AT2100 Air Head Crimp Tool
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 (AT200) 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)
22
20
18
16
14
*UL - 486 A
8
13
20
30
50
*UL – 486 C
8
10
10
15
25
**Military Class 2
15
19
38
50
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.
Doc. No. 64005-1400
Revision: C
Release Date: 12/09/02
Revision Date:08-06-03
UNCONTROLLED COPY
Page 1 of 8
AT2100 Air Head Crimp Tool
Wire Size: 14 – 16 AWG 2.00 – 1.30 mm²
Wire Strip Length Insul. Dia. Max.
Terminal
Terminal No.
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
Doc. No. 64005-1400
Revision: C
Release Date: 12/09/02
Revision Date:08-06-03
Wire Size: 14 – 16 AWG 2.00 – 1.30 mm²
Terminal No.
Terminal
Wire Strip Length Insul. Dia. Max.
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
Terminal No.
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
Terminal No.
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
UNCONTROLLED COPY
Page 2 of 8
AT2100 Air Head Crimp Tool
HEAVY DUTY
Wire Size: 16 – 20 AWG 1.30 – 0.50 mm²
Wire Strip Length Insul. Dia. Max.
Terminal
Terminal No.
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
Terminal No.
Terminal
Wire Strip Length Insul. Dia. Max.
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.
JAWS OPEN
SAFETY
SHIELD
WIRE
TERMINAL
FRONT EDGE
OF BARREL
LOCATOR
PUSH UP
Figure 1
TERMINAL
Figure 2
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).
Doc. No. 64005-1400
Revision: C
Release Date: 12/09/02
Revision Date:08-06-03
UNCONTROLLED COPY
Page 3 of 8
AT2100 Air Head Crimp Tool
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.
CONDUCTOR
PUNCH
INSULATION
PUNCH
TERMINAL
BARREL
LOCATOR
TERMINAL
CONDUCTOR
ANVIL
CONDUCTOR
PUNCH
INSULATION
PUNCH
BUTT SPLICE
TERMINAL
WIRE
INSULATION
ANVIL
WIRE
INSULATION
ANVIL
Figure 3
CONDUCTOR
ANVIL
1/16” INSIDE
INSULATION CRIMP
Figure 4
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:
LUBRICATION POINTS (BOTH SIDES)
LIGHT OIL (EVERY MONTH OR
5,000 CRIMPS)
1. Remove dust, moisture and other
contaminants with a clean brush, or
LOOSEN
soft, lint-free cloth.
M4 SCREW
2. Do not use any abrasive materials
3/32” HEX
that could damage the tool.
WRENCH
3. Make certain all pins, pivot points
Figure 5
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.
Doc. No. 64005-1400
Revision: C
Release Date: 12/09/02
Revision Date:08-06-03
UNCONTROLLED COPY
Page 4 of 8
AT2100 Air Head Crimp Tool
PIN GAUGE IN
CONDUCTOR CRIMP
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.
X
“Confining” Crimp
Nest Color Code
Blue
Wire Range
AWG
14 - 16
16 – 20 HD
18 - 22*
mm²
1.30 - 2.00
0.50 - 1.30
0.80 - 0.35
“X” Dimension
Conductor Crimp
Mean Go No Go
.122 .116
.128
.122 .116
.128
.122 .116
.128
Crimp Inspection
Marking
oo
oo
oo
* 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.
Doc. No. 64005-1400
Revision: C
Release Date: 12/09/02
Revision Date:08-06-03
UNCONTROLLED COPY
Page 5 of 8
AT2100 Air Head Crimp Tool
PARTS LIST
Item
1
2
3
Order No
64005-1400
64005-0000
64007-0375
64001-1470
4
5
6
7
8
9
64001-1402
64001-1401
64001-1404
64001-1403
N/A
N/A
Description
Quantity
Crimp Tool Head
(Fig. 6)
Basic Air Tool Head
1
Locator Assembly
1
Tooling Kit
1
Tooling Kit Only
Conductor Punch
1
Conductor Anvil
1
Insulation Punch
1
Insulation Anvil
1
4 mm Dia. by 5.0 mm Lg.Roll Pins
2**
#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).
M4 WING NUT
M4 FLAT WASHER
2
1
4
(2)
5
8
9
3
6
7
Doc. No. 64005-1400
Revision: C
Release Date: 12/09/02
Revision Date:08-06-03
Figure 6
UNCONTROLLED COPY
Page 6 of 8
AT2100 Air Head Crimp Tool
Parts List (Continued)
Item
Order No.
Description
64005-0000
Basic Air Tool Head
64005-0103
Nose Guard
64000-0077 Repair Kit (Springs, Rods Pivots ,Rings, and Washers)
N/A
M4 by 12LG. Freedrive Pan Head Screw
N/A
M4 by 30LG. Freedrive Pan Head Screw
N/A
3/16” by 3/8” Long Dowel Pin
Quantity
(Fig. 7)
1
1
1**
1**
1**
** The following purchased parts are available from an Industrial supply company such as MSC (1-800-645-7270).
2
(2)
2
(2)
2
(2)
(4)
2
5
2
(4)
4
1
2
3
(4)
Figure 7
Doc. No. 64005-1400
Revision: C
Release Date: 12/09/02
Revision Date:08-06-03
UNCONTROLLED COPY
Page 7 of 8
AT2100 Air Head Crimp Tool
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: (630) 969-4550
Fax: (630) 505-0049
Doc. No. 64005-1400
Revision: C
Release Date: 12/09/02
Revision Date:08-06-03
UNCONTROLLED COPY
Page 8 of 8
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