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
mm
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
2
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
3
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
4
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
5
91627-3001
91627-3002
91627-3003
91627-3004
91627-3005
91627-3006
91627-3501
91627-3502
91627-3503
91627-3504
6
91627-4001
91627-4002
91627-4003
91627-4004
91627-4005
91627-4006
91627-4007
91627-4501
91627-4502
91627-4503
7
91627-5001
91627-5002
91627-5003
91627-5004
91627-5005
91627-5006
91627-5501
91627-5502
91627-5503
91627-5504
91627-5505
8
91627-6001
91627-6002
91627-6501
91627-6502
9
91627-7001
91627-7002
91627-7003
91627-7501
91627-7502
91627-7503
91627-7504
10
91627-8001
91627-8501
11
91627-9001
91627-9251
12
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
2
91791-0001
3
91791-1001
91791-1002
91791-1004
91791-1504
4
91791-2001
91791-2004
5
91791-3001
6
91791-4001
7
91791-5001
8
91791-6001
9
91791-7001
10
91791-8001
11
91791-9001
12
91791-9501
93211
2
93211-0001
93211-0002
93211-0003
93211-0004
93211-0501
3
93211-1001
93211-1002
93211-1003
93211-1004
93211-1501
93211-1503
4
93211-2001
93211-2501
93211-2502
5
93211-3001
93211-3501
6
93211-4001
93211-4501
93211-4502
93211-4503
7
93211-5001
93211-5501
93211-5502
8
93211-6001
93211-6501
9
93211-7001
93211-7501
93211-7502
10
93211-8001
93211-8501
11
93211-9001
93211-9251
12
93211-9501
93211-9751
93322
2
93322-0001
93322-0501
3
93322-1001
93322-1002
93322-1501
4
93322-2001
93322-2501
5
93322-3001
93322-3501
6
93322-4001
93322-4501
7
93322-5001
93322-5501
8
93322-6001
93322-6501
9
93322-7001
93322-7501
10
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*
mm
In.
N
Lbf
0.50mm²
15.00 –15.20
0.591 –0.598
50
11
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
N/A
5
63816-0050
Hand Crimp Frame (Long)
N/A
N/A
5
63816-0200
Battery Power Tool (110 V)
63816-0600
Battery Power Crimp Adapter
6
63816-0250
Battery Power Tool (220 V)
63816-0600
Battery Power Crimp Adapter
6
63816-0100
Air Power Tool
63816-0700
Air Power Crimp Adapter
7
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
2
1
5
Figure 8
3
4
(2)
PARTS LIST
Item
Order Number
Description
Quantity
1
63827-6270
Modular Crimp Head
1
2
63816-0050
Hand Crimp Frame (Long)
1
3
63816-0001
Locking Pin
2
4
63600-0520
Tool Head Spring
2
5
63600-0525
Handle Spring
1
Visit our Web site at http://www.molex.com