molex AT 1991 User manual

AT-1991 Air Head Crimp Tool
Doc. No. 64005-0200 Release Date: 09-20-02 UNCONTROLLED COPY Page 1 of7
Revision: D Revision Date:05-27-05
Air Powered Crimp Tool Head
Operating Instruction and Specifications Sheet
Part No. 64005-0200
Eng. No. AT 1991
(Replaces 19283-0002)
FEATURES
 Quick-change tool head for the 19279-0001 (AT-200)
 Tooling kitis 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 meetor exceed the requirements of UL,
CSA andMilitary Class II
 3-nested tooleliminates the need for additional tools
 Pneumatic powered crimp tools help reduce fatigue and discomfortfrom repetitive manual crimping
SCOPE
AviKrimp/ InsulKrimpQuick Disconnect 10 - 22 AWG. This tool head is intended for use in the 19279-0001
(AT-200) either hand held or with optionalbench adapter 19078-0307 (ATBA) and foot switch.
Testing
Mechanical
The tensile test, or pull test, is a means of evaluating the mechanical properties ofthe crimped connections.
The following charts show the UL specifications for various wire sizes. The tensile strength is shown in
pounds and indicates the minimumacceptable force to break or separate the terminalfrom 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 ofthe productpart numbers and their specifications thatthis tool is designed to
run. We will be adding to this list and an up to date copy is available on www.molex.com.

AT-1991 Air Head Crimp Tool
Doc. No. 64005-0200 Release Date: 09-20-02 UNCONTROLLED COPY Page 2 of7
Revision: D Revision Date:05-27-05
Wire Size: 18 – 22 AWG 0.80 – 0.35 mm²
WireStripLength Insul.Dia.Max.
TerminalNo. Terminal
Eng No. (REF) In. mm In. mm
19017-0001 AA-2131 .375 9.53 .120 3.05
19017-0005 AA-2134 .312 7.94 .135 3.40
19017-0007 AA-2137 .312 7.94 .135 3.40
19017-0008 AA-2137-032 .312 7.94 .135 3.40
19017-0014 AA-2140 .312 7.94 .135 3.40
19017-0018 AA-2190 .312 7.94 .135 3.40
19017-0019 AA-2190-032 .312 7.94 .135 3.40
19019-0001 AA-8131 .343 8.73 .140 3.56
19019-0004 AA-8134 .250 6.35 .115 2.90
19019-0006 AA-8137 .250 6.35 .115 2.90
19019-0008 AA-8137-032 .250 6.35 .115 2.90
19019-0012 AA-8140 .250 6.35 .115 2.90
19019-0014 AA-8190 .250 6.35 .115 2.90
19019-0015 AA-8190-032 .250 6.35 .115 2.90
19019-0118 AA-8134-BK .250 6.35 .115 2.90
Wire Size: 14 – 16 AWG 2.00 – 1.30 mm²
WireStripLength Insul.Dia.Max.
TerminalNo. Terminal
Eng No. (REF) In. mm In. mm
19017-0023 BB-2132 .312 7.94 .145 3.70
19017-0028 BB-2135 .312 7.94 .145 3.70
19017-0031 BB-2138 .312 7.94 .145 3.70
Wire Size: 14 – 16 AWG 2.00 – 1.30 mm²
WireStripLength Insul.Dia.Max.TerminalNo. Terminal In. mm In. mm
19017-0032 BB-2138-032 .312 7.94 .145 3.70
19017-0037 BB-2141 .312 7.94 .145 3.70
19017-0043 BB-2191 .312 7.94 .145 3.70
19017-0044 BB-2191-032 .312 7.94 .145 3.70
19019-0022 BB-8132 .312 7.94 .138 3.50
19019-0025 BB-8135 .312 7.94 .138 3.50
19019-0027 BB-8138 .312 7.94 .138 3.50
19019-0028 BB-8138-032 .312 7.94 .138 3.50
19019-0034 BB-8191 .312 7.94 .138 3.50
19019-0035 BB-8191-032 .312 7.94 .138 3.50
19019-0061 BB-8135-BK .312 7.94 .138 3.51
19019-0117 BB-8141 .312 7.94 .138 3.51
Wire Size: 10 – 12 (AWG) 5.00 – 3.30 (MM²)
WireStripLength Insul.Dia.Max.TerminalNo. Terminal In mm In. mm
19002-0044 C-5265 .312 7.94 .245 6.22
19017-0047 C-2143 .375 9.53 .250 6.40
19019-0037 C-8143 .375 9.53 .225 5.70
19025-0005 CMCT-5 .375 9.53 .225 5.70
19606-0005 19606-0005 .375 9.53 .120 3.05
OPERATION
Refer to the instruction manualfor 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 ofthe locator
and the other is stored on the bottom ofthe locator.
2. Insertthe 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 ofthe 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.
TERMINAL
SAFETY
SHIELD
TAB LOCATOR
Figure 1
LOCATOR
JAWS
OPEN

AT-1991 Air Head Crimp Tool
Doc. No. 64005-0200 Release Date: 09-20-02 UNCONTROLLED COPY Page 3 of7
Revision: D Revision Date:05-27-05
5. Ifthe insulation partof the crimp needs to be adjusted, first loosen the M4 screw on the bottomtooljaw,
then inserta 3/32 hex wrench (supplied) into the bottomof 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 ofthe terminalis oriented up or
down in the tool ifusing unbrazed product, as this will provide higher pull force values.
Maintenance
Itis recommended that each
operator ofthe 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 thatcould damage the
tool.
3. Make certain all pins; pivot
points and bearing surfaces are protected with a thin coatof high quality machine oil. Do not oil
excessively. The 64005-0200 (AT-1991) was engineered for durability, but like any fine piece of equipment
it needs cleaning and lubrication for a maximumservice life oftrouble-free crimping. A lightoil,such as 30
weight automotive oil used at the oil points shown in Figure 4, every 5,000 crimps or monthly will
significantly enhance the toollife and ensure a stable calibration.
4. When tool is not in use store the tool in a clean,dry area.
LUBRICATION POINTS
(BOTH SIDES)
LIGHT OIL (EVERY MONTH
OR 5,000 CRIMPS)
LOOSEN M4
SCREW
Figure 4
3/32”HEX
WRENCH
WIRE
TERMINAL Figure 2
TERMINAL
BARREL
TERMINAL
2ND TAB
LOCATOR
WIRE
CONDUCTOR
PUNCH
INSULATION
ANVIL
Figure 3
INSULATION
PUNCH
CONDUCTO
RANVIL
WIRE STOPBUILT
INTO TERMINAL
LOCATOR

AT-1991 Air Head Crimp Tool
Doc. No. 64005-0200 Release Date: 09-20-02 UNCONTROLLED COPY Page 4 of7
Revision: D Revision Date:05-27-05
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
consistentmeasurements.
Wire Range “X”DimensionConductorCrimp
Nest Color Code AWG mm²Mean Go No Go CrimpInspection
Marking
Red 18 -22 0.35 -0.80 .069 .066 .072 oo
Blue 14 -16 1.30 -2.00 .092 .089 .095 o
Yellow 10 -12 3.30 -5.00 .100 .097 .103 oo
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 of30
days. Should such a defectoccur, we would repair or exchange the tool free of charge. This repair or
exchange will not be applicable to altered, misused or damaged tools.
PIN GAUGE IN
CONDUCTOR CRIMP
“Confining”Crimp
X

AT-1991 Air Head Crimp Tool
Doc. No. 64005-0200 Release Date: 09-20-02 UNCONTROLLED COPY Page 5 of7
Revision: D Revision Date:05-27-05
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
64005-0200 Crimp Tool Head (Fig. 5)
1 64005-0000 Basic Air Tool Head 1
2 64001-0275 Locator Assembly 1
3 64001-0270 Tooling Kit 1
Tooling Kit Only
4 64001-0214 Conductor Punch 1
5 64001-0212 Conductor Anvil 1
6 64001-0215 Insulation Punch 1
7 64001-0113 Insulation Anvil 1
8 N/A 4 mm Dia. by 5.0 mm Lg.Roll Pins 2**
9 N/A #10-32 by 5/16”Lg. Cup Pt. Set Screw 1**
** The following purchased parts are available from an Industrial supply company such as MSC (1-800-645-7270).

AT-1991 Air Head Crimp Tool
Doc. No. 64005-0200 Release Date: 09-20-02 UNCONTROLLED COPY Page 6 of7
Revision: D Revision Date:05-27-05
Parts List (Continued)
Item Order No. Description Quantity
64005-0000 Basic Air Tool Head (Fig. 6)
1 64005-0103 Nose Guard 1
2 64000-0077 Repair Kit (Springs, Rods Pivots,Rings,and Washers) 1
3 N/A M4 by 12LG. Freedrive Pan Head Screw 1**
4 N/A M4 by 30LG. Freedrive Pan Head Screw 1**
5 N/A 3/16”by 3/8”Long Dowel Pin 1**
** The following purchased parts are available from an Industrial supply company such as (MSC 1-800-645-7270).
Figure 6
3
4
2
2
2
5
1
(4)
(4)
(2)
(4)
2
2 (2)
(2)
2

AT-1991 Air Head Crimp Tool
Doc. No. 64005-0200 Release Date: 09-20-02 UNCONTROLLED COPY Page 7 of7
Revision: D Revision Date:05-27-05
Certificate of Calibration
Tool Order Number __________________
Tool Eng. Number___________________
Tool Revision______________________
Serial Number_____________________
Date ofManufacture
Pin Gauge ofConductor Nest/Nests or Slug height ifthe nest is the “F”Crimp style.
Range Conductor Nest # 1 = ____________- Actual = ____________-
Range Conductor Nest # 2 = ____________- Actual = ____________-
Range Conductor Nest # 3 = ____________- Actual = ____________-
Technician _______________________-
Date ofCalibration __________________-
Calibration should be done every 5,000 cycles or 3 months.
Tools should be lubricated during this operation.
Molex Application Tooling Group
1150 E. Diehl Road
Naperville, IL 60563
Tel: [phone]
Fax: [phone]