molex 207129 Series User manual

AT5757-CC Air Crimp Tool Head
Doc. No. ATS-640050700 Release Date: 12-11-02 UNCONTROLLED COPY age 1 of 6
Revision: C Revision Date: 01-24-11
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
 neumatic 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
roducts: Insulkrimp Male and Female Fully Insulated Quick Disconnect, erma-Seal Female Quick
Disconnect 18–22 AWG Conductor Crimp only. 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.
*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.
Wire Size: 1
–
22 AWG 0. 0
–
0.35 mm²
Terminal
No.
Terminal
Eng. No. (REF)
Wire Strip
Length
Insul
ation
Diameter Max.
In.
mm
In.
mm
19003
-
0001
AA
-
2201
0.234
5.953
0.135
3.429
19003
-
0005
AA
-
2201VN
0.234
5.953
0.135
3.429
19003
-
0008
AA
-
2201X
0.234
5.953
0.230
5.842
19003
-
0011
AA
-
2202
0.234
5.953
0.135
3.429
19003
-
0014
AA
-
2202X
0.234
5.953
0.230
5.842
19003
-
0017
AA
-
2203
0.234
5.
953
0.135
3.429
19003
-
0021
AA
-
2203X
0.234
5.953
0.230
5.842
19003
-
0024
AA
-
2204
0.234
5.953
0.135
3.429
19003
-
0027
AA
-
2204X
0.234
5.953
0.230
5.842
Wire Size: 1
–
22 AWG 0. 0
–
0.35 mm²
Terminal
No.
Terminal
Eng. No. (REF)
Wire Strip
Length
Insul
ation
Diameter Max.
In.
mm
In.
mm
19003
-
0030
AA
-
2205
0.234
5.953
0.135
3.429
19003
-
0033
AA
-
2205X
0.234
5.953
0.230
5.842
19003
-
0036
AA
-
22
13
0.234
5.953
0.135
3.429
19003
-
0038
AA
-
2214
0.234
5.953
0.135
3.429
19023
-
0053
AA
-
2207X
0.250
6.350
0.260
6.604
19164
-
0012
SAA
-
2140
0.203
5.159
19276
-
0002
AA
-
2201
-
LIF
0.234
5.953
0.135
3.429
Air Powered
Crimp Tool Head
Insulkrimp


Application Tooling
Specification Sheet
Order No. 64005
-
0700
Engineering No. AT 5757-CC
Wire Size (AWG)
*UL
-
310
22
8
20
13
18
20

AT5757-CC Air Crimp Tool Head
Doc. No. ATS-640050700 Release Date: 12-11-02 UNCONTROLLED COPY age 2 of 6
Revision: C Revision Date: 01-24-11
OPERATION
Refer to the instruction manual for the 19279-0001 (AT-200)
for mounting this crimp tool head.
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. ush the terminal and
wire onto the tab locator all the way to the stop in the color-
coded nest. The barrel of the terminal should be up. See
Figure 1.
3. ush 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.
Caution: Never operate this tool without the supplied safety shield in place. Never place fingers in the tool nests.
4. Remove the crimp and inspect for proper crimp location. 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.
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.
TERMINAL
SAFETY
SHIELD
TAB LOCATOR
Figure 1
LOCATOR
JAWS
OPEN
WIRE
TERMINAL
Figure 2
TERMINAL
BARREL
TERMINAL
2
ND
and 3
RD
TAB
LOCATOR
WIRE
CONDUCTOR
PUNCH
INSERT
ANVIL
Figure 3
INSERT
PUNCH
CONDUCTOR
ANVIL
1
ST
TAB
LOCATOR
LOCATOR
WIRE STOP BUILT
INTO TERMINAL

AT5757-CC Air Crimp Tool Head
Doc. No. ATS-640050700 Release Date: 12-11-02 UNCONTROLLED COPY age 3 of 6
Revision: C Revision Date: 01-24-11
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. 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. Use a light oil, such as 30 weight automotive oil used 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.
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
Wire Range
“X” Dimension
Conductor C
rimp
Crimp Inspection Marking
AWG
mm²
Mean
Go
No Go
Red
18
-
22
0.35
-
0.80
.080
.076
.088
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.
LUBRICATION POINTS
(BOTH SIDES)
LIGHT OIL (EVERY MONTH
OR 5,000 CRIMPS)
Figure 4
3/32” HEX
WRENCH
PIN GAUGE IN
CONDUCTOR CRIMP
“Confining” Crimp
X

AT5757-CC Air Crimp Tool Head
Doc. No. ATS-640050700 Release Date: 12-11-02 UNCONTROLLED COPY age 4 of 6
Revision: C Revision Date: 01-24-11
PARTS LIST
Item
Order No
Description
Quantity
64005
-
0700
Crimp Tool Head
Fig
ure
5
1
64005
-
0000
Basic Air Tool Head
1
2
64001
-
0
4
75
Locator Assembly
1
3
64001
-
0770
Tooling Kit
1
Tooling Kit Only
4
64001
-
0702
Conductor unch
1
5
64001
-
0701
Conductor Anvil
1
6
64001
-
0712
Insert unch
1
7
64001
-
0711
Insert Anvil
1
8
N/A
4mm Dia
meter
by 5.0mm L
on
g
Roll ins
2**
**
A
vailable from an
Industrial supply company such as (MSC (1
-
800
-
645
-
7270).
Figure 5
3
2
1
M4 LOCKNUT W/
HEX NYLON INSERT
M4 FLAT WASHER
4
5
6
7
(2)

AT5757-CC Air Crimp Tool Head
Doc. No. ATS-640050700 Release Date: 12-11-02 UNCONTROLLED COPY age 5 of 6
Revision: C Revision Date: 01-24-11
Parts List (Continued)
Item
Order No.
Description
Quantity
64005
-
0000
Basic Air Tool Head
Fig
ure
6
1
64005
-
0103
Nose Guard
1
2
64000
-
0077
Repair Kit (Springs, R
ods ivots ,Rings, and Washers)
1
3
N/A
M4 by 12
L
ong
. Freedrive an Head Screw
1**
4
N/A
M4 by 30
L
ong
Freedrive an Head Screw
1**
5
N/A
3/16” by 3/8” Long Dowel in
1**
**
A
vailable from an Industrial supply company such as MSC (1
-
800
-
645
-
7270).
Figure 6
3
4
2
2
2
5
1
(4)
(4)
(
2)
(4)
2
2
(2)
(2)
2

AT5757-CC Air Crimp Tool Head
Doc. No. ATS-640050700 Release Date: 12-11-02 UNCONTROLLED COPY age 6 of 6
Revision: C Revision Date: 01-24-11
Tool Order Number __________________
Tool Eng. Number___________________
Tool Revision______________________
Serial Number_____________________
Date of Manufacture
in 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
Air Powered
Crimp Tool Head
Insulkrimp


Certificate of Calibration Order No. 64005-0700
Engineering No. AT 5757-CC