Molex 64005-6200 Manual de usuario

Air Head Crimp Tool for InsulKrimp™ Piggyback QD

Doc. No: ATS-640056200 Release Date: 09-19-06 UNCONTROLLED COPY Page 1 of 7

Revision: C Revision Date: 10-07-14

Air Powered

Crimp Tool Head

Insulkrimp

Application Tooling

Specification Sheet

Order No. 64005-6200

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 for each of

the three nests

Insulation crimp adjustment allows a precise insulation crimp. To meet or exceed the requirements of UL,

CSA and Military Class II

3-nested tool eliminates the need for additional tools

Pneumatic powered crimp tools help reduce fatigue and discomfort from repetitive manual crimping

SCOPE

Products: InsulKrimp™Piggyback Quick Disconnect 10 - 22 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. It indicates the minimum acceptable force to break or separate the terminal from the conductor.

Wire Size (AWG)

*UL - 310

*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.

Air Head Crimp Tool for InsulKrimp™ Piggyback QD

Doc. No: ATS-640056200 Release Date: 09-19-06 UNCONTROLLED COPY Page 2 of 7

Revision: C Revision Date: 10-07-14

Wire Size: 10 –12 AWG 5.00 –3.30mm²

Terminal No.

Terminal Eng. No. (REF)

Terminal No. Mylar Tape

Wire Strip Length

Insulation Diameter

Maximum

In.

19011-0007

C-2303

19011-0008

.380

9.53

.260

6.48

Wire Size: 14 –16 AWG 2.00 –1.30mm²

Terminal No.

Terminal Eng. No. (REF)

Terminal No. Mylar Tape

Wire Strip Length

Insulation Diameter

Maximum

In.

19011-0004

BB-2302

19011-0006

.310

7.94

.150

3.68

19011-0037

19011-0038

.310

7.94

.140

3.56

Wire Size: 18 –22 AWG 0.80 –0.35mm²

Terminal No.

Terminal Eng. No. (REF)

Terminal No. Mylar Tape

Wire Strip Length

Insulation Diameter

Maximum

In.

19011-0001

AA-2301

19011-0003

.310

7.94

.140

3.56

19011-0035

19011-0036

.310

7.94

.110

2.79

OPERATION

Refer to the instruction manual for the 19279-0001 (AT-200)

for mounting this crimp tool head.

Crimping Terminals

1. Push the terminal onto the tab locator all the way to the

stop in the proper color-coded nest. The male tab of the

terminal should be up. See Figure 1.

2. The height of the locator may need to be adjusted when

changing from one terminal size to another. To do this,

loosen the locator lock nut, (See Figure 3), and adjust

height so the tab aligns with the female locator tab.

Tighten the lock nut.

3. 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 2.

CAUTION: Never operate this tool without the supplied safety shield in place. Never place fingers in the

tool nests.

4. 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.

MALE TAB

FACING UP

SAFETY

SHIELD

TAB LOCATOR

Figure 1

LOCATOR

JAWS

OPEN

Air Head Crimp Tool for InsulKrimp™ Piggyback QD

Doc. No: ATS-640056200 Release Date: 09-19-06 UNCONTROLLED COPY Page 3 of 7

Revision: C Revision Date: 10-07-14

TERMINAL

BARREL

TERMINAL TAB

TAB LOCATOR

WIRE

CONDUCTOR PUNCH

INSULATION ANVIL

Figure 3

INSULATION PUNCH

CONDUCTOR

ANVIL

WIRE STOP BUILT

INTO TERMINAL

LOCATOR

5. 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.

6. If the insulation part of the crimp needs to be adjusted, first loosen the M4 screw on the bottom tool jaw,

then 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.

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.

WIRE

TERMINAL

Figure 2

LUBRICATION POINTS

(BOTH SIDES)

LIGHT OIL (EVERY MONTH

OR 5,000 CRIMPS)

LOOSEN

M4 SCREW

Figure 4

3/32” HEX

WRENCH

Air Head Crimp Tool for InsulKrimp™ Piggyback QD

Doc. No: ATS-640056200 Release Date: 09-19-06 UNCONTROLLED COPY Page 4 of 7

Revision: C Revision Date: 10-07-14

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

No Go

Red

18 - 22

0.35 - 0.80

.080

.076

.084

N/A

Blue

14 - 16

1.30 - 2.00

.098

.094

.102

N/A

Yellow

10 - 12

3.30 - 5.00

.140

.136

.146

N/A

CAUTION: Repetitive use of this tool should be avoided.

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

“Confining ” Crimp

Air Head Crimp Tool for InsulKrimp™ Piggyback QD

Doc. No: ATS-640056200 Release Date: 09-19-06 UNCONTROLLED COPY Page 5 of 7

Revision: C Revision Date: 10-07-14

Figure 5

M4 LOCKNUT W/HEX

NYLON INSERT

M4 FLAT WASHER

(2)

PARTS LIST

Item

Order No.

Description

Quantity

64005-6200

Crimp Tool Head

Figure 5

64005-0000

Basic Air Tool Head

64001-6275

Locator Assembly

64001-6270

Tooling Kit

Tooling Kit Only

64001-6201

Conductor Punch

64001-62022

Conductor Anvil

64001-6203

Insulation Punch

64001-6204

Insulation Anvil

N/A

4mm Diameter by 5.0mm Long Roll Pins

2**

N/A

#10-32 by 5/16” Long Cup Point Set Screw

1**

** Available from an industrial supply company such as MSC (1-800-645-7270).

Air Head Crimp Tool for InsulKrimp™ Piggyback QD

Doc. No: ATS-640056200 Release Date: 09-19-06 UNCONTROLLED COPY Page 6 of 7

Revision: C Revision Date: 10-07-14

Figure 6

(4)

(2)

(4)

(2)

Parts List (Continued)

Item

Order No.

Description

Quantity

64005-0000

Basic Air Tool Head

Figure 6

64005-0103

Nose Guard

64000-0077

Repair Kit (Springs, Rods Pivots ,Rings, and Washers)

N/A

M4 by 12 Long Freedrive Pan Head Screw

1**

N/A

M4 by 30 Long Freedrive Pan Head Screw

1**

N/A

3/16” by 3/8” Long Dowel Pin

1**

** Available from an industrial supply company such as MSC (1-800-645-7270).

Air Head Crimp Tool for InsulKrimp™ Piggyback QD

Doc. No: ATS-640056200 Release Date: 09-19-06 UNCONTROLLED COPY Page 7 of 7

Revision: C Revision Date: 10-07-14

Air Powered

Crimp Tool Head

Insulkrimp

Certificate of Calibration

Order No. 64005-6200

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 = ____________-

Range Conductor Nest # 2 = ____________- Actual = ____________-

Range Conductor Nest # 3 = ____________- 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

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