Molex 105300 Series User manual

Hand Crimp Tool for Nano-Fit Crimp Terminals

Doc No: ATS-6382760HM Release Date: 10-17-14 UNCONTROLLED COPY Page 1 of 7

Revision: B Revision Date: 10-28-20

CONDUCTOR

BRUSH

STRIP LENGTH

SEAM

CONDUCTOR

CRIMP HEIGHT

CUT-OFF

TAB

BELL MOUTH

BEND UP

TWIST

ROLL

BEND

DOWN

WIRE

INSULATION CRIMP

Application Tooling Specification

FEATURES

A full cycle ratcheting hand tool ensures complete crimps

Ergonomically designed soft handles

Precisely designed crimping profiles with simple contact positioning

Easy handling due to outstanding force ratio

This tool is IPC/WHMA-A-620 Class 2 compliant as indicated and RoHS compliant

Modular crimp head is removable and can be used in the Electric Crimp Machine (Order No.

63816-1500), accompanied by Battery Powered Crimp Adapter (Order No. 63816-0600)

Can also be used in the Battery Powered Tool Order No. 63816-0270 (110 V) or 63816-0280

(220 V), accompanied by Battery Powered Crimp Adapter (Order No. 63816-0600)

SCOPE

Products: Nano-Fit Receptacle Terminals, 24 AWG and 26 AWG, UL1061 and UL1007 Insulations.

Terminal

Series

No.

Terminal Order No.

Wire Size

Insulation Diameter

Strip Length

IPC/WHMA-A-620 (1)

Terminal (2)

AWG

mm²

In.

105300

105300-1100

105300-1200

24-26

—

1.10-1.40

.043-.055

0.99-1.40

.039-.055

2.50-3.50

.098-.138

105300-1300

105300-1400

(1) To achieve optimum IPC/WHMA-A-620 Class 2 insulation crimps, use this insulation OD.

(2) Overall insulation OD specification for terminal.

DEFINITION OF TERMS

TYPE 4A

Order Number

63827-6000

Hand Crimp Tool for Nano-Fit Crimp Terminals

Doc No: ATS-6382760HM Release Date: 10-17-14 UNCONTROLLED COPY Page 2 of 7

Revision: B Revision Date: 10-28-20

CRIMP SPECIFICATION

Terminal Series No.

Bell Mouth

Cut-Off Tab Maximum

Conductor Brush

In.

105300

0.15-0.25

.006-.010

0.17

.007

0.25-1.00

.010_.039

Terminal Series No.

Bend Up

Bend Down

Twist

Roll

Seam

Degree

105300

Seam shall not be open

and no wire allowed out of

the crimping area

After crimping, the conductor profiles should measure the following:

Terminal

Series No.

Wire Size

Conductor Crimp

Insulation Crimp▲

Pull Force

Minimum

Profile

Height

Width (Ref)

Height (Ref)

Width (Ref)

AWG

mm2

In.

Lb.

105300

—

0.70-0.75

.027-.030

1.15

.045

1.60

.063

1.55

.061

22.3

1.70

.067

1.70

.067

—

0.65-0.70

.025-.027

1.15

.045

1.55

.061

1.55

.061

13.4

1.65

.065

1.70

.067

▲To achieve IPC/WHMA-A-620 Class 2 crimps, the following overall wire insulation diameter ranges are recommended:

Profile A (UL1061): 1.10-1.20mm (.043-.047”)

Profile B (UL1007): 1.30-1.40mm (.051-.055”)

Profile C (UL1061): 1.05-1.15mm (.041-.045”)

Profile D (UL1007): 1.20-1.30mm (.047-.051”)

Tool Qualification Notes

1. Pull force should be measured with no influence from the insulation crimp.

2. The above specifications are guidelines to an optimum crimp.

Notes

1. This tool should only be used for the terminals and wire gauges specified on this sheet.

2. This tool is not adjustable for crimp height. Variations in tools, terminals, wire stranding and

insulation types may affect crimp height.

3. This tool is intended for standard conductor sizes. It may not give a good insulation crimp

support for all insulation sizes.

4. Molex does not repair hand tools (see warranty above). The replacement parts listed are the

only parts available for repair. If the handles or crimp tooling is damaged or worn, a new tool

must be purchased.

5. Pull force should be used as the final criterion for an acceptable crimp. Pull force is measured

with no influence from the insulation crimp. The insulation should be stripped long (1/2 in.) so

the insulation grips on the terminal do not grip the wire insulation or the conductor. Refer to

the Molex Quality Crimping Handbook 63800-0029 for additional information on crimping and

crimp testing.

6. Molex does not certify hand crimp tools.

Hand Crimp Tool for Nano-Fit Crimp Terminals

Doc No: ATS-6382760HM Release Date: 10-17-14 UNCONTROLLED COPY Page 3 of 7

Revision: B Revision Date: 10-28-20

WIRE

INSULATION

PUNCH

TERMINAL

WIRE STOP BLADE

Figure 3

OPERATION

Open the tool by squeezing the handles together. At the end of the closing stroke, the ratchet

mechanism will release the handles, and the hand tool will spring open.

1. With the hand tool in the open position, pivot the terminal

locator open by pulling on the locator knob, and lift the

wire stop blade. See Figure 1.

2. Insert the terminal into the correct profile until the

terminal is fully seated and stops. Make sure the wire

stop blade is fully in the up position.

3. Gently pivot the locator closed.

4. Bring down the wire stop blade. Make sure the wire stop

blade is fully seated on the terminal behind the conductor

grip section.

5. Slide the pre-stripped wire into the terminal. Make sure to

aim the wire brush toward the tip point on the wire stop

blade. See Figure 2. Align the wire so that it is parallel

and sitting into the terminal. Maintain a light and constant

pressure on the wire that is seated in the

terminal at all times. (Do not let go of the wire.)

Be sure to hold the wire and terminal in place

until the terminal is fully crimped. See Figure 3.

6. Close the tool until the ratchet releases. The tool handles

will then spring open.

7. Lift the wire stop blade.

8. Carefully remove the crimped terminal. Pivot the

terminal locator slightly out, if necessary. See Figure 4.

Note: The tamper-proof ratchet action will not release the tool

until it has been fully closed.

Note: To maintain good brush control and a consistent bell

mouth, the crimping instructions must be followed.

TERMINAL

SEATED IN

LOCATOR

SWING

LOCATOR OPEN

Figure 1

HAND

TOOL

OPEN

WIRE

STOP

BLADE

PIVOT

LOCATOR

Figure 4

REMOVE

CRIMPED

WIRE

Figure 2

WIRE

TERMINAL

LOCATOR

INSULATION

PUNCH

INSULATION

ANVIL

WIRE STOP

BLADE

CONDUCTOR ANVIL

CONDUCTOR

PUNCH

Hand Crimp Tool for Nano-Fit Crimp Terminals

Doc No: ATS-6382760HM Release Date: 10-17-14 UNCONTROLLED COPY Page 4 of 7

Revision: B Revision Date: 10-28-20

INCORRECT

Figure 6

CORRECT

INCORRECT

M4 BHCS

PIVOT

LOCATOR

Figure 5

TERMINAL LOCATOR REPLACEMENT

This section describes the procedure for changing locators:

Removal

1. With the tool in the open position, pivot the terminal locator outward.

2. Remove the M4 BHCS. See Figure 5.

Installation

1. Place the locator on the hand tool. Install the M4 BHCS. See Figure 5.

2. Tighten the screw just enough to hold the locator. Make sure the locator can still float freely

with hand pressure.

3. Fully insert the proper terminal into the correct profile slot until the terminal is completely

seated and stops. Then, gently pivot the locator closed.

4. With hand pressure, slowly slide the locator to the correct position. See Figure 6.

5. Gently pivot the locator open without disturbing the location.

6. Hold the locator firmly in place, and slowly tighten the M4 BHCS.

MAINTENANCE

It is recommended that each operator of the tool be made aware of and responsible for the following

maintenance steps:

1. Remove dust, moisture and other contaminants with a clean brush or a soft, lint-free cloth.

2. Do not use any abrasive materials that could damage the tool.

3. Make certain all pins, pivot points and bearing surfaces are protected with a thin coat of high-

quality machine oil. Do not oil excessively. The tool was engineered for durability, but like

any other equipment, it needs cleaning and lubrication for a maximum service life of trouble-

free crimping. Light oil (such as 30 weight automotive oil) used at the oil points every 5,000

crimps or 3 months will significantly enhance the tool life.

4. Wipe excess oil from the hand tool, particularly from the crimping area. Oil transferred from

the crimping area onto certain terminations may affect the electrical characteristics of an

application.

5. When the tool is not in use, keep the handles closed to prevent objects from becoming

lodged in the crimping dies, and store the tool in a clean, dry area.

Miscrimps or Jams

Should this tool ever become stuck or jammed in a partially closed position, do not force the

handles open or closed. The tool will open easily by lifting the ratchet release lever. See Figure 10.

Hand Crimp Tool for Nano-Fit Crimp Terminals

Doc No: ATS-6382760HM Release Date: 10-17-14 UNCONTROLLED COPY Page 5 of 7

Revision: B Revision Date: 10-28-20

Warranty

This tool is for electrical terminal crimping purposes only. This tool is made of the best quality

materials. All vital components are long-life tested. All tools are warranted to be free of

manufacturing defects for a period of 30 days. Should such a defect occur, Molex will repair or

exchange the tool free of charge. This repair or exchange will not be applicable to altered, misused

or damaged tools. This tool is designed for hand use only. Any clamping, fixturing or use of handle

extensions voids this warranty.

CAUTION: Repetitive use of this tool should be avoided.

CAUTIONS

1. Manually powered hand tools are intended for low-volume use or field repair. This tool is

NOT intended for production use. Repetitive use of this tool should be avoided.

2. Insulated rubber handles are not protection against electrical shock.

3. Wear eye protection at all times.

4. Use only the Molex terminals specified for crimping with this tool.

CAUTION: Molex crimp specifications are valid only when used with Molex terminals and

tooling.

Hand Crimp Tool for Nano-Fit Crimp Terminals

Doc No: ATS-6382760HM Release Date: 10-17-14 UNCONTROLLED COPY Page 6 of 7

Revision: B Revision Date: 10-28-20

APPLICATIONS FOR THE MODULAR CRIMP HEAD

WARNING: NEVER operate, service, install or adjust this modular crimp head without proper

instruction and without first reading and understanding the instructions in the proper manual

or specification sheet. See chart below for the correct manual or specification sheet.

WARNING: NEVER install tooling or service this tool while it is plugged into any power source.

Disconnect the power by unplugging, or turn off the actuator from its power source.

CAUTION: Keep fingers away from the crimping area when operating this tool. It may cause

severe injury.

CAUTION: Wear safety glasses when operating or servicing this tool.

The chart below shows all applications for this modular crimp head:

Tool Order No.

Tool Description

Adapter Order No.

Adapter Description

Figure No.

63816-0000

Hand Crimp Frame (Short)

—

63816-0050

Hand Crimp Frame (Long)

—

63816-0270

Battery Power Tool (110 V)

63816-0600

Battery Power Crimp Adapter

63816-0280

Battery Power Tool (220 V)

63816-0600

Battery Power Crimp Adapter

63816-1500

Electric Crimp Machine

63816-0600

Battery Power Crimp Adapter

Applications for the Modular Crimp Head

Hand Crimp Tool

Battery Powered Tool

Electric Crimp Machine

Figure 7

Figure 8

Figure 9

MODULAR

CRIMP

HEAD

LOCKING

PINS

HAND CRIMP

FRAME LONG

OR SHORT

MODULAR

CRIMP

HEAD

BATTERY

POWERED

CRIMP

ADAPTER

LOCKING

PINS

LOCKING

PINS

BATTERY

POWERED

TOOL

ELECTRIC

CRIMP

MACHINE

MODULAR

CRIMP HEAD

BATTERY

POWER CRIMP

ADAPTER

Hand Crimp Tool for Nano-Fit Crimp Terminals

Doc No: ATS-6382760HM Release Date: 10-17-14 UNCONTROLLED COPY Page 7 of 7

Revision: B Revision Date: 10-28-20

RATCHET

RELEASE LEVER

HANDLE

SPRING

CRIMPING

SPRING (2)

LOCATOR

Figure 10

M4 X 12mm

LONG BHCS

M4 LOCKNUT

PARTS LIST

Item

Order Number

Description

Quantity

63827-6070

Modular Crimp Head

63816-0000

Hand Crimp Frame (Short)

63827-6075

Locator

63816-0001

Locking Pin

63600-0525

Handle Spring

63600-0520

Crimping Spring

Application Tooling Support

Phone: (402) 458-TOOL (8665)

E-Mail: [email protected]

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.

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