AT5758 Air Crimp Tool Head
Doc. No: ATS-640052000 Release Date: 12-11-02 UNCONTROLLED COPY Page 1 of 6
Revision: B Revision Date: 09-02-03
Air Powered
Crimp Tool Head
Avikrimp
and
InsulKrimp
Application Tooling
Specification Sheet Order No. 64005-2000
Engineering No. AT 5758
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 /InsulKrimp Female 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.
–
16 AWG 2.00
–
1.30 mm²
Terminal
No.
Terminal
Eng No. (REF)
Wire Strip
Length
Insul
ation
Diameter Max.
In.
mm
In.
mm
19017
-
0023
BB
-
2132
0.31
7.94
0.14
3.56
19017
-
0028
BB
-
2135
0.31
7.94
0.14
3.56
19017
-
0031
BB
-
2138
0.31
7.94
0.14
3.56
19017
-
0032
BB
-
2138
-
032
0.31
7.94
0.14
3.56
19017
-
0037
BB
-
2141
0.31
7.94
0.14
3.56
19017
-
0043
BB
-
2191
0.31
7.94
0.14
3.56
19017
-
0044
BB
-
2191
-
032
0.31
7.94
0.14
3.56
19019
-
0022
BB
-
8132
0.31
7.94
0.14
3.56
–
16 AWG 2.00
–
1.30 mm²
Terminal
No.
Terminal
Eng No. (REF)
Wire Strip
Length
Insul
ation
Diameter Max.
In.
mm
In.
mm
19019
-
0025
BB
-
8135
0.31
7.94
0.14
3.56
19019
-
0027
BB
-
8138
0.31
7.94
0.14
3.56
19019
-
0028
BB
-
8138
-
032
0.31
7.9
4
0.14
3.56
19019
-
0031
BB
-
8141
0.31
7.94
0.14
3.56
19019
-
0034
BB
-
8191
0.31
7.94
0.14
3.56
19019
-
0035
BB
-
8191
-
032
0.31
7.94
0.14
3.56
AT5758 Air Crimp Tool Head
Doc. No: ATS-640052000 Release Date: 12-11-02 UNCONTROLLED COPY Page 2 of 6
Revision: B Revision Date: 09-02-03
OPERATION
Refer to the instruction manual for the 19279-0001 (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 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 disconnect the air source and 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. Reconnect the air source.
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
WIRE STOP BUILT
INTO TERMINAL
2
ND
TAB
LOCATOR
WIRE
CONDUCTOR
PUNCH
INSULATION
ANVIL
Figure 3
INSULATION
PUNCH
CONDUCTOR
ANVIL
TAB LOCATOR
LOCATOR
TERMINAL
AT5758 Air Crimp Tool Head
Doc. No: ATS-640052000 Release Date: 12-11-02 UNCONTROLLED COPY Page 3 of 6
Revision: B Revision Date: 09-02-03
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
AWG
mm²
Mean
Go
No Go
Blue
14
-
16
1.30
-
2.00
.094
.091
.098
o
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
AT5758 Air Crimp Tool Head
Doc. No: ATS-640052000 Release Date: 12-11-02 UNCONTROLLED COPY Page 4 of 6
Revision: B Revision Date: 09-02-03
3
2
1
Figure 5
M4 LOCKNUT W/HEX
NYLON INSERT
M4 FLAT WASHER
4
5
9 6
7
8
(2)
PARTS LIST
Item
Order No
Description
Quantity
64005
-
2000
Crimp Tool Head
Figure 5
1
64005
-
0000
Basic Air Tool Head
1
2
64001
-
0275
Locator
Assembly
1
3
64001
-
2070
Tooling Kit
1
Tooling Kit Only
4
64001
-
1001
Conductor Punch
1
5
64001
-
1002
Conductor Anvil
1
6
64001
-
2015
Insulation Punch
1
7
64001
-
2013
Insulation Anvil
1
8
N/A
4 mm Dia. by 5.0 mm L
on
g
Roll Pins
2**
9
N/A
#10
-
32 by 5/16” L
on
g Cu
p Pt. Set Screw
1**
** Available from an Industrial supply company such as MSC (1
-
800
-
645
-
7270).
AT5758 Air Crimp Tool Head
Doc. No: ATS-640052000 Release Date: 12-11-02 UNCONTROLLED COPY Page 5 of 6
Revision: B Revision Date: 09-02-03
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
Figure 6
1
64005
-
0103
Nose Guar
d
1
2
64000
-
0077
Repair Kit (Springs, Rods Pivots ,Rings, and Washers)
1
3
N/A
M4 by 12
L
ong
Freedrive Pan Head Screw
1**
4
N/A
M4 by 30
L
ong
Freedrive Pan Head Screw
1**
5
N/A
3/16” by 3/8” Long Dowel Pin
1**
** Available from an Industrial supply c
ompany such as MSC (1
-
800
-
645
-
7270).
AT5758 Air Crimp Tool Head
Doc. No: ATS-640052000 Release Date: 12-11-02 UNCONTROLLED COPY Page 6 of 6
Revision: B Revision Date: 09-02-03
Air Powered
Crimp Tool Head
Avikrimp
and
InsulKrimp
Certificate of Calibration Order No. 64005-2000
Engineering No. AT 5758
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