Molex 63827-6270 User manual

Hand Tool for Appli-Mate RAST Power Connectors

Doc No: ATS-6382762HM Release Date: 10-27-14 UNCONTROLLED COPY Page 1 of 7

Revision: A Revision Date: 10-27-14

Application Tooling

Specification Sheet

Modular Crimp Head

Order No. 63827-6270

Hand Crimp Tool

Order No. 63827-6200

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 RAST Power connectors, 2 –12 circuits, 0.5mm² and 0.75mm² H05V-K wires.

Connector Series

Connector Order No.

Wire Size

Insulation Diameter

mm²

In.

91627 and 93211

See table below

0.5

2.1 –2.3

0.083 –0.091

91791 and 93322

See table below

0.75

2.3 –2.5

0.091 –0.098

Customer to cut off connector from molded chain

Contact Molex about approved AWG wires for these products

Connector Series No.

Circuit Size

Connector Assembly Order No.

91627

91627-0001

91627-0002

91627-0003

91627-0004

91627-0005

91627-0006

91627-0008

91627-0009

91627-0010

91627-0011

91627-0012

91627-0013

91627-0014

91627-0015

91627-0016

91627-0501

91627-0502

91627-0503

91627-0504

91627-0505

91627-0506

91627-0507

91627-0508

91627-1001

91627-1002

91627-1004

91627-1005

91627-1006

91627-1007

91627-1008

91627-1009

91627-1010

91627-1011

91627-1012

91627-1013

91627-1014

91627-1015

91627-1016

91627-1017

91627-1501

91627-1502

91627-1503

91627-1504

91627-1506

91627-1507

91627-1508

91627-2001

91627-2002

91627-2003

91627-2004

91627-2005

91627-2006

91627-2007

91627-2008

91627-2009

91627-2010

91627-2011

91627-2501

91627-2503

91627-3001

91627-3002

91627-3003

91627-3004

91627-3005

91627-3006

91627-3501

91627-3502

91627-3503

91627-3504

91627-4001

91627-4002

91627-4003

91627-4004

91627-4005

91627-4006

91627-4007

91627-4501

91627-4502

91627-4503

91627-5001

91627-5002

91627-5003

91627-5004

91627-5005

91627-5006

91627-5501

91627-5502

91627-5503

91627-5504

91627-5505

91627-6001

91627-6002

91627-6501

91627-6502

91627-7001

91627-7002

91627-7003

91627-7501

91627-7502

91627-7503

91627-7504

91627-8001

91627-8501

91627-9001

91627-9251

91627-9501

91627-9751

TYPE 4A

This datasheet has been downloaded fromhttp://www.digchip.com at this page

Hand Tool for Appli-Mate RAST Power Connectors

Doc No: ATS-6382762HM Release Date: 10-27-14 UNCONTROLLED COPY Page 2 of 7

Revision: A Revision Date: 10-27-14

Connector Series No.

Circuit Size

Connector Assembly Order No.

91791

91791-0001

91791-1001

91791-1002

91791-1004

91791-1504

91791-2001

91791-2004

91791-3001

91791-4001

91791-5001

91791-6001

91791-7001

91791-8001

91791-9001

91791-9501

93211

93211-0001

93211-0002

93211-0003

93211-0004

93211-0501

93211-1001

93211-1002

93211-1003

93211-1004

93211-1501

93211-1503

93211-2001

93211-2501

93211-2502

93211-3001

93211-3501

93211-4001

93211-4501

93211-4502

93211-4503

93211-5001

93211-5501

93211-5502

93211-6001

93211-6501

93211-7001

93211-7501

93211-7502

93211-8001

93211-8501

93211-9001

93211-9251

93211-9501

93211-9751

93322

93322-0001

93322-0501

93322-1001

93322-1002

93322-1501

93322-2001

93322-2501

93322-3001

93322-3501

93322-4001

93322-4501

93322-5001

93322-5501

93322-6001

93322-6501

93322-7001

93322-7501

93322-8001

93322-8501

DEFINITION OF TERMS

Terminated Height:

Reference:

Application Specification AS-91627-001

0.80 ± 0.10

CONTACT GAP

15.10 ±0 0.10

Hand Tool for Appli-Mate RAST Power Connectors

Doc No: ATS-6382762HM Release Date: 10-27-14 UNCONTROLLED COPY Page 3 of 7

Revision: A Revision Date: 10-27-14

TERMINATION SPECIFICATION

Wire Size

Terminated Height

Pull Force Minimum*

In.

Lbf

0.50mm²

15.00 –15.20

0.591 –0.598

0.75mm²

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.

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.

Termination Blade Position

To allow the un-terminated connector to fit in the tool, the termination blade must be raised. To raise the

termination blade, push the bar on the top of the tool in the “open” direction until it stops. See Figure 3.

SINGLE

CONNECTOR

0.3mm MAX

CUT-OFF

BURR

CUT OFF FROM CHAIN

Figure 2

CONNECTOR

CHAIN

Figure 3

PUSH IN TO RAISE

TERMINATION BLADE

BAR

MODULAR

CRIMP HEAD

Hand Tool for Appli-Mate RAST Power Connectors

Doc No: ATS-6382762HM Release Date: 10-27-14 UNCONTROLLED COPY Page 4 of 7

Revision: A Revision Date: 10-27-14

ORIENT THE

SLOT ON TOP

Figure 4

CONNECTOR

IN PLACE

TOOL NEST

CONNECTOR

STOP

BAR CLOSED

TERMINATION

BLADES DOWN

BAR OPEN

PUSH WIRE INTO CONNECTOR

PRESS WIRE

DOWN INTO COMB

Figure 5

CONNECTOR

RETAINING COMB

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. Before loading the connector in the tool, make sure the termination blade is raised (see Termination

Blade Position).

3. 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.

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

5. Lower the termination blade by pulling the bar away from the tool.

NOTE: If the termination blade is not

lowered, the connector will not be

completely terminated.

6. Place the wire into the

connector, pushing it in until it

stops against the back of the

connector housing.

7. To keep the wire in place, press

it into the retaining comb on the

front of the tool. See Figure 5.

8. Repeat steps 6 and 7 until all

wires are loaded into the

connector.

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

Release the handles and they will spring open.

10. Push in the bar to raise the termination blade.

NOTE: If the termination blade is not raised, it will be difficult to remove the connector from the tool.

11. 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 RAST Power Connectors

Doc No: ATS-6382762HM Release Date: 10-27-14 UNCONTROLLED COPY Page 5 of 7

Revision: A Revision Date: 10-27-14

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 RAST Power Connectors

Doc No: ATS-6382762HM Release Date: 10-27-14 UNCONTROLLED COPY Page 6 of 7

Revision: A Revision Date: 10-27-14

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.

63827-6270

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 RAST Power Connectors

Doc No: ATS-6382762HM Release Date: 10-27-14 UNCONTROLLED COPY Page 7 of 7

Revision: A Revision Date: 10-27-14

RATCHET

RELEASE LEVER

HANDLE

SPRING

Figure 8

(2)

PARTS LIST

Item

Order Number

Description

Quantity

63827-6270

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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