Hand Tool for Appli-Mate RAST5 Connectors
Application Tooling
Specification Sheet
Modular Crimp Head
Order No. 63827-6370
TYPE 4A
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 638160250 (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.
Wire Size
Insulation Diameter
mm²
mm
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
Connector Order No.
Connector Series
90833
90835
Assembly Order Number
90833-0001
90833-0011
90833-0021
90833-0051
90833-0062
90833-0503
90833-0524
90833-0535
90833-1251
90833-1261
90833-1282
90833-2012
90833-2751
90833-2781
90833-3522
90833-4266
90833-6007
90833-9002
90833-9026
90833-9201
90833-9305
90833-9504
90833-9901
90835-0001
Doc No: ATS-6382763HM
Revision: A
90833-0002
90833-0012
90833-0022
90833-0052
90833-0063
90833-0504
90833-0525
90833-0536
90833-1252
90833-1262
90833-1283
90833-2019
90833-2752
90833-3500
90833-3523
90833-5000
90833-6008
90833-9003
90833-9027
90833-9202
90833-9306
90833-9601
90833-0003
90833-0013
90833-0025
90833-0053
90833-0064
90833-0505
90833-0526
90833-0537
90833-1253
90833-1264
90833-1284
90833-2023
90833-2764
90833-3501
90833-3524
90833-5001
90833-6023
90833-9004
90833-9028
90833-9203
90833-9401
90833-9602
90833-0004
90833-0014
90833-0026
90833-0054
90833-0065
90833-0506
90833-0528
90833-0538
90833-1254
90833-1267
90833-2001
90833-2024
90833-2765
90833-3502
90833-4250
90833-5004
90833-6024
90833-9005
90833-9029
90833-9204
90833-9402
90833-9603
90833-0005
90833-0015
90833-0027
90833-0056
90833-0066
90833-0507
90833-0529
90833-0539
90833-1255
90833-1271
90833-2002
90833-2025
90833-2773
90833-3503
90833-4251
90833-5010
90833-6025
90833-9006
90833-9101
90833-9205
90833-9403
90833-9701
90833-0006
90833-0016
90833-0028
90833-0057
90833-0068
90833-0508
90833-0530
90833-0540
90833-1256
90833-1272
90833-2006
90833-2026
90833-2776
90833-3513
90833-4254
90833-5012
90833-7000
90833-9021
90833-9102
90833-9206
90833-9404
90833-9702
90833-0007
90833-0017
90833-0032
90833-0058
90833-0069
90833-0509
90833-0531
90833-0541
90833-1257
90833-1273
90833-2007
90833-2027
90833-2777
90833-3514
90833-4255
90833-6000
90833-7001
90833-9022
90833-9103
90833-9301
90833-9405
90833-9703
90833-0008
90833-0018
90833-0047
90833-0059
90833-0500
90833-0510
90833-0532
90833-0542
90833-1258
90833-1276
90833-2008
90833-2028
90833-2778
90833-3518
90833-4256
90833-6001
90833-8000
90833-9023
90833-9104
90833-9302
90833-9501
90833-9704
90833-0009
90833-0019
90833-0048
90833-0060
90833-0501
90833-0511
90833-0533
90833-0543
90833-1259
90833-1277
90833-2010
90833-2029
90833-2779
90833-3520
90833-4261
90833-6005
90833-8001
90833-9024
90833-9105
90833-9303
90833-9502
90833-9705
90833-0010
90833-0020
90833-0050
90833-0061
90833-0502
90833-0513
90833-0534
90833-0544
90833-1260
90833-1279
90833-2011
90833-2750
90833-2780
90833-3521
90833-4264
90833-6006
90833-9001
90833-9025
90833-9106
90833-9304
90833-9503
90833-9801
90835-0003 90835-0019 90835-0034 90835-0035 90835-0036 90835-0037 90835-0038 90835-0039 90835-0040
Release Date: 10-01-14
Revision Date: 10-01-14
UNCONTROLLED COPY
Page 1 of 9
Hand Tool for Appli-Mate RAST5 Connectors
Connector Series
91247
91338
91777
91778
91779
91886
91954
Assembly Order Number
90835-0041
90835-0500
90835-0536
90835-1285
90835-9024
91247-0001
91338-0001
91338-0011
91338-0601
91338-1005
91338-3601
91777-0001
91777-0011
91777-0021
91777-0031
91777-3104
91778-0001
91778-0011
91778-0021
91778-0031
91778-0042
91778-0108
91778-0118
91778-0128
91778-0138
91778-0203
91778-0213
91778-0303
91778-0313
91778-0403
91778-0503
91778-0513
91778-0607
91778-0707
91778-0808
91778-9021
91778-9037
91778-9061
91778-9082
91778-9097
91778-9121
91779-0001
91779-0019
91779-0110
91779-0204
91779-9104
91886-0001
91886-0011
91886-0107
91886-0205
91886-0301
91886-0311
91886-0405
91886-0602
91886-0703
91886-0804
91886-9001
91886-9043
91886-9071
91886-9092
91886-9104
91954-0001
91954-0011
Doc No: ATS-6382763HM
Revision: A
90835-0042
90835-0501
90835-0537
90835-9001
90835-9025
91247-0002
91338-0002
91338-0012
91338-0607
91338-1006
91338-3607
91777-0002
91777-0012
91777-0022
91777-0032
91777-3105
91778-0002
91778-0012
91778-0022
91778-0032
91778-0043
91778-0109
91778-0119
91778-0129
91778-0139
91778-0204
91778-0214
91778-0304
91778-0314
91778-0404
91778-0504
91778-0514
91778-0608
91778-0708
91778-0809
91778-9022
91778-9041
91778-9062
91778-9083
91778-9098
90835-0043
90835-0502
90835-1251
90835-9002
90835-9026
91247-0003
91338-0003
91338-0013
91338-0700
91338-1007
91338-3700
91777-0003
91777-0013
91777-0023
91777-0102
91777-3106
91778-0003
91778-0013
91778-0023
91778-0033
91778-0044
91778-0110
91778-0120
91778-0130
91778-0140
91778-0205
91778-0215
91778-0305
91778-0315
91778-0405
91778-0505
91778-0515
91778-0609
91778-0709
91778-0810
91778-9023
91778-9042
91778-9063
91778-9084
91778-9101
90835-0044
90835-0518
90835-1254
90835-9003
90835-9027
91247-0004
91338-0004
91338-0102
91338-0701
91338-3102
91338-3800
91777-0004
91777-0014
91777-0024
91777-0103
91777-3107
91778-0004
91778-0014
91778-0024
91778-0034
91778-0101
91778-0111
91778-0121
91778-0131
91778-0141
91778-0206
91778-0216
91778-0306
91778-0316
91778-0406
91778-0506
91778-0516
91778-0610
91778-0801
91778-0811
91778-9024
91778-9043
91778-9064
91778-9085
91778-9102
90835-0045
90835-0519
90835-1268
90835-9004
90835-9101
91247-0005
91338-0005
91338-0103
91338-0800
91338-3103
91338-3801
91777-0005
91777-0015
91777-0025
91777-0104
90835-0046
90835-0520
90835-1269
90835-9005
90835-9102
91247-0006
91338-0006
91338-0104
91338-0801
91338-3104
90835-0047
90835-0521
90835-1273
90835-9006
90835-9103
90835-0048
90835-0522
90835-1281
90835-9021
90835-9104
90835-0057
90835-0523
90835-1283
90835-9022
90835-0058
90835-0534
90835-1284
90835-9023
91338-0007
91338-0105
91338-1001
91338-3105
91338-0008
91338-0403
91338-1002
91338-3403
91338-0009
91338-0501
91338-1003
91338-3501
91338-0010
91338-0507
91338-1004
91338-3507
91777-0006
91777-0016
91777-0026
91777-0105
91777-0007
91777-0017
91777-0027
91777-0106
91777-0008
91777-0018
91777-0028
91777-0107
91777-0009
91777-0019
91777-0029
91777-3102
91777-0010
91777-0020
91777-0030
91777-3103
91778-0005
91778-0015
91778-0025
91778-0035
91778-0102
91778-0112
91778-0122
91778-0132
91778-0142
91778-0207
91778-0217
91778-0307
91778-0317
91778-0407
91778-0507
91778-0601
91778-0701
91778-0802
91778-0812
91778-9031
91778-9051
91778-9065
91778-9091
91778-9103
91778-0006
91778-0016
91778-0026
91778-0036
91778-0103
91778-0113
91778-0123
91778-0133
91778-0143
91778-0208
91778-0218
91778-0308
91778-0318
91778-0408
91778-0508
91778-0602
91778-0702
91778-0803
91778-0813
91778-9032
91778-9052
91778-9071
91778-9092
91778-9104
91778-0007
91778-0017
91778-0027
91778-0037
91778-0104
91778-0114
91778-0124
91778-0134
91778-0144
91778-0209
91778-0219
91778-0309
91778-0319
91778-0409
91778-0509
91778-0603
91778-0703
91778-0804
91778-0901
91778-9033
91778-9053
91778-9072
91778-9093
91778-9105
91778-0008
91778-0018
91778-0028
91778-0038
91778-0105
91778-0115
91778-0125
91778-0135
91778-0145
91778-0210
91778-0220
91778-0310
91778-0320
91778-0410
91778-0510
91778-0604
91778-0704
91778-0805
91778-0902
91778-9034
91778-9054
91778-9073
91778-9094
91778-9106
91778-0009
91778-0019
91778-0029
91778-0039
91778-0106
91778-0116
91778-0126
91778-0136
91778-0201
91778-0211
91778-0301
91778-0311
91778-0401
91778-0501
91778-0511
91778-0605
91778-0705
91778-0806
91778-1001
91778-9035
91778-9055
91778-9074
91778-9095
91778-9107
91778-0010
91778-0020
91778-0030
91778-0040
91778-0107
91778-0117
91778-0127
91778-0137
91778-0202
91778-0212
91778-0302
91778-0312
91778-0402
91778-0502
91778-0512
91778-0606
91778-0706
91778-0807
91778-1002
91778-9036
91778-9056
91778-9081
91778-9096
91778-9111
91779-0002
91779-0101
91779-0111
91779-0205
91779-9105
91886-0002
91886-0012
91886-0108
91886-0206
91886-0302
91886-0312
91886-0406
91886-0603
91886-0704
91886-0805
91886-9023
91886-9051
91886-9072
91886-9093
91886-9105
91954-0002
91954-0012
91779-0003
91779-0102
91779-0112
91779-0206
91779-9106
91886-0003
91886-0013
91886-0109
91886-0207
91886-0303
91886-0313
91886-0407
91886-0604
91886-0705
91886-0806
91886-9024
91886-9052
91886-9073
91886-9094
91886-9111
91954-0003
91954-0013
91779-0004
91779-0103
91779-0113
91779-9001
91779-9201
91886-0004
91886-0014
91886-0110
91886-0208
91886-0304
91886-0314
91886-0408
91886-0605
91886-0706
91886-0807
91886-9031
91886-9053
91886-9074
91886-9095
91886-9121
91954-0004
91954-0014
91779-0005
91779-0104
91779-0114
91779-9002
91779-9202
91886-0005
91886-0101
91886-0111
91886-0209
91886-0305
91886-0315
91886-0409
91886-0606
91886-0707
91886-0808
91886-9032
91886-9054
91886-9081
91886-9096
91779-0006
91779-0105
91779-0115
91779-9003
91779-9203
91886-0006
91886-0102
91886-0112
91886-0210
91886-0306
91886-0316
91886-0410
91886-0607
91886-0708
91886-0809
91886-9033
91886-9055
91886-9082
91886-9097
91779-0007
91779-0106
91779-0116
91779-9004
91779-9204
91886-0007
91886-0103
91886-0201
91886-0211
91886-0307
91886-0401
91886-0501
91886-0608
91886-0709
91886-0901
91886-9036
91886-9061
91886-9083
91886-9098
91779-0008
91779-0107
91779-0201
91779-9101
91779-9205
91886-0008
91886-0104
91886-0202
91886-0212
91886-0308
91886-0402
91886-0512
91886-0609
91886-0801
91886-0902
91886-9037
91886-9062
91886-9084
91886-9101
91779-0009
91779-0108
91779-0202
91779-9102
91779-9206
91886-0009
91886-0105
91886-0203
91886-0213
91886-0309
91886-0403
91886-0513
91886-0701
91886-0802
91886-1001
91886-9041
91886-9063
91886-9085
91886-9102
91779-0010
91779-0109
91779-0203
91779-9103
Release Date: 10-01-14
Revision Date: 10-01-14
91886-0010
91886-0106
91886-0204
91886-0214
91886-0310
91886-0404
91886-0601
91886-0702
91886-0803
91886-1002
91886-9042
91886-9064
91886-9091
91886-9103
91954-0005 91954-0006 91954-0007 91954-0008 91954-0009 91954-0010
91954-0015 91954-0016 91954-0017 91954-0018 91954-0019 91954-0020
UNCONTROLLED COPY
Page 2 of 9
Hand Tool for Appli-Mate RAST5 Connectors
Connector Series
92000
93052
93057
93210
93213
93396
Assembly Order Number
91954-0021
91954-0031
91954-0050
91954-0060
91954-0070
91954-0080
91954-0090
91954-0100
91954-0110
91954-0120
91954-0208
91954-0306
91954-0402
91954-0503
91954-0604
91954-0706
92000-0001
92000-0104
93052-0001
93052-0011
93052-0021
93052-0053
93052-0064
93052-0077
93052-0509
93052-0531
93052-1000
93052-1260
93052-1283
93052-2019
93052-2764
93052-3502
93052-4250
93052-5012
93052-7000
93057-0001
93057-0011
93057-0021
93057-0105
93057-0115
93057-0125
93057-0206
93057-0304
93057-0314
93057-0408
93057-0508
93057-0606
93057-0707
93057-0808
93210-0001
93210-0101
93210-0203
93213-0001
93213-0011
93213-0106
93396-0001
93396-0101
93396-0203
Doc No: ATS-6382763HM
Revision: A
91954-0022
91954-0041
91954-0051
91954-0061
91954-0071
91954-0081
91954-0091
91954-0101
91954-0111
91954-0121
91954-0209
91954-0307
91954-0403
91954-0504
91954-0605
91954-0023
91954-0042
91954-0052
91954-0062
91954-0072
91954-0082
91954-0092
91954-0102
91954-0112
91954-0122
91954-0210
91954-0308
91954-0404
91954-0505
91954-0606
91954-0024
91954-0043
91954-0053
91954-0063
91954-0073
91954-0083
91954-0093
91954-0103
91954-0113
91954-0201
91954-0211
91954-0309
91954-0405
91954-0506
91954-0607
91954-0025
91954-0044
91954-0054
91954-0064
91954-0074
91954-0084
91954-0094
91954-0104
91954-0114
91954-0202
91954-0212
91954-0310
91954-0406
91954-0507
91954-0608
91954-0026
91954-0045
91954-0055
91954-0065
91954-0075
91954-0085
91954-0095
91954-0105
91954-0115
91954-0203
91954-0301
91954-0311
91954-0407
91954-0508
91954-0701
91954-0027
91954-0046
91954-0056
91954-0066
91954-0076
91954-0086
91954-0096
91954-0106
91954-0116
91954-0204
91954-0302
91954-0312
91954-0408
91954-0509
91954-0702
91954-0028
91954-0047
91954-0057
91954-0067
91954-0077
91954-0087
91954-0097
91954-0107
91954-0117
91954-0205
91954-0303
91954-0313
91954-0409
91954-0601
91954-0703
91954-0029
91954-0048
91954-0058
91954-0068
91954-0078
91954-0088
91954-0098
91954-0108
91954-0118
91954-0206
91954-0304
91954-0314
91954-0501
91954-0602
91954-0704
91954-0030
91954-0049
91954-0059
91954-0069
91954-0079
91954-0089
91954-0099
91954-0109
91954-0119
91954-0207
91954-0305
91954-0401
91954-0502
91954-0603
91954-0705
92000-0002
92000-0105
93052-0002
93052-0012
93052-0022
93052-0054
93052-0066
93052-0500
93052-0510
93052-0532
93052-1251
93052-1264
93052-1284
93052-2023
93052-2765
93052-3503
93052-4251
93052-6000
93052-7001
93057-0002
93057-0012
93057-0022
93057-0106
93057-0116
93057-0126
93057-0207
93057-0305
93057-0315
93057-0409
93057-0509
93057-0607
93057-0708
93057-0809
93210-0002
93210-0102
93210-0204
93213-0002
93213-0012
93213-0107
93396-0002
93396-0102
93396-0204
92000-0003
92000-0106
93052-0003
93052-0013
93052-0025
93052-0056
93052-0069
93052-0501
93052-0511
93052-0533
93052-1252
93052-1267
93052-2001
93052-2025
93052-2773
93052-3513
93052-4254
93052-6001
93052-8000
93057-0003
93057-0013
93057-0023
93057-0107
93057-0117
93057-0127
93057-0208
93057-0306
93057-0316
93057-0410
93057-0510
93057-0608
93057-0709
93057-0901
93210-0003
93210-0103
93210-9001
93213-0003
93213-0013
93213-3102
93396-0003
93396-0103
92000-0004
92000-0107
93052-0004
93052-0014
93052-0027
93052-0057
93052-0070
93052-0502
93052-0513
93052-0534
93052-1253
93052-1271
93052-2002
93052-2026
93052-2776
93052-3514
93052-4255
93052-6005
93052-8001
93057-0004
93057-0014
93057-0024
93057-0108
93057-0118
93057-0128
93057-0209
93057-0307
93057-0401
93057-0501
93057-0511
93057-0609
93057-0801
93057-0902
93210-0004
93210-0104
93210-9002
93213-0004
93213-0014
93213-3103
93396-0004
93396-0104
92000-0005
92000-0108
93052-0005
93052-0015
93052-0032
93052-0058
93052-0071
93052-0503
93052-0524
93052-0535
93052-1254
93052-1272
93052-2006
93052-2027
93052-2777
93052-3518
93052-4256
93052-6006
92000-0006
92000-0201
93052-0006
93052-0016
93052-0047
93052-0059
93052-0072
93052-0504
93052-0525
93052-0536
93052-1255
93052-1273
93052-2007
93052-2028
93052-2778
93052-3520
93052-4261
93052-6007
92000-0007
92000-0202
93052-0007
93052-0017
93052-0048
93052-0060
93052-0073
93052-0505
93052-0526
93052-0537
93052-1256
93052-1276
93052-2008
93052-2029
93052-2779
93052-3521
93052-4264
93052-6008
92000-0101
92000-0203
93052-0008
93052-0018
93052-0050
93052-0061
93052-0074
93052-0506
93052-0528
93052-0540
93052-1257
93052-1277
93052-2010
93052-2750
93052-2780
93052-3522
93052-5000
93052-6023
92000-0102
92000-0204
93052-0009
93052-0019
93052-0051
93052-0062
93052-0075
93052-0507
93052-0529
93052-0541
93052-1258
93052-1279
93052-2011
93052-2751
93052-3500
93052-3523
93052-5001
93052-6024
92000-0103
93057-0005
93057-0015
93057-0025
93057-0109
93057-0119
93057-0129
93057-0210
93057-0308
93057-0402
93057-0502
93057-0512
93057-0701
93057-0802
93057-1001
93210-0005
93210-0105
93210-9003
93213-0005
93213-0015
93213-3104
93396-0005
93396-0105
93057-0006
93057-0016
93057-0026
93057-0110
93057-0120
93057-0201
93057-0211
93057-0309
93057-0403
93057-0503
93057-0601
93057-0702
93057-0803
93057-1002
93210-0006
93210-0106
93210-9101
93213-0006
93213-0016
93213-3105
93396-0006
93396-0106
93057-0007
93057-0017
93057-0101
93057-0111
93057-0121
93057-0202
93057-0212
93057-0310
93057-0404
93057-0504
93057-0602
93057-0703
93057-0804
93057-0008
93057-0018
93057-0102
93057-0112
93057-0122
93057-0203
93057-0301
93057-0311
93057-0405
93057-0505
93057-0603
93057-0704
93057-0805
93057-0009
93057-0019
93057-0103
93057-0113
93057-0123
93057-0204
93057-0302
93057-0312
93057-0406
93057-0506
93057-0604
93057-0705
93057-0806
93057-0010
93057-0020
93057-0104
93057-0114
93057-0124
93057-0205
93057-0303
93057-0313
93057-0407
93057-0507
93057-0605
93057-0706
93057-0807
93210-0007
93210-0107
93210-9102
93213-0007
93213-0102
93213-3106
93396-0007
93396-0107
93210-0008
93210-0108
93210-9201
93213-0008
93213-0103
93213-3107
93396-0008
93396-0108
93210-0009
93210-0201
93210-9202
93213-0009
93213-0104
93210-0011
93210-0202
Release Date: 10-01-14
Revision Date: 10-01-14
UNCONTROLLED COPY
93052-0010
93052-0020
93052-0052
93052-0063
93052-0076
93052-0508
93052-0530
93052-0542
93052-1259
93052-1282
93052-2012
93052-2752
93052-3501
93052-3524
93052-5010
93052-6025
93213-0010
93213-0105
93396-0009 93396-0011
93396-0201 93396-0202
Page 3 of 9
Hand Tool for Appli-Mate RAST5 Connectors
DEFINITION OF TERMS
Terminated Height:
1.9
1.9
23.00+0.20/-0.10
25.00+0.20/-0.10
INSULATION
DISPLACEMENT
AREA
INSULATION
DISPLACEMENT
AREA
FOR SERIES: 90835, 91779, 92000,
93210, and 93396
FOR SERIES: 90833, 91247, 91338, 91777, 91778,
91886, 91954, 93052, 93057, and 93213
Reference:
Application Specification AS-99033-0004
TERMINATION SPECIFICATION
Wire Size
0.38mm²
0.50mm²
0.75mm²
1.0mm²
1.5mm²
Terminated Height
mm
In.
22.90 – 23.20
0.901 – 0.913
24.90 – 25.20
0.980 – 0.992
Customer to cut off connector from molded chain
Pull Force Minimum*
N
Lbf
50
11.2
70
15.7
100
22.5
110
24.7
150
33.7
*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.
Doc No: ATS-6382763HM
Revision: A
Release Date: 10-01-14
Revision Date: 10-01-14
UNCONTROLLED COPY
Page 4 of 9
Hand Tool for Appli-Mate RAST5 Connectors
SETUP
Connector Preparation
Trim one connector off the molded chain using a razor blade, as shown below. See Figure 2.
CUT OFF FROM CHAIN
UPPER HOUSING
LOWER HOUSING
REMOVED
SINGLE
CONNECTOR
LOWER HOUSING
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.
ADJUSTED FOR
1.0mm², and 1.5mm²
KNOB
ADJUSTED FOR
0.38mm², 0.50mm²,
and 0.75mm²
REVERSIBLE
BLOCK
Figure 3
OUTER WIRE
COMB LOWERED
OUTER WIRE
COMB RAISED
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.
Doc No: ATS-6382763HM
Revision: A
Release Date: 10-01-14
Revision Date: 10-01-14
UNCONTROLLED COPY
Page 5 of 9
Hand Tool for Appli-Mate RAST5 Connectors
OPERATION
CONNECTOR
IN PLACE
TOOL NEST
TABS FACE
OUT
Figure 4
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.
PLACE THE 1-CIRCUIT
CONNECTOR BETWEEN
THE PINS
CONNECTOR
RETAINING COMB
LOCATING
PINS
PRESS WIRE
DOWN INTO COMB
Figure 6
PUSH WIRE INTO
CONNECTOR
Figure 5
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.
Doc No: ATS-6382763HM
Revision: A
Release Date: 10-01-14
Revision Date: 10-01-14
UNCONTROLLED COPY
Page 6 of 9
Hand Tool for Appli-Mate RAST5 Connectors
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.
Doc No: ATS-6382763HM
Revision: A
Release Date: 10-01-14
Revision Date: 10-01-14
UNCONTROLLED COPY
Page 7 of 9
Hand Tool for Appli-Mate RAST5 Connectors
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.
63827-6370
Tool
Tool
Adapter
Adapter
Figure
Order no.
Description
Order No.
Description
No.
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
MODULAR
CRIMP
HEAD
LOCKING
PINS
HAND CRIMP
FRAME LONG
OR SHORT
LOCKING
PINS
LOCKING
PINS
BATTERY
POWER
CRIMP
ADAPTER
LOCKING PINS
Figure 5
Doc No: ATS-6382763HM
Revision: A
MODULAR
CRIMP
HEAD
Air Powered Tool
BATTERY
POWERED
TOOL
AIR POWER
CRIMP
ADAPTER
AIR
POWER
TOOL
Figure 6
Release Date: 10-01-14
Revision Date: 10-01-14
MODULAR
CRIMP HEAD
UNCONTROLLED COPY
LOCKING
PINS
Figure 7
Page 8 of 9
Hand Tool for Appli-Mate RAST5 Connectors
PARTS LIST
Item Order Number
Description
Quantity
1
63827-6370
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
5
HANDLE
SPRING
2
1
RATCHET
RELEASE LEVER
3
4
(2)
Figure 8
Visit our Web site at http://www.molex.com
Doc No: ATS-6382763HM
Revision: A
Release Date: 10-01-14
Revision Date: 10-01-14
UNCONTROLLED COPY
Page 9 of 9
