molex Avikrimp AT 5762 User manual

AT5762 Air Crimp Head Tool
Doc. No: ATS-640051100 Release Date: 12-10-02 UNCONTROLLED COPY age 1 of 6
Revision: D Revision Date: 01-24-11
Air Powered
Crimp Tool Head
Avikrimp


Application Tooling
Speci ication 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
 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: 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.
Wire Size: 14
–
16 AWG 2.00
–
1.30 mm²
Terminal No. Terminal
Eng No. (REF)
Wire
Strip Length
Insul
ation Diameter Maximum
In.
mm
In.
mm
19002
-
0024
BB
-
5263
0.25
6.35
0.16
3.94
19002
-
0028
BB
-
5269
0.25
6.35
0.16
3.94
19002
-
0031
BB
-
5273
0.25
6.35
0.16
3.94
19002
-
0034
BB
-
5277
0.25
6.35
0.16
3.94
19002
-
0037
BB
-
5281
0.25
6.35
0.16
3.9
4
19002
-
0040
BB
-
5287
0.25
6.35
0.16
3.94
19002
-
0042
BB
-
5289
0.25
6.35
0.16
3.94
19277
-
0005
BB
-
5263
-
LIF
0.25
6.35
0.16
3.94

AT5762 Air Crimp Head Tool
Doc. No: ATS-640051100 Release Date: 12-10-02 UNCONTROLLED COPY age 2 of 6
Revision: D 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
proper color-coded nest. The barrel of the terminal
should be up. See Figure 1.
Caution: Never operate this tool without the supplied safety shield in place. Never place fingers in the tool nests.
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.
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
SAFETY
SHIELD
TAB LOCATOR
Figure 1
LOCATOR
JAWS
OPEN
2
ND
and 3
RD
TAB
LOCATOR
LOCATOR
WIRE
TERMINAL
Figure 2
TERMINAL
BARREL
TERMINAL
WIRE
CONDUCTOR PUNCH
INSULATION ANVIL
INSULATION
PUNCH
1
ST
TAB
LOCATOR
WIRE STOP BUILT
INTO TERMINAL
Figure 3
CONDUCTOR ANVIL

AT5762 Air Crimp Head Tool
Doc. No: ATS-640051100 Release Date: 12-10-02 UNCONTROLLED COPY age 3 of 6
Revision: D 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. 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
AWG
mm²
Mean
Go
No Go
Blue
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.
PIN GAUGE IN
CONDUCTOR CRIMP
“Con ining” Crimp
X
LUBRICATION POINTS
(BOTH SIDES)
LIGHT OIL (EVERY MONTH
OR 5,000 CRIMPS)
Figure 4
3/32” HEX
WRENCH

AT5762 Air Crimp Head Tool
Doc. No: ATS-640051100 Release Date: 12-10-02 UNCONTROLLED COPY age 4 of 6
Revision: D Revision Date: 01-24-11
PARTS LIST
Item
Order No
Description
Quantity
64005
-
1100
Crimp Tool Head
Fig
ure
5
1
64005
-
0000
Basic Air Tool Head
1
2
64001
-
0
4
75
Locator Assembly
1
3
64001
-
1170
Tooling Kit
1
Tooling Kit Only
4
64001
-
1102
Conductor unch
1
5
64001
-
1101
Conductor Anvil
1
6
64001
-
1104
Insulation unch
1
7
64001
-
1103
Insulation Anvil
1
8
N/A
4mm Dia
meter
by 5.0mm L
on
g
Roll ins
2**
9
N/A
#10
-
32 by 5/16” L
on
g Cup t. Set Screw
1**
**
A
vailable f
rom an Industrial supply company such as MSC (1
-
800
-
645
-
7270).
3
2
1
Figure 5
M4 LOCKNUT W/HEX
NYLON INSERT
M4 FLAT WASHER
4
5
9 6
7
8 (2)

AT5762 Air Crimp Head Tool
Doc. No: ATS-640051100 Release Date: 12-10-02 UNCONTROLLED COPY age 5 of 6
Revision: D Revision Date: 01-24-11
Figure 6
3
4
2
2
2
5
1
(4)
(4)
(2)
(4)
2
2
(2)
(2)
2
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 (Spri
ngs, Rods 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).

AT5762 Air Crimp Head Tool
Doc. No: ATS-640051100 Release Date: 12-10-02 UNCONTROLLED COPY age 6 of 6
Revision: D Revision Date: 01-24-11
Air Powered
Crimp Tool Head
Avikrimp


Certi icate o Calibration Order No. 64005-1100
Engineering No. AT 5762
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