molex 64005-0400 User manual

AT-1994 Air Head Crimp Tool
Doc. No. ATS-640050400 Release Date: 09-23-02 UNCONTROLLED COPY Page 1 of 7
Revision: K Revision Date: 01-09-15
Air Powered
Crimp Tool Head
Insulkrimp
Type AT
Application Tooling
Specification Sheet
Order No. 64005-0400
Engineering No. AT 1994
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
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Quick Disconnects Terminals 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 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
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.
Wire Size: 18 –22 AWG 0.80 –0.35mm²
Terminal
No.
Terminal
Eng. No. (REF)
Wire Strip
Length
Insulation
Diameter Maximum
In
mm
In
mm
19003-0001
AA-2201
.234
5.94
.135
3.43
19003-0005
AA-2201VN
.234
5.94
.135
3.43
19003-0008
AA-2201X
.234
5.94
.230
5.84
Wire Size: 18 –22 AWG 0.80 –0.35mm²
Terminal
No.
Terminal
Eng. No. (REF)
Wire Strip
Length
Insulation
Diameter Maximum
In
mm
In
mm
19003-0011
AA-2202
.234
5.94
.135
3.43
19003-0014
AA-2202X
.234
5.94
.230
5.84
19003-0017
AA-2203
.234
5.94
.135
3.43

AT 1994 Air Crimp Tool Head
Doc. No. ATS-640050400 Release Date: 09-23-02 UNCONTROLLED COPY Page 2 of 7
Revision: K Revision Date: 01-09-15
Wire Size: 18 –22 AWG 0.80 –0.35mm²
Terminal
No.
Terminal
Eng. No. (REF)
Wire Strip
Length
Insulation
Diameter Maximum
In
mm
In
mm
19003-0018
AA-2203-BK
.234
5.94
.135
3.43
19003-0021
AA-2203X
.234
5.94
.230
5.84
19003-0024
AA-2204
.234
5.94
.135
3.43
19003-0027
AA-2204X
.234
5.94
.230
5.84
19003-0030
AA-2205
.234
5.94
.135
3.43
19003-0033
AA-2205X
.234
5.94
.230
5.84
19003-0036
AA-2213
.234
5.94
.135
3.43
19003-0038
AA-2214
.234
5.94
.135
3.43
19023-0053
190230053
.234
5.94
.135
3.43
19023-0062
190230062
.234
5.94
.135
3.43
19164-0012
SAA-2140
.203
5.16
.215
5.46
19276-0002
AA-2201-LIF
.234
5.94
.135
3.43
Wire Size: 14 –16 AWG 2.00 –1.30mm²
Terminal
No.
Terminal
Eng No. (REF)
Wire Strip
Length
Insulation Diameter
Maximum
In
mm
In
mm
19003-0040
BB-2206
.250
6.35
.160
4.06
19003-0044
BB-2206VB
.250
6.35
.160
4.06
19003-0047
BB-2206X
.250
6.35
.260
6.60
19003-0050
BB-2207
.250
6.35
.160
4.06
19003-0053
BB-2207X
.250
6.35
.260
6.60
19003-0056
BB-2208
.250
6.35
.160
4.06
19003-0059
BB-2208X
.250
6.35
.260
6.60
19003-0062
BB-2215
.250
6.35
.160
4.06
19003-0063
BB-2216
.250
6.35
.160
4.06
19040-0166
19040-0166
.250
6.35
.160
4.06
19164-0047
SBB-2141
.203
5.16
.240
6.09
19276-0005
BB-2206-LIF
.250
6.35
.160
4.06
OPERATION
Refer to the instruction manual for the 19279-0001 (AT-200) for
mounting this crimp tool head.
Crimping Terminals
1. There are 3 Tab Locator Blades supplied with the tool. One
is for .187 and .250 Tabs; one is for .205 Tabs and .110
Tabs and a third is for LIF connectors. Make sure the
proper blade is installed on the top of the locator and the
other is stored on the bottom of the locator.
2. Push the terminal and the 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 1.
TERMINAL
TAB LOCATOR
SAFETY SHIELD
Figure 1
LOCATOR
JAWS OPEN
TERMINAL
BARREL
TERMINAL
2ND and 3RD TAB
LOCATOR
WIRE
PUNCH INSERT
ANVIL INSERT
Figure 3
CONDUCTOR PUNCH
CONDUCTOR ANVIL
LOCATOR
WIRE STOP BUILT
INTO TERMINAL
WIRE
TERMINAL
Figure 2

AT 1994 Air Crimp Tool Head
Doc. No. ATS-640050400 Release Date: 09-23-02 UNCONTROLLED COPY Page 3 of 7
Revision: K Revision Date: 01-09-15
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 wire’s 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. Molex offers a Crimp Inspection Handbook for
closed barrel industrial product. See our website or contact your sales engineer.
5. If the insulation part of the crimp needs to be adjusted, first disconnect the air source and loosen the M4
screw on the bottom tool jaw and 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. Reconnect the air source.
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.
LUBRICATION POINTS
(BOTH SIDES)
LIGHT OIL (EVERY MONTH
OR 5,000 CRIMPS)
Figure 4
3/32” HEX
WRENCH
LOOSEN THE
M4 SCREW

AT 1994 Air Crimp Tool Head
Doc. No. ATS-640050400 Release Date: 09-23-02 UNCONTROLLED COPY Page 4 of 7
Revision: K Revision Date: 01-09-15
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
.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
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

AT 1994 Air Crimp Tool Head
Doc. No. ATS-640050400 Release Date: 09-23-02 UNCONTROLLED COPY Page 5 of 7
Revision: K Revision Date: 01-09-15
3
2
1
Figure 5
M4 LOCKNUT W/HEX
NYLON INSERT
M4 FLAT WASHER
4
5
6
7
8
(2)
PARTS LIST
Item
Order No
Description
Quantity
64005-0400
Crimp Tool Head
Figure 5
1
64005-0000
Basic Air Tool Head
1
2
64001-0475
Locator Assembly
1
3
64001-0470
Tooling Kit
1
Tooling Kit Only
4
64001-0214
Conductor Punch
1
5
64001-0212
Conductor Anvil
1
6
64001-0312
Insert Punch
1
7
64001-0311
Insert Anvil
1
8
N/A
4mm Diameter. by 5.0mm Long.Roll Pins
2**
** Available from an Industrial supply company such as (MSC 1-800-645-7270).

AT 1994 Air Crimp Tool Head
Doc. No. ATS-640050400 Release Date: 09-23-02 UNCONTROLLED COPY Page 6 of 7
Revision: K Revision Date: 01-09-15
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).

AT 1994 Air Crimp Tool Head
Doc. No. ATS-640050400 Release Date: 09-23-02 UNCONTROLLED COPY Page 7 of 7
Revision: K Revision Date: 01-09-15
Air Powered
Crimp Tool Head
Insulkrimp
Certificate of Calibration
Order No. 64005-0400
Engineering No. AT 1994
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