0640051100

AT5762 Air Crimp Head Tool Air Powered Crimp Tool Head Avikrimp  Application Tooling Specification Sheet Order No. 64005-1100 Engineering No. AT 5762 FEATURES Quick change tool head for the 19279-0001 (AT-200) Tooling kit is interchangeable with other kits in the 64001 and 64003 Series A precision user-friendly terminal locator wire stop holds terminals in the proper crimping position Insulation crimp adjustment allows a precise insulation crimp. To meet or exceed the requirements of UL, CSA and Military Class II Pneumatic powered crimp tools help reduce fatigue and discomfort from repetitive manual crimping. Single color-coded crimp pocket eliminates the possibility of using the wrong pocket SCOPE Products: Avikrimp Female Fully Insulated Quick Disconnect 14–16 AWG. This tool head is intended for use in the 19279-0001 (AT-200) either hand held or with optional bench adapter 19078-0307 (ATBA) and foot switch. Testing Mechanical The tensile test, or pull test, is a means of evaluating the mechanical properties of the crimped connections. The following charts show the UL specifications for various wire sizes. The tensile strength is shown in pounds and indicates the minimum acceptable force to break or separate the terminal from the conductor. Wire Size (AWG) *UL - 310 16 30 14 50 *UL – 310 – Quick Disconnects The following is a partial list of the product part numbers and their specifications that this tool is designed to run. We will be adding to this list and an up to date copy is available on www.molex.com. Terminal No. 19002-0024 19002-0028 19002-0031 19002-0034 19002-0037 19002-0040 19002-0042 19277-0005 Doc. No: ATS-640051100 Revision: D Wire Size: 14 – 16 AWG 2.00 – 1.30 mm² Wire Strip Length Insulation Diameter Maximum Terminal Eng No. (REF) In. mm In. mm BB-5263 0.25 6.35 0.16 3.94 BB-5269 0.25 6.35 0.16 3.94 BB-5273 0.25 6.35 0.16 3.94 BB-5277 0.25 6.35 0.16 3.94 BB-5281 0.25 6.35 0.16 3.94 BB-5287 0.25 6.35 0.16 3.94 BB-5289 0.25 6.35 0.16 3.94 BB-5263-LIF 0.25 6.35 0.16 3.94 Release Date: 12-10-02 Revision Date: 01-24-11 UNCONTROLLED COPY Page 1 of 6 AT5762 Air Crimp Head Tool OPERATION JAWS OPEN Refer to the instruction manual for the 19279-0001 (AT-200) for mounting this crimp tool head. SAFETY SHIELD Crimping Terminals 1. There are 3 Tab Locator Blades supplied with the tool. One is for .187 and .250 Tabs; one is for .205 Tabs and .110 Tabs and a third is for LIF connectors. Make sure the proper blade is installed on the top of the locator and the other is stored on the bottom of the locator. 2. Insert the wire into the terminal. Push the terminal and wire onto the tab locator all the way to the stop in the proper color-coded nest. The barrel of the terminal should be up. See Figure 1. TERMINAL LOCATOR TAB LOCATOR Figure 1 Caution: Never operate this tool without the supplied safety shield in place. Never place fingers in the tool nests. 3. Push on the wire to assure it is still fully seated in the terminal. The wires end should butt against the wire stop stamped into each terminal. See Figure 2 and 3. Cycle the tool. 4. Remove the crimp and inspect for proper crimp location, and check for insulation closure. Molex offers a Crimp Inspection Handbook for closed barrel industrial product. See our website or contact your sales engineer. 5. If the insulation part of the crimp needs to be adjusted, first loosen the M4 screw on the bottom tool jaw and insert a 3/32 hex wrench (supplied) into the bottom of the lower die. See Figure 4. A clockwise (CW) rotation decreases insulation crimp while a counter-clockwise (CCW) rotation increases insulation crimp. After adjusting retighten the M4 screw. CONDUCTOR PUNCH INSULATION PUNCH WIRE STOP BUILT INTO TERMINAL TERMINAL WIRE 1ST TAB LOCATOR LOCATOR TERMINAL WIRE 2ND and 3RD TAB LOCATOR TERMINAL BARREL Figure 2 CONDUCTOR ANVIL Figure 3 INSULATION ANVIL Note: Whenever crimping without the locator, make sure the seam of the terminal is oriented up or down in the tool if using unbrazed product, as this will provide higher pull force values. Doc. No: ATS-640051100 Revision: D Release Date: 12-10-02 Revision Date: 01-24-11 UNCONTROLLED COPY Page 2 of 6 AT5762 Air Crimp Head Tool Maintenance It is recommended that each operator of the tool be made aware of, and responsible for, the following maintenance steps: LUBRICATION POINTS (BOTH SIDES) LIGHT OIL (EVERY MONTH OR 5,000 CRIMPS) 1. Remove dust, moisture and other contaminants with a clean brush, or soft, lint free cloth. 3/32” HEX 2. Do not use any abrasive materials that could damage WRENCH Figure 4 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. This tool was engineered for durability, but like any fine piece of equipment it needs cleaning and lubrication for a maximum service life of trouble-free crimping. A light oil, such as 30 weight automotive oil at the oil points shown in Figure 4, every 5,000 crimps or monthly will significantly enhance the tool life and ensure a stable calibration. 4. When tool is not in use store the tool in a clean, dry area. PIN GAUGE IN CONDUCTOR CRIMP Tool Calibration A Certificate of Calibration (see last page) was supplied with the tool. To recalibrate this tool, pin gauge measurements should be taken in each conductor nest and compared to this chart. The tool should be lubricated prior to recalibration to ensure consistent measurements. Nest Color Code Blue X “Confining” Crimp Wire Range “X” Dimension Conductor Crimp Crimp Inspection Marking AWG mm² Mean Go No Go 14 - 16 1.30 - 2.00 .110 .105 .113 oo 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, we would repair or exchange the tool free of charge. This repair or exchange will not be applicable to altered, misused or damaged tools. CAUTION: Molex crimp specifications are valid only when used with Molex terminals, applicators and tooling. Doc. No: ATS-640051100 Revision: D Release Date: 12-10-02 Revision Date: 01-24-11 UNCONTROLLED COPY Page 3 of 6 AT5762 Air Crimp Head Tool PARTS LIST Item Order No 64005-1100 64005-0000 64001-0475 64001-1170 Description Quantity Crimp Tool Head Figure 5 1 Basic Air Tool Head 1 2 Locator Assembly 1 3 Tooling Kit 1 Tooling Kit Only 4 64001-1102 Conductor Punch 1 5 64001-1101 Conductor Anvil 1 6 64001-1104 Insulation Punch 1 7 64001-1103 Insulation Anvil 1 8 N/A 4mm Diameter by 5.0mm Long Roll Pins 2** 9 N/A #10-32 by 5/16” Long Cup Pt. Set Screw 1** ** Available from an Industrial supply company such as MSC (1-800-645-7270). M4 LOCKNUT W/HEX NYLON INSERT M4 FLAT WASHER 2 1 4 5 8 9 (2) 3 6 7 Figure 5 Doc. No: ATS-640051100 Revision: D Release Date: 12-10-02 Revision Date: 01-24-11 UNCONTROLLED COPY Page 4 of 6 AT5762 Air Crimp Head Tool Parts List (Continued) Item Order No. Description Quantity 64005-0000 Basic Air Tool Head Figure 6 1 64005-0103 Nose Guard 1 2 64000-0077 Repair Kit (Springs, Rods Pivots ,Rings, and Washers) 1 3 N/A M4 by 12 Long Freedrive Pan Head Screw 1** 4 N/A M4 by 30 Long Freedrive Pan Head Screw 1** 5 N/A 3/16” by 3/8” Long Dowel Pin 1** ** Available from an Industrial supply company such as MSC (1-800-645-7270). 2 (2) (2) 2 2 (2) (4) 2 5 2 (4) 4 1 3 2 (4) Figure 6 Doc. No: ATS-640051100 Revision: D Release Date: 12-10-02 Revision Date: 01-24-11 UNCONTROLLED COPY Page 5 of 6 AT5762 Air Crimp Head Tool Air Powered Crimp Tool Head Avikrimp  Certificate of Calibration Order No. 64005-1100 Engineering No. AT 5762 Tool Order Number __________________ Tool Eng. Number___________________ Tool Revision______________________ Serial Number_____________________ Date of Manufacture Pin Gauge of Conductor Nest/Nests or Slug height if the nest is the “F” Crimp style. Range Conductor Nest # 1 = ____________ Actual = ____________ Technician _______________________ Date of Calibration __________________ Calibration should be done every 5,000 cycles or 3 months. Tools should be lubricated during this operation. Visit our Web site at http://www.molex.com Doc. No: ATS-640051100 Revision: D Release Date: 12-10-02 Revision Date: 01-24-11 UNCONTROLLED COPY Page 6 of 6