SAE AS 5259 8-2017 CRIMPING TOOL AND ACCESSORIES 18VDC BATTERY ELECTRIC PORTABLE HYDRAULIC WIRE SIZE 8 TO 00 UN-INSULATED AND SIZE 8 THROUGH 2 INSULATED CRIMP BARRELS.pdf

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1、 AEROSPACE STANDARD CRIMPING TOOL AND ACCESSORIES, 18VDC BATTERY ELECTRIC, PORTABLE HYDRAULIC, WIRE SIZE 8 TO 00 UN-INSULATED, AND SIZE 8 THROUGH 2 INSULATED CRIMP BARRELS AS5259/8 Copyright 2017 SAE International All rights reserved. No part of this publication may be reproduced, stored in a retrie

2、val system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-4970 (outside USA) Fax: 724-776-0790 Email: Custome

3、rServicesae.org SAE WEB ADDRESS: http:/www.sae.org ISSUED2017-05THIRD ANGLE PROJECTION CUSTODIAN: AE-8/AE-8C2 FEDERAL SUPPLY CLASS 5120 AS5259 /8 SHEET 1 OF 4 PROCUREMENT SPECIFICATION: AS5259 SAE Technical Standards Board Rules provide that: “This report is published by SAEtoadvance thestate of tec

4、hnicaland engineering sciences. The useof this report is entirely voluntary, and its applicability andsuitability for any particularuse, includingany patent infringement arisingtherefrom,is the sole responsibility of theuser.” SAE reviews eachtechnical reportatleast every fiveyears at whichtime it m

5、ay be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions.SAE values your input. To provide feedback on this Technical Report, please visit http:/standards.sae.org/AS5259/8 RATIONALE PROVIDE A STANDARD TOOL (CONTROLLED BY A SPECIFICATION) TO REPLACE NONST

6、ANDARD (COMMERCIAL) TOOLS PROCURED BY USERS TO TERMINATE SAE INTERNATIONAL STANDARD WIRING COMPONENTS. NOTICE THE COMPLETE REQUIREMENTS FOR PROCURING THE PRODUCT DESCRIBED HEREIN SHALL CONSIST OF THIS DOCUMENT AND THE LATEST ISSUE OF AS5259. CAUTION: TOOL IS NOT TO BE USED IN EXPLOSIVE ENVIRONMENTS.

7、 AS5259/8 TOOL IS POWERED BY AN ELECTRICAL (BATTERY) DRIVE SYSTEM. CAUTION SHOULD BE USED WHEN OPERATING THE TOOL. DO NOT INSTALL/REMOVE THE BATTERY OR OPERATE TOOL IN OR NEAR POTENTIALLY EXPLOSIVE VAPORS OR FLAMMABLE LIQUIDS. ELECTRICAL SPARKS PRODUCED BY STORED ELECTRICAL ENERGY MAY CAUSE UNEXPECT

8、ED IGNITION OF FLAMMABLE HAZARDS. CAUTION LABELS FIGURE 1 - AS5259/8-01 BASIC CRIMPING TOOL AEROSPACE STANDARD AS5259 /8 SHEET 2 OF 4 CRIMPING TOOL AND ACCESSORIES, 18VDC BATTERY ELECTRIC, PORTABLE HYDRAULIC, WIRE SIZE 8 TO 00 UN-INSULATED, AND SIZE 8 THROUGH 2 INSULATED CRIMP BARRELS REQUIREMENTS:

9、AS SPECIFIED IN AS5259 AND THIS SPECIFICATION. 1. CONFIGURATION a. DIMENSIONS SHALL BE IN INCHES. UNLESS OTHERWISE SPECIFIED, TOLERANCES SHALL BE .015 AND ANGLES 1. BASIC TOOL CONFIGURATION SHALL BE OPTIONAL WITHIN ENVELOPE DIMENSIONS. b. DIES SHALL BE IN ACCORDANCE WITH AS5259/7 AND AS SPECIFIED IN

10、 TABLE 1. c. DIE INSPECTION GAGES SHALL BE IN ACCORDANCE AS5259/6 AND AS SPECIFIED IN TABLE 1. d. TOOL SHALL HAVE A MANUAL DIE RETRACT SWITCH THAT PERMITS THE DIES TO BE OPENED PRIOR TO A COMPLETE CRIMP (SEE APPLICATION NOTES). A COMPONENT IS CONSIDERED COMPLETELY CRIMPED ONLY WHEN THE DIES ARE CLOS

11、ED (SEE AS5259). e. TOOL SHALL GENERATE AN OUTPUT FORCE OF 5.5 TONS (11000 LBF) AT THE DIE FACES AND AUTO RETRACT AFTER COMPLETION OF CRIMP CYCLE. f. TOOL SHALL HAVE A RECHARGEABLE BATTERY FOR POWER (SEE MANUFACTURERS INSTRUCTIONS). BATTERY SHALL BE ATTACHABLE AND REMOVABLE TO/FROM THE TOOL AND CHAR

12、GER WITH A LATCH MECHANISM. g. MAXIMUM WEIGHT WITH HEAVIEST DIE SPECIFIED IN TABLE 1 SHALL BE 6.5 POUNDS. h. TOOL SHALL HAVE LANYARD TO SUPPORT TOOL ON A HOOK. THE LANYARD WILL NOT PULL OUT WHEN DROPPED 3 FEET ON AN ATTACHED ROPE OR CHAIN. i. UNLESS OTHERWISE SPECIFIED IN THE PURCHASE ORDER, THE TOO

13、L SHALL BE SUPPLIED IN A STORAGE CONTAINER IN ACCORDANCE WITH AS5259. THE CONTAINER SHALL INCLUDE TWO BATTERIES, THE CHARGER AND OTHER ACCESSORIES AS NEEDED TO OPERATE THE TOOL. AS5259/7 DIES AND GAGES ARE NOT REQUIRED, BUT THE CONTAINER SHALL PROVIDE SPACE FOR THE DIES AND GAGES LISTED IN TABLE 1.

14、j. ALL BURRS SHALL BE REMOVED AND BREAK SHARP EDGES. k. MANUFACTURER INSTRUCTION SHALL BE PROVIDED WITH EACH TOOL. AS A MINIMUM THE INSTRUCTION SHALL CONTAIN THE FOLLOWING INFORMATION (SEE AS5259 FOR MORE DETAILS): 1. PART NUMBERS FOR ALL ACCESSORIES (BATTERY, CHARGER, ETC.). IF THE PART NUMBERS ARE

15、 OTHER THAN THE TOOL MANUFACTURER PART NUMBER, THE SOURCE OF THE ACCESSORIES SHALL BE PROVIDED. 2. INSTRUCTION ON HOW TO USE THE CHARGER AND HOW TO DETERMINE THE BATTERY IS FULLY CHARGED. 3. INSTRUCTION ON HOW TO OPERATE THE TOOL (INSERTION/REMOVAL AND GAGING OF THE DIES, COMPONENT ALIGNMENT, TOOL P

16、ERFORMANCE, COMPONENT INSPECTION, INSPECTION OF THE CRIMP, ETC.). 4. ALL COMPONENT PARTS NUMBER WITH RELATED DIES AND GAGES THAT CAN BE PERFORMED WITH THE AS5259/8 TOOL. 5. SAFETY ISSUES AND WARNINGS. 2. MATERIALS a. TOOL HEAD SHALL BE STEEL WITH A BLACK OXIDE FINISH DESIGNED TO MEET THE PERFORMANCE

17、 REQUIREMENTS OF AS5259. 3. MARKING a. MANUFACTURER NAME OR SYMBOL, PART NUMBER, AND SAE PART IDENTIFICATION NUMBER (M5259/8-01) IS REQUIRED ON THE TOOL (LOCATION OPTIONAL). SUPPLIER SYMBOL SHALL BE IN ACCORDANCE WITH AIR1351. b. SAE PART IDENTIFICATION NUMBER M5259 /8 -01 I I I I I I_ BASIC TOOL DA

18、SH NUMBER (SEE AS5259/7 FOR CRIMP DIES) I I_ DETAIL SPECIFICATION NUMBER I_ PART NUMBER DESIGNATION (M) AND BASIC SPECIFICATION NUMBER c. LABELS SHALL BE PRESENT AND LEGIBLE AFTER ALL QUALIFICATION TESTS. AEROSPACE STANDARD AS5259 /8 SHEET 3 OF 4 CRIMPING TOOL AND ACCESSORIES, 18VDC BATTERY ELECTRIC

19、, PORTABLE HYDRAULIC, WIRE SIZE 8 TO 00 UN-INSULATED, AND SIZE 8 THROUGH 2 INSULATED CRIMP BARRELS 4. QUALIFICATION EXCEPTIONS a. TOOL PERFORMANCE AND CONFIGURATION OF OPERATION CRITICAL COMPONENTS MAY BE QUALIFIED BY SIMILARITY TO AS5259/5 OR AS5259/4 AS AGREED TO BY THE QUALIFYING AUTHORITY. b. HI

20、GH COMPRESSION FORCE SHALL BE PERFORMED ON WIRE SIZE 00. THE ACTUATION FORCE IS NOT APPLICABLE. c. CRIMP COMPRESSION FORCE SHALL BE PERFORMED AT THE TEMPERATURES SPECIFIED ON A WIRE SIZE 00 FOLLOWED BY INSPECTION GAGING AND A CRIMP TENSILE STRENGTH AS SPECIFIED BY THE COMPONENT SPECIFICATION. THE CO

21、MPRESSION FORCE VALUE NOT REQUIRED. d. LIFE TEST NOT REQUIRED (CERTIFICATION TO 10000 CYCLES IS REQUIRED). e. CORROSION TEST NOT REQUIRED. f. WHEN A QUALIFIED SUPPLIER HAS BEEN DETERMINED FOR THE TOOL IN ACCORDANCE WITH AS5259; THE AS5259/8-01 MAY BE USED WITH COMPONENT SPECIFICATION LISTED IN TABLE

22、 1, AND WILL BE APPROVED/LISTED FOR USE ON THE COMPONENT DETAIL SPECIFICATION. THIS APPLIES TO SAE SPECIFICATIONS ONLY. COMPONENTS WHICH REMAIN UNDER MILITARY SPECIFICATIONS WILL REQUIRE VERIFICATION OF COMPLIANCE. APPLICATION NOTES 1. SCOPE AS5259/8 IS DESIGNED TO FUNCTION AS A REMOTE ELECTRICAL PU

23、MP VERSION OF THE AS5259/4-01 OR THE AS5259/5-01 BASIC TOOLS MANUAL PUMP VERSIONS. CRIMPING IS LIMITED TO WIRE SIZES 8 THROUGH 2 FOR INSULATED TERMINALS AND 8 THROUGH 00 FOR UN-INSULATED TERMINALS AND CONTACTS (SEE TABLE 1). 2. DIE RETRACTION SWITCH THE MANUAL DIE RETRACTION SWITCH CONTROL IS INTEND

24、ED TO PERMIT THE USER THE ABILITY TO RELAX/OPEN PARTIALLY CLOSED DIES FOR REPOSITIONING OF THE CRIMP TERMINATION AND/OR THE WIRE. PARTIAL COMPONENT CRIMPS ARE NOT ACCEPTABLE AND WILL CAUSE POTENTIAL HOTSPOTS OR LOST VOLTAGE AT THE CRIMP INTERFACE. 3. WARNINGS STANDARD GUIDANCE FOR HANDLING AND DISPO

25、SING OF A BATTERY APPLIES. CONSULT LOCAL AUTHORITIES FOR FURTHER INFORMATION. OTHER SUPPLIER WARNINGS AND NOTIFICATIONS SHALL BE FOLLOWED WHEN USING THIS TOOL (SEE INSTRUCTIONS AND FIGURE 1). 4. DIE INSPECTIONS GO/NO-GO GAGE INSPECTION RECOMMENDED AT PERIODIC INTERVALS (SEE AS5259/6). 5. AS5259/8 IS

26、 DESIGNED TO CRIMP THE STANDARD COMPONENTS LISTED IN TABLE 1. AEROSPACE STANDARD AS5259 /8 SHEET 4 OF 4 CRIMPING TOOL AND ACCESSORIES, 18VDC BATTERY ELECTRIC, PORTABLE HYDRAULIC, WIRE SIZE 8 TO 00 UN-INSULATED, AND SIZE 8 THROUGH 2 INSULATED CRIMP BARRELS TABLE 1 - M5259/8-01 COMPONENT REFERENCES BY

27、 WIRE SIZE AS5259/8 CRIMP TOOL PART NUMBER COMPONENT SAE SPECIFICATIONS WIRE SIZE (REF) AS5259/7 DIE PART NUMBER M5259/7 4/ AS5259/6 GAGE PART NUMBER M5259/8-01 SAE AS7928 1/ AS20659 AS7928/11 SAE AS7974 2/ AS7974/1 AS7974/2 AS7928/3 AS7928/4 AS21378 AS25486 AS25487 AS25488 AS90328 8 -001 MS90486-8

28、-010 M5259/6-001 6 -002 MS90486-6 -011 M5259/6-002 4 -003 MS90486-4 -012 M5259/6-003 2 -004 MS90486-2 -013 M5259/6-004 1 -005 MS90486-1 0 -006 MS90486-01 -014 M5259/6-005 00 -007 MS90486-02 -015 M5259/6-006 SAE AS7928 3/ AS7928/4 AS7928/13 AS25036 AS7928/12 8 -016 MS23003-8 6 -017 MS23003-6 4 -018 M

29、S23003-4 2 -019 MS23003-2 1/ UN-INSULATED COPPER TERMINAL 2/ COPPER CONTACT 3/ INSULATED COPPER TERMINAL 4/ M5259/7-010 THROUGH -015 ARE INDENT DIES AND EXCLUDE WIRE SIZE 1 6. SUPERSESSION INFORMATION a. MILITARY COMPONENT SPECIFICATIONS ARE DIRECTLY SUPERSEDED BY SAE SPECIFICATIONS AS SHOWN IN TABL

30、E 2 WITHOUT PART NUMBER CHANGE. THE AS5259/8 TOOL AND DIES SPECIFIED IN TABLE 2 WILL WORK WITH SUPERSEDED MILITARY SPECIFICATION COMPONENTS. TABLE 2 - COMPONENT SUPERSEDING INFORMATION AS APPLICABLE TO AS5259/8 COMPONENT MILITARY SPECIFICATIONS SUPERSEDING SAE SPECIFICATIONS COMPONENT MILITARY SPECI

31、FICATIONS SUPERSEDING SAE SPECIFICATIONS MIL-C-7974 AS7974 MS25487 AS25487 MIL-C-7974/1 AS7974/1 MS25488 AS25488 MIL-C-7974/2 AS7974/2 MS90328 AS90328 MIL-C-7974/3 AS7974/3 MIL-T-7928 AS7928 MIL-C-7974/4 AS7974/4 MIL-T-7928/4 AS7928/4 MS21378 AS21378 MS25036 AS25036 MS25486 AS25486 MS20659 AS20659 S

32、PECIFICATION NOTES 1. IT IS THE RESPONSIBILITY OF THE COMPONENT SPECIFICATION PREPARER TO DETERMINE IF A SPECIFIC TOOL CAN BE USED TO CRIMP SPECIFIC WIRE BARRELS OTHER THAN THOSE LISTED IN TABLE 1. AFTER THE TOOL HAS BEEN DETERMINED TO BE ACCEPTABLE FOR THE COMPONENT, THE PREPARER IS RECOMMENDED TO

33、REQUEST SAE AE-8C2 TO EXPAND THE COMPONENT REFERENCE LIST OR TO ESTABLISH AN AS5259/Y DETAIL SPECIFICATION WHICH THE PREPARER CAN THEN REFERENCE IN THE COMPONENT SPECIFICATION. 2. REVISION INDICATOR: A CHANGE BAR (I) LOCATED IN THE LEFT MARGIN IS FOR THE CONVENIENCE OF THE USER IN LOCATING AREAS WHE

34、RE TECHNICAL REVISIONS, NOT EDITORIAL CHANGES, HAVE BEEN MADE TO THE PREVIOUS ISSUE OF THIS DOCUMENT. AN (R) SYMBOL TO THE LEFT OF THE DOCUMENT TITLE INDICATES A COMPLETE REVISION OF THE DOCUMENT, INCLUDING TECHNICAL REVISIONS. CHANGE BARS AND (R) ARE NOT USED IN ORIGINAL PUBLICATIONS, NOR IN DOCUMENTS THAT CONTAIN EDITORIAL CHANGES ONLY.