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
mm
In.
mm
In.
mm
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
mm
In.
mm
In.
mm
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
Degree
105300
3
3
4
8
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)
A
B
C
D
AWG
mm2
mm
In.
mm
In.
mm
In.
mm
In.
N
Lb.
24
24
26
26
105300
24
—
0.70-0.75
.027-.030
1.15
.045
1.60
.063
1.55
.061
22.3
5
X
1.70
.067
1.70
.067
X
26
—
0.65-0.70
.025-.027
1.15
.045
1.55
.061
1.55
.061
13.4
3
X
1.65
.065
1.70
.067
X
▲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)
—
—
7
63816-0050
Hand Crimp Frame (Long)
—
—
7
63816-0270
Battery Power Tool (110 V)
63816-0600
Battery Power Crimp Adapter
8
63816-0280
Battery Power Tool (220 V)
63816-0600
Battery Power Crimp Adapter
8
63816-1500
Electric Crimp Machine
63816-0600
Battery Power Crimp Adapter
9
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
2
1
4
Figure 10
M4 X 12mm
LONG BHCS
3
5
6
M4 LOCKNUT
PARTS LIST
Item
Order Number
Description
Quantity
1
63827-6070
Modular Crimp Head
1
2
63816-0000
Hand Crimp Frame (Short)
1
3
63827-6075
Locator
1
4
63816-0001
Locking Pin
2
5
63600-0525
Handle Spring
1
6
63600-0520
Crimping Spring
2
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.