molex 64005-6200 User manual

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
22
8
20
13
18
20
16
30
14
50
12
70
10
80
*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
mm
In.
mm
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.
mm
In.
mm
19011-0004
BB-2302
19011-0006
.310
7.94
.150
3.68
19011-0037
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.
mm
In.
mm
19011-0001
AA-2301
19011-0003
.310
7.94
.140
3.56
19011-0035
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
Go
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
X

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
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
64005-6200
Crimp Tool Head
Figure 5
1
64005-0000
Basic Air Tool Head
1
2
64001-6275
Locator Assembly
1
3
64001-6270
Tooling Kit
1
Tooling Kit Only
4
64001-6201
Conductor Punch
1
5
64001-62022
Conductor Anvil
1
6
64001-6203
Insulation Punch
1
7
64001-6204
Insulation Anvil
1
8
N/A
4mm Diameter by 5.0mm Long Roll Pins
2**
9
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
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 Guard
1
2
64000-0077
Repair Kit (Springs, Rods Pivots ,Rings, and Washers)
1
3
N/A
M4 by 12 Long Freedrive Pan Head Screw
1**
4
N/A
M4 by 30 Long Freedrive Pan Head Screw
1**
5
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