 PSI (7 BAR) is required to obtain maximum
pressure.
Check hydraulic connections.
Refit as needed.
Application Tooling Support
Phone: +1-402-458-TOOL (8665)
E-Mail: applicationtooling@molex.com
Website: www.molex.com/applicationtooling
Molex is a registered trademark of Molex, LLC in the United States of America and may be registered in other countries; all other
trademarks listed herein belong to their respective owners.
Doc No. TM-638161700 Release Date: 03-21-14
Revision: D
Revision Date: 05-10-17
UNCONTROLLED COPY
Page 28 of 29
Hydraulic Dieless Crimping Tool
For more information use the Crimping Testing and Inspection Handbook for Industrial (Closed Barrel
products).
There is no charge for this book, which can be found on the Molex website (www.molex.com) or contact your local
Molex sales engineer.
Doc No. TM-638161700 Release Date: 03-21-14
Revision: D
Revision Date: 05-10-17
UNCONTROLLED COPY
Page 29 of 29
