molex 207129 Series Use and care manual

AT2200HD Air Head Crimp Tool
Doc. No: ATS-64005-1600 Release Date: 01-17-0 UNCONTROLLED COPY Page 1 of 6
Revision: A Revision Date: 06-25-0
Air Powered
Crimp Tool Head
Avikrimp


InsulKrimp


Cer ifica e of Calibra ion
Order No. 64005-1600
Engineering No. AT 2200HD
FEATURES
 Quick change tool head for the 19279-0001 (AT-200)
 Tooling kit is interchangeable with other kits in the 64001 and 6400 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 Terminals 14-16 AWG Heavy Duty, (Rings, Spades, Railroad Rings and
Test Terminals.) This tool head is intended for use in the 19279-0001 (AT-200) either hand held or with optional
bench adapter 19078-0 07 (ATBA) and foot switch.
Tes ing
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
-
486 A
16
0
14
50
*UL - 486 A - Terminals (copper conductors only).
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 S rip
Leng h
Insula ion
Diame er Max.
In.
mm
In
.
mm
19054
-
006
B
-
201
-
12HDX
0. 1
7.94
0.25
6. 5
19054
-
0066
B
-
201
-
8HDX
0. 1
7.94
0.25
6. 5
19054
-
0070
B
-
201
-
76HDX
0. 1
7.94
0.25
6.
5
19054
-
0090
B
-
228
-
06HDX
0. 1
7.94
0.25
6. 5
19054
-
0092
B
-
228
-
08HDX
0. 1
7.94
0.25
6. 5
19054
-
0094
B
-
228
-
10HDX
0. 1
7.94
0.25
6. 5
19054
-
0096
B
-
2 0
-
10HDX
0. 1
7.94
0.25
6. 5
19054
-
0097
B
-
2 0
-
14HDX
0. 1
7.94
0.25
6. 5
Wire Size: 14
–
16 AWG 2.00
–
1.30 mm²
Terminal
No.
Terminal
Eng. No. (REF)
Wire S rip
Leng h
Insula ion
Diame er Max.
In.
mm
In
.
mm
19054
-
0098
B
-
2 0
-
56HDX
0. 1
7.94
0.25
6. 5
19054
-
0126
B
-
240
-
8HDX
0. 1
7.94
0.25
6. 5
19058
-
0016
B
-
801
-
12HD
0. 8
9.5
0.2
5.72
19058
-
0026
B
-
801
-
76HD
0. 8
9.5
0.2
5.72
19058
-
0041
B
-
828
-
08HD
0. 8
9.5
0.2
5.72
19058
-
0047
B
-
828
-
10HD
0. 8
9.5
0.2
5.72
19058
-
0058
B
-
8 0
-
10HDRR
0. 8
9.5
0.25
6.22
19058
-
006
B
-
8 0
-
14HD
0. 8
9.5
0.2
5.72

AT2200HD Air Head Crimp Tool
Doc. No: ATS-64005-1600 Release Date: 01-17-0 UNCONTROLLED COPY Page 2 of 6
Revision: A Revision Date: 06-25-0
Wire Size: 14
–
16 AWG 2.00
–
1.30 mm²
Terminal
No.
Terminal
Eng. No. (REF)
Wire S rip
Leng h
Insula ion
Diame er Max.
In.
mm
In
.
mm
19058
-
0064
B
-
8 0
-
14HD
-
0
0. 8
9.5
0.2
5.72
19058
-
0066
B
-
8 0
-
14HDRR
0. 8
9.5
0.25
6.22
19058
-
0072
B
-
8 0
-
56HD
0. 8
9.5
0.2
5.72
19058
-
007
B
-
8 0
-
56HD
-
0
0. 8
9.5
0.2
5.72
19058
-
0075
B
-
8 0
-
56HDRR
0. 8
9.5
0.25
6.22
19058
-
0117
B
-
840
-
8HD
0. 8
9.5
0.2
5.72
19058
-
0155
TT
-
1614HD
0. 8
9.5
0.21
5. 8
Wire Size: 14
–
16 AWG 2.00
–
1.30 mm²
Terminal
No.
Terminal
Eng. No. (REF)
Wire S rip
Leng h
Insula ion
Diame er Max.
In.
mm
In
.
mm
19142
-
00 7
B
-
241
-
10HDX
0. 1
7.94
0.25
6. 5
19142
-
0040
B
-
268
-
14HDX
0. 1
7.94
0.25
6. 5
19197
-
0020
B
-
841
-
08HD
0. 8
9.5
0.2
5.72
19197
-
002
B
-
841
-
10HD
0. 8
9.5
0.2
5.72
19197
-
00 8
B
-
841
-
08HDX
0.28
7.14
0.2
5.72
19197
-
0041
B
-
841
-
10HDX
0.28
7.14
0.2
5.72
OPERATION
Refer to the instruction manual for the 19279-0001 (AT-200) for mounting
this crimp tool head.
Crimping Terminals
1. Adjust the locator up or down until the terminal being run sits flat and
straight in the tool.
2. Insert the wire into the terminal. Push up on the locator blade and
push the terminal and wire with the barrel facing up into the color-
coded nest with front edge of the barrel against the locator. See
Figure 1. Release the locator blade to hold the terminal in position.
Cau ion: Never operate this tool without the supplied safety shield in place. Never place fingers in the tool nests.
. Push on wire to assure it is still fully seated in the terminal. See Figure 2 and . Cycle the tool.
4. Lift the locator blade or wire stop and remove the crimped terminal. Inspect for proper crimp location, and
check for insulation closure. Locator is adjustable up and down to keep terminals straight after crimping.
5. If the insulation part of the crimp needs to be adjusted, first disconnect air source and loosen the M4 screw on
the bottom tool jaw, then insert a / 2” 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 air source.
TERMINAL
FRONT EDGE
OF BARREL
SAFETY
SHIELD
PUSH UP
Figure 1
LOCATOR
JAWS
OPEN
TERMINAL
Figure 2
WIRE
Figure 3
TERMINAL
BARREL
TERMINAL
LOCATOR
WIRE
CONDUCTOR
PUNCH
INSULATION
ANVIL
INSULATION
PUNCH
CONDUCTOR
ANVIL

AT2200HD Air Head Crimp Tool
Doc. No: ATS-64005-1600 Release Date: 01-17-0 UNCONTROLLED COPY Page of 6
Revision: A Revision Date: 06-25-0
Main enance
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.
. 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 0 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 Calibra ion
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.
Nes Color
Code
Wire
Range
“X” Dimension
Conduc or Crimp
Crimp Inspec ion Marking
AWG
mm²
Mean
Go
No Go
Yellow
14
-
16
2.00
–
1. 0
.151
.150
.15
o
Warran y
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)
LOOSEN M4
SCREW
Figure
4
3/32” HEX
WRENCH
PIN GAUGE IN
CONDUCTOR CRIMP
“Confining” Crimp
X

AT2200HD Air Head Crimp Tool
Doc. No: ATS-64005-1600 Release Date: 01-17-0 UNCONTROLLED COPY Page 4 of 6
Revision: A Revision Date: 06-25-0
3
2
1
Figure 5
M4 WING NUT
M4 FLAT WASHER
4
5
9
6
7
8
(2)
PARTS LIST
I em
Order No
Descrip ion
Quan i y
64005
-
1600
Crimp Tool Head
Figure 5
1
64005
-
0000
Basic Air Tool Head
1
2
64001
-
1675
Locator Assembly
1
64001
-
1670
Tooling Kit
1
Tooling Ki Only
4
64001
-
1602
Conductor Punch
1
5
64001
-
1601
Conductor Anvil
1
6
64001
-
1606
Insulation Punch
1
7
64001
-
1505
Insulation Anvil
1
8
N/A
4 mm Dia. by 5.0 mm L
ong
Roll Pins
2**
9
N/A
#10
-
2 by 5/16” Lg. Cup Pt. Set Screw
1**
** Available from an Industrial supply company such as MSC (1
-
800
-
645
-
7270).

AT2200HD Air Head Crimp Tool
Doc. No: ATS-64005-1600 Release Date: 01-17-0 UNCONTROLLED COPY Page 5 of 6
Revision: A Revision Date: 06-25-0
Figure 6
3
4
2
2
2
5
1
(4)
(4)
(2)
(4)
2
2
(2)
(2)
2
Par s Lis (Con inued)
I em
Order No.
Descrip ion
Quan i y
64005
-
0000
Basic Air Tool Head
Figure 6
1
64005
-
010
Nose Guard
1
2
64000
-
0077
Repair Kit (Springs, Rods Pivots ,Rings, and Washers)
1
N/A
M4 by 12
L
ong
Freedrive Pan Head Screw
1**
4
N/A
M4 by 0
L
ong
Freedrive Pan Head Screw
1**
5
N/A
/16” by /8” Long Dowel Pin
1**
** Available from an Industrial supply company such as (MSC 1
-
800
-
645
-
7270).

AT2200HD Air Head Crimp Tool
Doc. No: ATS-64005-1600 Release Date: 01-17-0 UNCONTROLLED COPY Page 6 of 6
Revision: A Revision Date: 06-25-0
Air Powered
Crimp Tool Head
Avikrimp

 and
InsulKrimp


Cer ifica e of Calibra ion
Order No. 64005-1600
Engineering No. AT 2200HD
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 months.
Tools should be lubricated during this operation.
Visit our Web site at http://www.molex.com