molex AT 2100 User manual

AT2100 Air Head Crimp Tool
Doc. No. 64005-1400 Release Date: 12/09/02 UNCONTROLLED COPY Page 1 of 8
Revision: C Revision Date:08-06-03
Air Powered Crimp Tool Head
Operating Instruction Sheet And Specifications
Part No. 64005-1400
Eng. No. AT 2100
(Replaces 19283-0009 and
19283-0010 AT 2150)
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
 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
AviKrimp/InsulKrimpTerminals 14-16 AWG, (Rings, Spades, Hooks, Splices, Snap Spades, Flanged Spades and Wire Pin
Terminals). Some Male Quick Disconnects and 3 to 4 Way Connectors. Also terminates ends of step down butt splices14-16 to
18-22 AWG. And Heavy Duty Terminals 16-20 AWG (Green color code). 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 and Government specifications (MIL-T-7928) for various wire sizes. The tensile strength is shown in pounds and
indicates the minimum acceptable force to break or separate terminal from the conductor.
Wire Size (AWG) *UL - 486 A *UL – 486 C **Military Class 2
22 8 8 15
20 13 10 19
18 20 10 38
16 30 15 50
14 50 25 70
*UL - 486 A - Terminals (Copper conductors only).
*UL - 486 C - Butt Splices, Parallel Splices, Closed End Connectors and Wire Nuts.
**Military Class 2– Military Approved Terminals only as listed
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.

AT2100 Air Head Crimp Tool
Doc. No. 64005-1400 Release Date: 12/09/02 UNCONTROLLED COPY Page 2 of 8
Revision: C Revision Date:08-06-03
Wire Size: 14 – 16 AWG 2.00 –1.30 mm²
Wire Strip Length Insul. Dia. Max.
Terminal No. Terminal
Eng No. (REF) In mm In. mm
19023-0012 MCT-2X .312 7.94 .175 4.45
19025-0007 MCT-5 .312 7.94 .170 4.32
19025-0008 MCT-57 .312 7.94 .170 4.32
19034-0007 B-279X .312 7.94 .175 4.45
19034-0009 B-289X .312 7.94 .170 4.30
19035-0005 B-579 .312 7.94 .170 4.42
19035-0009 B-589 .312 7.94 .170 4.42
19036-0006 B-879 .312 7.94 .170 4.32
19036-0008 B-889 .312 7.94 .170 4.32
19070-0059 BB-218-38X .234 5.95 .175 4.45
19070-0063 BB-218-56X .234 5.95 .175 4.45
19070-0065 BB-223-02X .234 5.95 .175 4.45
19070-0067 BB-223-04X .234 5.95 .175 4.45
19070-0069 BB-223-06X .234 5.95 .175 4.45
19070-0071 BB-223-08X .234 5.95 .175 4.45
19070-0073 BB-225-10X .234 5.95 .175 4.45
19070-0075 BB-225-14X .234 5.95 .175 4.45
19070-0078 BB-225-56X .234 5.95 .175 4.45
19070-0083 BB-237-06X .234 5.95 .175 4.45
19070-0086 BB-237-08X .234 5.95 .175 4.45
19070-0090 BB-237-10X .234 5.95 .175 4.45
19070-0099 BB-239-08X .234 5.95 .175 4.45
19070-0102 BB-239-10X .234 5.95 .175 4.45
19073-0059 BB-818-38 .250 6.35 .170 4.32
19073-0061 BB-818-56 .250 6.35 .170 4.32
19073-0065 BB-823-04 .250 6.35 .170 4.32
19073-0067 BB-823-06 .250 6.35 .170 4.32
19073-0072 BB-823-08 .250 6.35 .170 4.32
19073-0074 BB-825-10 .250 6.35 .170 4.32
19073-0076 BB-825-14 .250 6.35 .170 4.32
19073-0079 BB-825-56 .250 6.35 .170 4.32
19073-0081 BB-837-04 .250 6.35 .170 4.32
19073-0083 BB-837-06 .250 6.35 .170 4.32
19073-0085 BB-837-08 .250 6.35 .170 4.32
19073-0087 BB-837-10 .250 6.35 .170 4.32
19073-0094 BB-839-08 .250 6.35 .170 4.32
19073-0097 BB-839-10 .250 6.35 .170 4.32
19080-0003 B-2006-MSX .312 7.94 .175 4.45
19081-0003 B-5006-MS .312 7.94
19090-0044 BB-213-04X .234 5.95 .175 4.45
19090-0046 BB-213-06X .234 5.95 .175 4.45
19090-0048 BB-213-08X .234 5.95 .175 4.45
190900071 BB-288-06X .234 5.95 .175 4.45
19090-0075 BB-288-10X .234 5.95 .175 4.45
19095-0135 BB-883-10 .250 6.35 .175 4.45
19095-0138 BB-886-08 .250 6.35 .170 4.32
19095-0140 BB-887-06 .250 6.35 .170 4.32
19095-0141 BB-887-08 .250 6.35 .170 4.32
19099-0025 BB-2707-05X .234 5.95 .175 4.45
19099-0027 BB-2707-06X .234 5.95 .175 4.45
19099-0032 BB-2716-08X .234 5.95 .175 4.45
19115-0016 BB-8193-06 .250 6.35 .170 4.32
19115-0018 BB-8194-08 .250 6.35 .170 4.32
19115-0020 BB-8195-10 .250 6.35 .170 4.32
19115-0022 BB-8707-05 .250 6.35 .170 4.32
19115-0024 BB-8707-06 .250 6.35 .170 4.32
19115-0031 BB-8717-10 .250 6.35 .170 4.32
19115-0079 BB-8716-08 .250 6.35 .170 4.32
19121-0026 BB-216-06X .234 5.95 .175 4.45
19121-0028 BB-216-08X .234 5.95 .175 4.45
19121-0030 BB-216-10X .234 5.95 .175 4.45
Wire Size: 14 –16 AWG 2.00 –1.30 mm²
Wire Strip Length Insul. Dia. Max.Terminal No. Terminal
In mm In. mm
19121-0040 BB-283-10X .234 5.95 .175 4.45
19127-0039 BB-816-06 .250 6.35 .170 4.32
19127-0042 BB-816-08 .250 6.35 .170 4.32
19127-0099 BB-816-10 .250 6.35 .170 4.32
19131-0007 BB-287-08X .234 5.95 .175 4.45
19131-0014 BB-2781-10X .234 5.95 .175 4.45
19131-0018 BB-2781-08X .234 5.95 .175 4.45
19131-0020 BB-2781-06X .234 5.95 .175 4.45
1913-10023 BB-2471-06X .234 5.95 .175 4.45
19131-0025 BB-2471-04X .234 5.95 .175 4.45
19139-0038 BB-8471-04 .250 6.35 .170 4.32
19139-0044 BB-8781-08 .250 6.35 .170 4.32
19139-0045 BB-8781-10 .250 6.35 .175 4.45
19144-0013 BB-207-04X .312 7.94 .170 4.42
19144-0015 BB-207-06X .234 5.95 .175 4.45
19144-0018 BB-224-06X .234 5.95 .175 4.45
19144-0020 BB-224-08X .234 5.95 .175 4.45
19154-0015 B-231X .234 5.95 .175 4.45
19154-0022 BA-631X .281 7.14 .175 4.45
19154-0023 BS-V-331X .281 7.14 .179 4.57
19179-0008 BB-219-06X .234 5.95 .175 4.45
19179-0010 BB-219-08X .234 5.95 .175 4.45
19179-0012 BB-219-10X .234 5.95 .175 4.45
19183-0009 BB-819-08 .250 6.35 .170 4.32
19183-0011 BB-819-10 .250 6.35 .170 4.32
19198-0012 BB-807-06 .234 5.95 .175 4.45
19198-0016 BB-824-06 .250 6.35 .170 4.32
19198-0019 BB-824-08 .250 6.35 .170 4.32
19198-0025 BB-827-10 .250 6.35 .170 4.32
19204-0013 B-2XCX .312 7.94 .175 4.45
19204-0014 B-2YCX .312 7.94 .175 4.45
19204-0017 B-5XC .312 7.94 .170 4.42
19204-0018 B-5YC .312 7.94 .170 4.42
19206-0004 B-204X .281 7.14 .175 4.45
19206-0005 BS-V-304X .281 7.14 .175 4.45
19212-0005 WP-2614X .250 6.35 .170 4.32
19213-0011 WP-8614 .187 4.76 .175 4.45
STEP DOWN BUTT SPLICE
Wire Size: 14 –16 AWG 2.00 –1.30 mm²
to 18-22 AWG .080-0.35 mm²
Wire Strip Length Insul. Dia. Max.
Terminal No. Terminal
Eng No. (REF) In mm In mm
19154-0022 BA-631X .281 7.14 .175 4.45
MILITARY CLASS 2
Wire Size: 14 –16 AWG 2.00 –1.30 mm²
Wire Strip Length Insul. Dia. Max.
Terminal No. Terminal
Eng No. (REF) In mm In mm
19095-0074 BB-882-2 .250 6.35 .171 4.36
19095-0076 BB-883-2 .250 6.35 .171 4.36
19095-0133 BB-880-2 .250 6.35 .171 4.36
19095-0134 BB-881-2 .250 6.35 .171 4.36
19095-0136 BB-884-2 .250 6.35 .171 4.36
19095-0137 BB-885-2 .250 6.35 .171 4.36
19095-0139 BB-886-2 .250 6.35 .171 4.36

AT2100 Air Head Crimp Tool
Doc. No. 64005-1400 Release Date: 12/09/02 UNCONTROLLED COPY Page 3 of 8
Revision: C Revision Date:08-06-03
TERMINAL FRONT EDGE
OF BARREL
SAFETY
SHIELD
PUSH UP Figure 1
LOCATOR
JAWS OPEN
Figure 2
TERMINAL
WIRE
HEAVY DUTY
Wire Size: 16 –20 AWG 1.30 –0.50 mm²
Wire Strip Length Insul. Dia. Max.
Terminal No. Terminal
Eng No. (REF) In. mm In. mm
19054-0060 AB-225-10HD .234 5.94 .170 4.32
19054-0061 AB-225-14HD .234 5.94 .170 4.32
19054-0062 AB-225-56HD .234 5.94 .170 4.32
HEAVY DUTY
Wire Size: 16 –20 AWG 1.30 –0.50 mm²
Wire Strip Length Insul. Dia. Max.Terminal No. Terminal
In. mm In. mm
19073-0051 AB-825-10HD .234 5.94 .170 4.32
19073-0053 AB-825-14HD .234 5.94 .170 4.32
19073-0055 AB-825-56HD .234 5.94 .170 4.32
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.
Caution: Never operate this tool without the supplied safety shield in place. Never place fingers in the tool nests.
3. Push on wire to assure it is still fully seated in the terminal. (See Figure 2 and 3). Cycle the tool.
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.
4. When crimping butt splices, or 3-way and 4-way terminals the locator must be removed. Splices must be visually aligned with
the tooling 1/16”inside the insulation crimp (See Figure 4).

AT2100 Air Head Crimp Tool
Doc. No. 64005-1400 Release Date: 12/09/02 UNCONTROLLED COPY Page 4 of 8
Revision: C Revision Date:08-06-03
TERMINAL
BARREL
TERMINAL
LOCATOR
WIRE
CONDUCTOR
PUNCH
INSULATION
ANVIL
Figure 3
INSULATION
PUNCH
CONDUCTOR
ANVIL
CONDUCTOR
ANVIL
Figure 4
INSULATION
ANVIL
WIRE
INSULATION
PUNCH
CONDUCTOR
PUNCH
BUTT SPLICE
TERMINAL
1/16”INSIDE
INSULATION CRIMP
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.
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 3/32”hex wrench (supplied) into the bottom of the lower die (See Figure 5). 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.
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. The 64005-1400 (AT-2100) 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. A
light oil, such as 30 weight automotive oil used at the oil points shown in Figure 5, 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.
LUBRICATION POINTS (BOTH SIDES)
LIGHT OIL (EVERY MONTH OR
5,000 CRIMPS)
LOOSEN
M4 SCREW
Figure 5
3/32”HEX
WRENCH

AT2100 Air Head Crimp Tool
Doc. No. 64005-1400 Release Date: 12/09/02 UNCONTROLLED COPY Page 5 of 8
Revision: C Revision Date:08-06-03
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.
Wire Range “X”Dimension
Conductor Crimp
Nest Color Code
AWG mm²Mean Go No Go
Crimp Inspection
Marking
14 - 16 1.30 - 2.00 .122 .116 .128 o o
16 –20 HD 0.50 - 1.30 .122 .116 .128 o o
Blue
18 - 22* 0.80 - 0.35 .122 .116 .128 o o
* 18 - 22 End of step down butt splice only.
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.
PIN GAUGE IN
CONDUCTOR CRIMP
“Confining”Crimp
X

AT2100 Air Head Crimp Tool
Doc. No. 64005-1400 Release Date: 12/09/02 UNCONTROLLED COPY Page 6 of 8
Revision: C Revision Date:08-06-03
3
2
1
Figure 6
M4 WING NUT
M4 FLAT WASHER
4
5
9 6
7
8
(2)
PARTS LIST
Item Order No Description Quantity
64005-1400 Crimp Tool Head (Fig. 6)
1 64005-0000 Basic Air Tool Head 1
2 64007-0375 Locator Assembly 1
3 64001-1470 Tooling Kit 1
Tooling Kit Only
4 64001-1402 Conductor Punch 1
5 64001-1401 Conductor Anvil 1
6 64001-1404 Insulation Punch 1
7 64001-1403 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).

AT2100 Air Head Crimp Tool
Doc. No. 64005-1400 Release Date: 12/09/02 UNCONTROLLED COPY Page 7 of 8
Revision: C Revision Date:08-06-03
Figure 7
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 (Fig. 7)
64005-0103 Nose Guard 1
64000-0077 Repair Kit (Springs, Rods Pivots ,Rings, and Washers) 1
N/A M4 by 12LG. Freedrive Pan Head Screw 1**
N/A M4 by 30LG. Freedrive Pan Head Screw 1**
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).

AT2100 Air Head Crimp Tool
Doc. No. 64005-1400 Release Date: 12/09/02 UNCONTROLLED COPY Page 8 of 8
Revision: C Revision Date:08-06-03
Certificate of Calibration
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.
Molex Application Tooling Group
1150 E. Diehl Road
Naperville, IL 60563
Tel: [phone]
Fax: [phone]