molex AT FIFG User manual

AT-FIFG Air Head Crimp Tool
Doc No. ATS-640054100 Release Date 09-22-03 UNCONTROLLED COPY Page 1 of 6
Revision C Revision Date 04-12-12
Air Powered
Crimp Tool Head
InsulKrimp™
Applica ion Tooling
Specifica ion Shee Order No. 64005-4100
Engineering No. AT FIFG
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
 Pneumatic powered crimp tools help reduce fatigue and discomfort from repetitive manual crimping
SCOPE
Products InsulKrimp™ Flag Quick Disconnects fully Insulated (Standard Flare) Terminals 14-22 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 and 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
*UL – 310 – Quick Disconnects, Flags and Couplers
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: 18
–
22 AWG 0.80
–
0.35mm²
Terminal No. Terminal Eng No. (REF)
Wire S rip Leng h
Insul
a ion
Dia
me er
Max
imum
In.
mm
In.
mm
19007
-
0001
AA
-
2220
.344
8.73
.176
4.47
19007
-
0005
AA
-
2220X
.344
8.73
.240
6.10
19007
-
0009
AA
-
2222
.344
8.73
.176
4.47
19007
-
0011
AA
-
2222X
.344
8.73
.240
6.10
19007
-
0015
AA
-
2223
.344
8.73
.176
4.47
19007
-
0017
AA
-
2223X
.344
8.73
.240
6.10
19007
-
0064
AA
-
2220V
.344
8.73
.176
4.47
19007
-
0067
AA
-
2222V
.344
8.73
.176
4.47
19007
-
0070
AA
-
2223V
.34
4
8.73
.176
4.47

AT-FIFG Air Head Crimp Tool
Doc No. ATS-640054100 Release Date 09-22-03 UNCONTROLLED COPY Page 2 of 6
Revision C Revision Date 04-12-12
Wire Size: 14
–
16 AWG 2.00
–
1.30mm²
Terminal No. Terminal Eng No. (REF)
Wire S rip Leng h
Insul
a ion
Dia
me er
Max
imum
In.
mm
In.
mm
19007
-
0021
BB
-
2221
.313
7.94
.200
5.08
19007
-
0025
BB
-
2221X
.313
7.94
.265
6.73
19007
-
0029
BB
-
2224
.313
7.94
.200
5.08
19007
-
0031
BB
-
2224X
.313
7.94
.265
6.73
19007
-
0035
BB
-
2225
.313
7.94
.200
5.08
19007
-
0037
BB
-
2225X
.313
7.94
.265
6.73
19007
-
0073
BB
-
2221V
.313
7.94
.200
5.08
19007
-
0076
BB
-
2224V
.313
7.94
.200
5.08
19007
-
0079
BB
-
2225V
.313
7
.94
.200
5.08
Opera ion
Refer to the instruction manual for the 19279-0001 (AT-200) for mounting this
crimp tool head.
Crimping Terminals
1. Place the flag terminal barrel into the conductor anvil of the lower jaw. Make
sure the closed end of the barrel is touching the locator. See Figure 1.
Cau ion: Never operate this tool without the supplied safety shield in place. Never place fingers in the
tool nests.
2. Insert the properly stripped wire into the terminal barrel. See figure 3.
3. Push on the wire to assure it is fully seated in the terminal. See Figure 2 and 3. Cycle the tool.
4. Remove the crimped terminal. Inspect for proper crimp.
Main enance
It is recommended that each operator of the tool be made aware of, and responsible for, the following
maintenance steps
Figure 1
LOCATOR
TERMINAL
TERMINAL
WIRE
CONDUCTOR ANVIL
Figure 3
CONDUCTOR PUNCH
WIRE
TERMINAL
Figure 2
JAWS
OPEN
SAFETY
SHIELD
LOCATOR

AT-FIFG Air Head Crimp Tool
Doc No. ATS-640054100 Release Date 09-22-03 UNCONTROLLED COPY Page 3 of 6
Revision C Revision Date 04-12-12
“ X ”
NOT POSSIBLE TO PIN GAUGE, MEASURE A
CRIMPED UNINSULATED TERMINAL OR SLUG*
*
SOLDER, LEAD OR
SIMILAR SOFT METAL
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. 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.
Tool Calibra ion
A Certificate of Calibration (see last page) was supplied with the tool. To recalibrate this tool, measurements
should be taken from 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
Blue
14
-
16
2.00
-
1.30
.078
.076
.088
---
Red
18
-
22
0.80
-
0.35
.068
.066
.070
---
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)
Figure 4

AT-FIFG Air Head Crimp Tool
Doc No. ATS-640054100 Release Date 09-22-03 UNCONTROLLED COPY Page 4 of 6
Revision C Revision Date 04-12-12
2
3
1
Figure 5
M4 LOCKNUT W/
HEX NYLON INSERT
4
5
M4 X 20LG
PAN HEAD SCREW
PARTS LIST
I em
Order No
Descrip ion
Quan i y
64005
-
4100
Crimp Tool Head
Fig
ure
5
1
64005
-
0000
Basic Air Tool Head
1
2
64001
-
4175
Locator Assembly
1
3
64001
-
4170
Tooling Kit
1
Tooling Kit Only
4
64001
-
4102
Conductor Punch
1
5
64001
-
4101
Conductor Anvil
1

AT-FIFG Air Head Crimp Tool
Doc No. ATS-640054100 Release Date 09-22-03 UNCONTROLLED COPY Page 5 of 6
Revision C Revision Date 04-12-12
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
-
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 Sc
rew
1**
4
N/A
M4 by 30
Llong
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).

AT-FIFG Air Head Crimp Tool
Doc No. ATS-640054100 Release Date 09-22-03 UNCONTROLLED COPY Page 6 of 6
Revision C Revision Date 04-12-12
Air Powered
Crimp Tool Head
InsulKrimp™
Cer ifica e of Calibra ion
Order No. 64005-4100
Engineering No. AT FIFG
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 = --------------------
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