Molex 207129 Series User manual

Hand Tool for Appli-Mate RAST5 Connectors

Doc No: ATS-6382763HM Release Date: 10-01-14 UNCONTROLLED COPY Page 1 of 9

Revision: A Revision Date: 10-01-14

Application Tooling

Specification Sheet

Modular Crimp Head

Order No. 63827-6370

Hand Crimp Tool

Order No. 63827-6300

FEATURES

A full cycle ratcheting hand tool ensures complete terminations

Ergonomically designed soft handles

Wire gripping comb holds wires in place before termination

Easy handling due to outstanding force ratio

Modular Crimp Head is removable and can be used in the Air Powered Tool Order No.63816-0100,

accompanied by Air Powered Crimp Adapter (Order No. 63816-0700)

Modular Crimp Head can also be used in the Battery Powered Tool Order No.63816-0200 (110 V) or 63816-

0250 (220 V), accompanied by Battery Powered Crimp Adapter (Order No. 63816-0600)

SCOPE

Products: Appli-Mate RAST5 connectors, 1 –12 circuits, 0.38mm² –1.5mm² wires.

Connector Series

Connector Order No.

Wire Size

Insulation Diameter

mm²

In.

91954

See table below

0.38

1.3 –1.5

0.051 –0.059

90833, 91338, 91777, 91778, 91886, 93052, 93057, 93213

See table below

0.5 –0.75

2.0 –2.5

0.078 –0.098

90835, 91247, 91779, 92000, 93210, 93396

See table below

1.0 –1.5

2.65 –3.10

0.104 –0.122

Customer to cut off connector from molded chain

Contact Molex about approved AWG wires for these products

Connector Series

Assembly Order Number

90833

90833-0001

90833-0002

90833-0003

90833-0004

90833-0005

90833-0006

90833-0007

90833-0008

90833-0009

90833-0010

90833-0011

90833-0012

90833-0013

90833-0014

90833-0015

90833-0016

90833-0017

90833-0018

90833-0019

90833-0020

90833-0021

90833-0022

90833-0025

90833-0026

90833-0027

90833-0028

90833-0032

90833-0047

90833-0048

90833-0050

90833-0051

90833-0052

90833-0053

90833-0054

90833-0056

90833-0057

90833-0058

90833-0059

90833-0060

90833-0061

90833-0062

90833-0063

90833-0064

90833-0065

90833-0066

90833-0068

90833-0069

90833-0500

90833-0501

90833-0502

90833-0503

90833-0504

90833-0505

90833-0506

90833-0507

90833-0508

90833-0509

90833-0510

90833-0511

90833-0513

90833-0524

90833-0525

90833-0526

90833-0528

90833-0529

90833-0530

90833-0531

90833-0532

90833-0533

90833-0534

90833-0535

90833-0536

90833-0537

90833-0538

90833-0539

90833-0540

90833-0541

90833-0542

90833-0543

90833-0544

90833-1251

90833-1252

90833-1253

90833-1254

90833-1255

90833-1256

90833-1257

90833-1258

90833-1259

90833-1260

90833-1261

90833-1262

90833-1264

90833-1267

90833-1271

90833-1272

90833-1273

90833-1276

90833-1277

90833-1279

90833-1282

90833-1283

90833-1284

90833-2001

90833-2002

90833-2006

90833-2007

90833-2008

90833-2010

90833-2011

90833-2012

90833-2019

90833-2023

90833-2024

90833-2025

90833-2026

90833-2027

90833-2028

90833-2029

90833-2750

90833-2751

90833-2752

90833-2764

90833-2765

90833-2773

90833-2776

90833-2777

90833-2778

90833-2779

90833-2780

90833-2781

90833-3500

90833-3501

90833-3502

90833-3503

90833-3513

90833-3514

90833-3518

90833-3520

90833-3521

90833-3522

90833-3523

90833-3524

90833-4250

90833-4251

90833-4254

90833-4255

90833-4256

90833-4261

90833-4264

90833-4266

90833-5000

90833-5001

90833-5004

90833-5010

90833-5012

90833-6000

90833-6001

90833-6005

90833-6006

90833-6007

90833-6008

90833-6023

90833-6024

90833-6025

90833-7000

90833-7001

90833-8000

90833-8001

90833-9001

90833-9002

90833-9003

90833-9004

90833-9005

90833-9006

90833-9021

90833-9022

90833-9023

90833-9024

90833-9025

90833-9026

90833-9027

90833-9028

90833-9029

90833-9101

90833-9102

90833-9103

90833-9104

90833-9105

90833-9106

90833-9201

90833-9202

90833-9203

90833-9204

90833-9205

90833-9206

90833-9301

90833-9302

90833-9303

90833-9304

90833-9305

90833-9306

90833-9401

90833-9402

90833-9403

90833-9404

90833-9405

90833-9501

90833-9502

90833-9503

90833-9504

90833-9601

90833-9602

90833-9603

90833-9701

90833-9702

90833-9703

90833-9704

90833-9705

90833-9801

90833-9901

90835

90835-0001

90835-0003

90835-0019

90835-0034

90835-0035

90835-0036

90835-0037

90835-0038

90835-0039

90835-0040

TYPE 4A

Hand Tool for Appli-Mate RAST5 Connectors

Doc No: ATS-6382763HM Release Date: 10-01-14 UNCONTROLLED COPY Page 2 of 9

Revision: A Revision Date: 10-01-14

Connector Series

Assembly Order Number

90835-0041

90835-0042

90835-0043

90835-0044

90835-0045

90835-0046

90835-0047

90835-0048

90835-0057

90835-0058

90835-0500

90835-0501

90835-0502

90835-0518

90835-0519

90835-0520

90835-0521

90835-0522

90835-0523

90835-0534

90835-0536

90835-0537

90835-1251

90835-1254

90835-1268

90835-1269

90835-1273

90835-1281

90835-1283

90835-1284

90835-1285

90835-9001

90835-9002

90835-9003

90835-9004

90835-9005

90835-9006

90835-9021

90835-9022

90835-9023

90835-9024

90835-9025

90835-9026

90835-9027

90835-9101

90835-9102

90835-9103

90835-9104

91247

91247-0001

91247-0002

91247-0003

91247-0004

91247-0005

91247-0006

91338

91338-0001

91338-0002

91338-0003

91338-0004

91338-0005

91338-0006

91338-0007

91338-0008

91338-0009

91338-0010

91338-0011

91338-0012

91338-0013

91338-0102

91338-0103

91338-0104

91338-0105

91338-0403

91338-0501

91338-0507

91338-0601

91338-0607

91338-0700

91338-0701

91338-0800

91338-0801

91338-1001

91338-1002

91338-1003

91338-1004

91338-1005

91338-1006

91338-1007

91338-3102

91338-3103

91338-3104

91338-3105

91338-3403

91338-3501

91338-3507

91338-3601

91338-3607

91338-3700

91338-3800

91338-3801

91777

91777-0001

91777-0002

91777-0003

91777-0004

91777-0005

91777-0006

91777-0007

91777-0008

91777-0009

91777-0010

91777-0011

91777-0012

91777-0013

91777-0014

91777-0015

91777-0016

91777-0017

91777-0018

91777-0019

91777-0020

91777-0021

91777-0022

91777-0023

91777-0024

91777-0025

91777-0026

91777-0027

91777-0028

91777-0029

91777-0030

91777-0031

91777-0032

91777-0102

91777-0103

91777-0104

91777-0105

91777-0106

91777-0107

91777-3102

91777-3103

91777-3104

91777-3105

91777-3106

91777-3107

91778

91778-0001

91778-0002

91778-0003

91778-0004

91778-0005

91778-0006

91778-0007

91778-0008

91778-0009

91778-0010

91778-0011

91778-0012

91778-0013

91778-0014

91778-0015

91778-0016

91778-0017

91778-0018

91778-0019

91778-0020

91778-0021

91778-0022

91778-0023

91778-0024

91778-0025

91778-0026

91778-0027

91778-0028

91778-0029

91778-0030

91778-0031

91778-0032

91778-0033

91778-0034

91778-0035

91778-0036

91778-0037

91778-0038

91778-0039

91778-0040

91778-0042

91778-0043

91778-0044

91778-0101

91778-0102

91778-0103

91778-0104

91778-0105

91778-0106

91778-0107

91778-0108

91778-0109

91778-0110

91778-0111

91778-0112

91778-0113

91778-0114

91778-0115

91778-0116

91778-0117

91778-0118

91778-0119

91778-0120

91778-0121

91778-0122

91778-0123

91778-0124

91778-0125

91778-0126

91778-0127

91778-0128

91778-0129

91778-0130

91778-0131

91778-0132

91778-0133

91778-0134

91778-0135

91778-0136

91778-0137

91778-0138

91778-0139

91778-0140

91778-0141

91778-0142

91778-0143

91778-0144

91778-0145

91778-0201

91778-0202

91778-0203

91778-0204

91778-0205

91778-0206

91778-0207

91778-0208

91778-0209

91778-0210

91778-0211

91778-0212

91778-0213

91778-0214

91778-0215

91778-0216

91778-0217

91778-0218

91778-0219

91778-0220

91778-0301

91778-0302

91778-0303

91778-0304

91778-0305

91778-0306

91778-0307

91778-0308

91778-0309

91778-0310

91778-0311

91778-0312

91778-0313

91778-0314

91778-0315

91778-0316

91778-0317

91778-0318

91778-0319

91778-0320

91778-0401

91778-0402

91778-0403

91778-0404

91778-0405

91778-0406

91778-0407

91778-0408

91778-0409

91778-0410

91778-0501

91778-0502

91778-0503

91778-0504

91778-0505

91778-0506

91778-0507

91778-0508

91778-0509

91778-0510

91778-0511

91778-0512

91778-0513

91778-0514

91778-0515

91778-0516

91778-0601

91778-0602

91778-0603

91778-0604

91778-0605

91778-0606

91778-0607

91778-0608

91778-0609

91778-0610

91778-0701

91778-0702

91778-0703

91778-0704

91778-0705

91778-0706

91778-0707

91778-0708

91778-0709

91778-0801

91778-0802

91778-0803

91778-0804

91778-0805

91778-0806

91778-0807

91778-0808

91778-0809

91778-0810

91778-0811

91778-0812

91778-0813

91778-0901

91778-0902

91778-1001

91778-1002

91778-9021

91778-9022

91778-9023

91778-9024

91778-9031

91778-9032

91778-9033

91778-9034

91778-9035

91778-9036

91778-9037

91778-9041

91778-9042

91778-9043

91778-9051

91778-9052

91778-9053

91778-9054

91778-9055

91778-9056

91778-9061

91778-9062

91778-9063

91778-9064

91778-9065

91778-9071

91778-9072

91778-9073

91778-9074

91778-9081

91778-9082

91778-9083

91778-9084

91778-9085

91778-9091

91778-9092

91778-9093

91778-9094

91778-9095

91778-9096

91778-9097

91778-9098

91778-9101

91778-9102

91778-9103

91778-9104

91778-9105

91778-9106

91778-9107

91778-9111

91778-9121

91779

91779-0001

91779-0002

91779-0003

91779-0004

91779-0005

91779-0006

91779-0007

91779-0008

91779-0009

91779-0010

91779-0019

91779-0101

91779-0102

91779-0103

91779-0104

91779-0105

91779-0106

91779-0107

91779-0108

91779-0109

91779-0110

91779-0111

91779-0112

91779-0113

91779-0114

91779-0115

91779-0116

91779-0201

91779-0202

91779-0203

91779-0204

91779-0205

91779-0206

91779-9001

91779-9002

91779-9003

91779-9004

91779-9101

91779-9102

91779-9103

91779-9104

91779-9105

91779-9106

91779-9201

91779-9202

91779-9203

91779-9204

91779-9205

91779-9206

91886

91886-0001

91886-0002

91886-0003

91886-0004

91886-0005

91886-0006

91886-0007

91886-0008

91886-0009

91886-0010

91886-0011

91886-0012

91886-0013

91886-0014

91886-0101

91886-0102

91886-0103

91886-0104

91886-0105

91886-0106

91886-0107

91886-0108

91886-0109

91886-0110

91886-0111

91886-0112

91886-0201

91886-0202

91886-0203

91886-0204

91886-0205

91886-0206

91886-0207

91886-0208

91886-0209

91886-0210

91886-0211

91886-0212

91886-0213

91886-0214

91886-0301

91886-0302

91886-0303

91886-0304

91886-0305

91886-0306

91886-0307

91886-0308

91886-0309

91886-0310

91886-0311

91886-0312

91886-0313

91886-0314

91886-0315

91886-0316

91886-0401

91886-0402

91886-0403

91886-0404

91886-0405

91886-0406

91886-0407

91886-0408

91886-0409

91886-0410

91886-0501

91886-0512

91886-0513

91886-0601

91886-0602

91886-0603

91886-0604

91886-0605

91886-0606

91886-0607

91886-0608

91886-0609

91886-0701

91886-0702

91886-0703

91886-0704

91886-0705

91886-0706

91886-0707

91886-0708

91886-0709

91886-0801

91886-0802

91886-0803

91886-0804

91886-0805

91886-0806

91886-0807

91886-0808

91886-0809

91886-0901

91886-0902

91886-1001

91886-1002

91886-9001

91886-9023

91886-9024

91886-9031

91886-9032

91886-9033

91886-9036

91886-9037

91886-9041

91886-9042

91886-9043

91886-9051

91886-9052

91886-9053

91886-9054

91886-9055

91886-9061

91886-9062

91886-9063

91886-9064

91886-9071

91886-9072

91886-9073

91886-9074

91886-9081

91886-9082

91886-9083

91886-9084

91886-9085

91886-9091

91886-9092

91886-9093

91886-9094

91886-9095

91886-9096

91886-9097

91886-9098

91886-9101

91886-9102

91886-9103

91886-9104

91886-9105

91886-9111

91886-9121

91954

91954-0001

91954-0002

91954-0003

91954-0004

91954-0005

91954-0006

91954-0007

91954-0008

91954-0009

91954-0010

91954-0011

91954-0012

91954-0013

91954-0014

91954-0015

91954-0016

91954-0017

91954-0018

91954-0019

91954-0020

Hand Tool for Appli-Mate RAST5 Connectors

Doc No: ATS-6382763HM Release Date: 10-01-14 UNCONTROLLED COPY Page 3 of 9

Revision: A Revision Date: 10-01-14

Connector Series

Assembly Order Number

91954-0021

91954-0022

91954-0023

91954-0024

91954-0025

91954-0026

91954-0027

91954-0028

91954-0029

91954-0030

91954-0031

91954-0041

91954-0042

91954-0043

91954-0044

91954-0045

91954-0046

91954-0047

91954-0048

91954-0049

91954-0050

91954-0051

91954-0052

91954-0053

91954-0054

91954-0055

91954-0056

91954-0057

91954-0058

91954-0059

91954-0060

91954-0061

91954-0062

91954-0063

91954-0064

91954-0065

91954-0066

91954-0067

91954-0068

91954-0069

91954-0070

91954-0071

91954-0072

91954-0073

91954-0074

91954-0075

91954-0076

91954-0077

91954-0078

91954-0079

91954-0080

91954-0081

91954-0082

91954-0083

91954-0084

91954-0085

91954-0086

91954-0087

91954-0088

91954-0089

91954-0090

91954-0091

91954-0092

91954-0093

91954-0094

91954-0095

91954-0096

91954-0097

91954-0098

91954-0099

91954-0100

91954-0101

91954-0102

91954-0103

91954-0104

91954-0105

91954-0106

91954-0107

91954-0108

91954-0109

91954-0110

91954-0111

91954-0112

91954-0113

91954-0114

91954-0115

91954-0116

91954-0117

91954-0118

91954-0119

91954-0120

91954-0121

91954-0122

91954-0201

91954-0202

91954-0203

91954-0204

91954-0205

91954-0206

91954-0207

91954-0208

91954-0209

91954-0210

91954-0211

91954-0212

91954-0301

91954-0302

91954-0303

91954-0304

91954-0305

91954-0306

91954-0307

91954-0308

91954-0309

91954-0310

91954-0311

91954-0312

91954-0313

91954-0314

91954-0401

91954-0402

91954-0403

91954-0404

91954-0405

91954-0406

91954-0407

91954-0408

91954-0409

91954-0501

91954-0502

91954-0503

91954-0504

91954-0505

91954-0506

91954-0507

91954-0508

91954-0509

91954-0601

91954-0602

91954-0603

91954-0604

91954-0605

91954-0606

91954-0607

91954-0608

91954-0701

91954-0702

91954-0703

91954-0704

91954-0705

91954-0706

92000

92000-0001

92000-0002

92000-0003

92000-0004

92000-0005

92000-0006

92000-0007

92000-0101

92000-0102

92000-0103

92000-0104

92000-0105

92000-0106

92000-0107

92000-0108

92000-0201

92000-0202

92000-0203

92000-0204

93052

93052-0001

93052-0002

93052-0003

93052-0004

93052-0005

93052-0006

93052-0007

93052-0008

93052-0009

93052-0010

93052-0011

93052-0012

93052-0013

93052-0014

93052-0015

93052-0016

93052-0017

93052-0018

93052-0019

93052-0020

93052-0021

93052-0022

93052-0025

93052-0027

93052-0032

93052-0047

93052-0048

93052-0050

93052-0051

93052-0052

93052-0053

93052-0054

93052-0056

93052-0057

93052-0058

93052-0059

93052-0060

93052-0061

93052-0062

93052-0063

93052-0064

93052-0066

93052-0069

93052-0070

93052-0071

93052-0072

93052-0073

93052-0074

93052-0075

93052-0076

93052-0077

93052-0500

93052-0501

93052-0502

93052-0503

93052-0504

93052-0505

93052-0506

93052-0507

93052-0508

93052-0509

93052-0510

93052-0511

93052-0513

93052-0524

93052-0525

93052-0526

93052-0528

93052-0529

93052-0530

93052-0531

93052-0532

93052-0533

93052-0534

93052-0535

93052-0536

93052-0537

93052-0540

93052-0541

93052-0542

93052-1000

93052-1251

93052-1252

93052-1253

93052-1254

93052-1255

93052-1256

93052-1257

93052-1258

93052-1259

93052-1260

93052-1264

93052-1267

93052-1271

93052-1272

93052-1273

93052-1276

93052-1277

93052-1279

93052-1282

93052-1283

93052-1284

93052-2001

93052-2002

93052-2006

93052-2007

93052-2008

93052-2010

93052-2011

93052-2012

93052-2019

93052-2023

93052-2025

93052-2026

93052-2027

93052-2028

93052-2029

93052-2750

93052-2751

93052-2752

93052-2764

93052-2765

93052-2773

93052-2776

93052-2777

93052-2778

93052-2779

93052-2780

93052-3500

93052-3501

93052-3502

93052-3503

93052-3513

93052-3514

93052-3518

93052-3520

93052-3521

93052-3522

93052-3523

93052-3524

93052-4250

93052-4251

93052-4254

93052-4255

93052-4256

93052-4261

93052-4264

93052-5000

93052-5001

93052-5010

93052-5012

93052-6000

93052-6001

93052-6005

93052-6006

93052-6007

93052-6008

93052-6023

93052-6024

93052-6025

93052-7000

93052-7001

93052-8000

93052-8001

93057

93057-0001

93057-0002

93057-0003

93057-0004

93057-0005

93057-0006

93057-0007

93057-0008

93057-0009

93057-0010

93057-0011

93057-0012

93057-0013

93057-0014

93057-0015

93057-0016

93057-0017

93057-0018

93057-0019

93057-0020

93057-0021

93057-0022

93057-0023

93057-0024

93057-0025

93057-0026

93057-0101

93057-0102

93057-0103

93057-0104

93057-0105

93057-0106

93057-0107

93057-0108

93057-0109

93057-0110

93057-0111

93057-0112

93057-0113

93057-0114

93057-0115

93057-0116

93057-0117

93057-0118

93057-0119

93057-0120

93057-0121

93057-0122

93057-0123

93057-0124

93057-0125

93057-0126

93057-0127

93057-0128

93057-0129

93057-0201

93057-0202

93057-0203

93057-0204

93057-0205

93057-0206

93057-0207

93057-0208

93057-0209

93057-0210

93057-0211

93057-0212

93057-0301

93057-0302

93057-0303

93057-0304

93057-0305

93057-0306

93057-0307

93057-0308

93057-0309

93057-0310

93057-0311

93057-0312

93057-0313

93057-0314

93057-0315

93057-0316

93057-0401

93057-0402

93057-0403

93057-0404

93057-0405

93057-0406

93057-0407

93057-0408

93057-0409

93057-0410

93057-0501

93057-0502

93057-0503

93057-0504

93057-0505

93057-0506

93057-0507

93057-0508

93057-0509

93057-0510

93057-0511

93057-0512

93057-0601

93057-0602

93057-0603

93057-0604

93057-0605

93057-0606

93057-0607

93057-0608

93057-0609

93057-0701

93057-0702

93057-0703

93057-0704

93057-0705

93057-0706

93057-0707

93057-0708

93057-0709

93057-0801

93057-0802

93057-0803

93057-0804

93057-0805

93057-0806

93057-0807

93057-0808

93057-0809

93057-0901

93057-0902

93057-1001

93057-1002

93210

93210-0001

93210-0002

93210-0003

93210-0004

93210-0005

93210-0006

93210-0007

93210-0008

93210-0009

93210-0011

93210-0101

93210-0102

93210-0103

93210-0104

93210-0105

93210-0106

93210-0107

93210-0108

93210-0201

93210-0202

93210-0203

93210-0204

93210-9001

93210-9002

93210-9003

93210-9101

93210-9102

93210-9201

93210-9202

93213

93213-0001

93213-0002

93213-0003

93213-0004

93213-0005

93213-0006

93213-0007

93213-0008

93213-0009

93213-0010

93213-0011

93213-0012

93213-0013

93213-0014

93213-0015

93213-0016

93213-0102

93213-0103

93213-0104

93213-0105

93213-0106

93213-0107

93213-3102

93213-3103

93213-3104

93213-3105

93213-3106

93213-3107

93396

93396-0001

93396-0002

93396-0003

93396-0004

93396-0005

93396-0006

93396-0007

93396-0008

93396-0009

93396-0011

93396-0101

93396-0102

93396-0103

93396-0104

93396-0105

93396-0106

93396-0107

93396-0108

93396-0201

93396-0202

93396-0203

93396-0204

Hand Tool for Appli-Mate RAST5 Connectors

Doc No: ATS-6382763HM Release Date: 10-01-14 UNCONTROLLED COPY Page 4 of 9

Revision: A Revision Date: 10-01-14

1.9

23.00+0.20/-0.10

INSULATION

DISPLACEMENT

AREA

INSULATION

DISPLACEMENT

AREA

25.00+0.20/-0.10

FOR SERIES: 90833, 91247, 91338, 91777, 91778,

91886, 91954, 93052, 93057, and 93213

FOR SERIES: 90835, 91779, 92000,

93210, and 93396

DEFINITION OF TERMS

Terminated Height:

Reference:

Application Specification AS-99033-0004

TERMINATION SPECIFICATION

Wire Size

Terminated Height

Pull Force Minimum*

In.

Lbf

0.38mm²

22.90 –23.20

0.901 –0.913

11.2

0.50mm²

15.7

0.75mm²

100

22.5

1.0mm²

24.90 –25.20

0.980 –0.992

110

24.7

1.5mm²

150

33.7

Customer to cut off connector from molded chain

*Parallel or 90° to the wire axis

Notes:

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

2. Variations in tools, connectors, wire stranding, and insulation types may affect termination height.

3. 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.

4. Terminated height should be used as the final criteria for an acceptable crimp. Pull force is a reference

only.

5. Molex does not certify crimp hand tools.

Hand Tool for Appli-Mate RAST5 Connectors

Doc No: ATS-6382763HM Release Date: 10-01-14 UNCONTROLLED COPY Page 5 of 9

Revision: A Revision Date: 10-01-14

SINGLE

CONNECTOR

LOWER HOUSING

REMOVED

CUT OFF FROM CHAIN

Figure 2

UPPER HOUSING

LOWER HOUSING

ADJUSTED FOR

0.38mm², 0.50mm²,

and 0.75mm²

ADJUSTED FOR

1.0mm², and 1.5mm²

OUTER WIRE

COMB LOWERED

OUTER WIRE

COMB RAISED

Figure 3

REVERSIBLE

BLOCK

KNOB

SETUP

Connector Preparation

Trim one connector off the molded chain using a razor blade, as shown below. See Figure 2.

When trimming the connector off the molded chain, be careful to not accidentally close the connector partway.

If the connector is closed too far, wires will be unable to fit into it.

Terminated Height Adjustment

Depending on the connector to be terminated, there is a reversible block in the tool that is used to adjust the

terminated height of the connector. Loosen the knob on the back of the tool head and rotate the block to the

correct position. Tighten the knob to keep the block in place. See Figure 3.

Wire Retaining Comb Adjustment

There are two wire combs in the tool which hold the inserted wires in place prior to termination. The inner

comb is used for smaller diameter wires and is lower. The outer comb (for larger wires) can be raised by

loosening the knob and raising the comb.

Hand Tool for Appli-Mate RAST5 Connectors

Doc No: ATS-6382763HM Release Date: 10-01-14 UNCONTROLLED COPY Page 6 of 9

Revision: A Revision Date: 10-01-14

TABS FACE

OUT

Figure 4

CONNECTOR

IN PLACE

TOOL NEST

PUSH WIRE INTO

CONNECTOR

PRESS WIRE

DOWN INTO COMB

Figure 5

CONNECTOR

RETAINING COMB

PLACE THE 1-CIRCUIT

CONNECTOR BETWEEN

THE PINS

Figure 6

LOCATING

PINS

OPERATION

1. 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.

2. With the hand tool in the open position, load the connector in the tool. The tool nest is polarized to accept

the connector in only one orientation (tabs facing outward) See Figure 4.

3. Push the connector all the way to the left until it stops.

4. Place the wire into the connector, pushing it in until it stops.

5. To keep the wire in place, press it into the retaining comb on the front of the tool. See Figure 5.

6. Repeat steps 3 and 4 until all wires are loaded into the connector.

7. Note: for the 1-circuit connector, position the connector between the pins on the left side of the tool. See

Figure 6.

8. To terminate the connector, squeeze the tool handles together until the anti-backup ratchet releases.

Release the handles and they will spring open.

9. Lift all wires out of the retaining comb and pull the finished connector out of the tool.

Note: The tamper proof ratchet action will not release the tool until it has been fully closed.

Hand Tool for Appli-Mate RAST5 Connectors

Doc No: ATS-6382763HM Release Date: 10-01-14 UNCONTROLLED COPY Page 7 of 9

Revision: A Revision Date: 10-01-14

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 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 connectors or 3 months, will significantly enhance the tool life.

4. Wipe excess oil from hand tool, particularly from the connector nest area. Any oil transferred from the

termination area onto the contacts may affect its electrical characteristics.

5. When tool is not in use, keep the handles closed to prevent objects from becoming lodged in the nest 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 8.

Warranty

This tool is for electrical connector termination 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, 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. 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 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 connectors specified for this tool.

CAUTION: Molex specifications are valid only when used with Molex connectors and tooling.

Hand Tool for Appli-Mate RAST5 Connectors

Doc No: ATS-6382763HM Release Date: 10-01-14 UNCONTROLLED COPY Page 8 of 9

Revision: A Revision Date: 10-01-14

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 into any power source. Disconnect the

power by unplugging or turn off the Actuator from its power source.

CAUTION: Keep fingers away from the termination 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.

Modular Crimp Head

Order No.

Tool

Order no.

Tool

Description

Adapter

Order No.

Adapter

Description

Figure

No.

63827-6370

63816-0000

Hand Crimp Frame (Short)

N/A

63816-0050

Hand Crimp Frame (Long)

N/A

63816-0200

Battery Power Tool (110 V)

63816-0600

Battery Power Crimp Adapter

63816-0250

Battery Power Tool (220 V)

63816-0600

Battery Power Crimp Adapter

63816-0100

Air Power Tool

63816-0700

Air Power Crimp Adapter

Applications for the Modular Crimp Head

Hand Crimp Tool

Battery Powered Tool

Air Powered Tool

Figure 5

Figure 6

Figure 7

AIR

POWER

TOOL

MODULAR

CRIMP HEAD

LOCKING

PINS

LOCKING

PINS

AIR POWER

CRIMP

ADAPTER

MODULAR

CRIMP

HEAD

BATTERY

POWER

CRIMP

ADAPTER

LOCKING

PINS

LOCKING PINS

BATTERY

POWERED

TOOL

MODULAR

CRIMP

HEAD

LOCKING

PINS

HAND CRIMP

FRAME LONG

OR SHORT

Hand Tool for Appli-Mate RAST5 Connectors

Doc No: ATS-6382763HM Release Date: 10-01-14 UNCONTROLLED COPY Page 9 of 9

Revision: A Revision Date: 10-01-14

RATCHET

RELEASE LEVER

HANDLE

SPRING

Figure 8

(2)

PARTS LIST

Item

Order Number

Description

Quantity

63827-6370

Modular Crimp Head

63816-0050

Hand Crimp Frame (Long)

63816-0001

Locking Pin

63600-0520

Tool Head Spring

63600-0525

Handle Spring

Visit our Web site at http://www.molex.com

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