molex Avikrimp 64005-3000 User manual

AT-5763 Air Crimp Head Tool
Doc. No: ATS-640053000 Release Date: 05-2 -03 UNCONTROLLED COPY Page 1 of 6
Revision: C Revision Date: 03-10-05
Air Powered
Crimp Tool Head
Avikrimp


Application Tooling
Speci ication Sheet Order No. 64005-3000
Engineering No. AT 5763
FEATURES
 Quick change tool head for the 1 27 -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 10–12 AWG (Expanded Flare and Oval Barrel).
This tool head is intended for use in the 1 27 -0001 (AT-200) either hand held or with optional bench adapter
1 078-0307 (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
12
70
10
80
*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: 10
–
12 AWG 5.00
–
3.30 mm²
Terminal No. Terminal
Eng No. (REF)
Wire Strip Length
Insul
ation
Dia
meter
Max.
In.
mm
In.
mm
1 002
-
0044
C
-
5265
.310
7. 4
.250
6.22

AT-5763 Air Crimp Head Tool
Doc. No: ATS-640053000 Release Date: 05-2 -03 UNCONTROLLED COPY Page 2 of 6
Revision: C Revision Date: 03-10-05
OPERATION
Refer to the instruction manual for the 1 27 -0001 (AT-200) for
mounting this crimp tool head.
Crimping Terminals
1. There are 2 tab locator blades supplied with the tool. One is
for .187 and .250 tabs; the other is for .205 tabs and .110 tabs.
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 down with
the flat side facing up. See 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.
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
FLAT SIDE UP
SAFETY
SHIELD
TAB LOCATOR
Figure 1
LOCATOR
JAWS
OPEN
WIRE TERMINAL
Figure 2
TERMINAL
BARREL
WIRE
CONDUCTOR
PUNCH
INSULATION
PUNCH
1
ST
TAB
LOCATOR
WIRE STOP BUILT
INTO TERMINAL
2
ND
TAB LOCATOR
Figure 3
LOCATOR
INSULATION
ANVIL
CONDUCTOR
ANVIL

AT-5763 Air Crimp Head Tool
Doc. No: ATS-640053000 Release Date: 05-2 -03 UNCONTROLLED COPY Page 3 of 6
Revision: C Revision Date: 03-10-05
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 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 Crimp
Crimp Inspection Marking
A
WG
mm²
Mean
Go
No Go
Yellow
10
-
12
3.30
-
5.00
.121
.118
.124
---
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.
PIN GAUGE IN
CONDUCTOR CRIMP
“Con ining” Crimp
X
LOOSEN
M4 SCREW
LUBRICATION POINTS
(BOTH SIDES)
LIGHT OIL (EVERY MONTH
OR 5,000 CRIMPS)
Figure 4
3/32” HEX
WRENCH

AT-5763 Air Crimp Head Tool
Doc. No: ATS-640053000 Release Date: 05-2 -03 UNCONTROLLED COPY Page 4 of 6
Revision: C Revision Date: 03-10-05
3
2
1
Figure 5
M4 L
OCKNUT W/HEX
NYLON INSERT M4 FLAT WASHER
4
5
9
6
7
8
(2)
PARTS LIST
Item
Order No
Description
Quantity
64005
-
3000
Crimp Tool Head
Figure 5
1
64005
-
0000
Basic Air Tool Head
1
2
64001
-
3075
Locator Assembly
1
3
64001
-
307
0
Tooling Kit
1
Tooling Kit Only
4
64001
-
3002
Conductor Punch
1
5
64001
-
3001
Conductor Anvil
1
6
64001
-
3004
Insulation Punch
1
7
64001
-
3003
Insulation Anvil
1
8
N/A
4 mm Dia. by 5.0 mm L
ong
Roll Pins
2**
N/A
#10
-
32 by 5/16” L
ong
Cup Pt. Set Screw
1**
*
* Available from an Industrial supply company such as MSC (1
-
800
-
645
-
7270).

AT-5763 Air Crimp Head Tool
Doc. No: ATS-640053000 Release Date: 05-2 -03 UNCONTROLLED COPY Page 5 of 6
Revision: C Revision Date: 03-10-05
Figure 6
3
3
2
2
2
4
1
(4)
(4)
(
2)
(4)
2
2
(2)
(2)
2
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 K
it (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).

AT-5763 Air Crimp Head Tool
Doc. No: ATS-640053000 Release Date: 05-2 -03 UNCONTROLLED COPY Page 6 of 6
Revision: C Revision Date: 03-10-05
Air Powered
Crimp Tool Head
Avikrimp


Certi icate o Calibration
Order No. 64005-3000
Engineering No. AT 5763
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