0640051600

AT2200HD Air Head Crimp Tool Air Powered Crimp Tool Head Operating Instruction Sheet And Specifications Part No. 64005-1600 Eng. No. AT 2200HD (Replaces 19283-0014) FEATURES Œ Œ Œ Œ Œ Œ 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 Heavy Duty, (Rings, Spades, Railroad Rings and Test Terminals.) 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 - 486 A 16 14 30 50 *UL - 486 A - Terminals (copper conductors only). 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: 14 – 16 AWG 2.00 – 1.30 mm² Wire Strip Length Insul. Dia. Max. Terminal Terminal No. Eng No. (REF) In. mm In. mm 19054-0063 B-201-12HDX 0.31 7.94 0.25 6.35 19054-0066 B-201-38HDX 0.31 7.94 0.25 6.35 19054-0070 B-201-76HDX 0.31 7.94 0.25 6.35 19054-0090 B-228-06HDX 0.31 7.94 0.25 6.35 19054-0092 B-228-08HDX 0.31 7.94 0.25 6.35 19054-0094 B-228-10HDX 0.31 7.94 0.25 6.35 19054-0096 B-230-10HDX 0.31 7.94 0.25 6.35 19054-0097 B-230-14HDX 0.31 7.94 0.25 6.35 19054-0098 B-230-56HDX 0.31 7.94 0.25 6.35 Doc. No. 64005-1600 Revision: A Release Date: 01-17-03 Revision Date: 06-25-03 Terminal No. 19054-0126 19058-0016 19058-0026 19058-0041 19058-0047 19058-0058 19058-0063 19058-0064 19058-0066 Wire Size: 14 – 16 AWG 2.00 – 1.30 mm² Terminal Wire Strip Length Insul. Dia. Max. In. mm In. mm B-240-38HDX 0.31 7.94 0.25 6.35 B-801-12HD 0.38 9.53 0.23 5.72 B-801-76HD 0.38 9.53 0.23 5.72 B-828-08HD 0.38 9.53 0.23 5.72 B-828-10HD 0.38 9.53 0.23 5.72 B-830-10HDRR 0.38 9.53 0.25 6.22 B-830-14HD 0.38 9.53 0.23 5.72 B-830-14HD-03 0.38 9.53 0.23 5.72 B-830-14HDRR 0.38 9.53 0.25 6.22 UNCONTROLLED COPY Page 1 of 6 AT2200HD 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 19058-0072 B-830-56HD 0.38 9.53 0.23 5.72 19058-0073 B-830-56HD-03 0.38 9.53 0.23 5.72 19058-0075 B-830-56HDRR 0.38 9.53 0.25 6.22 19058-0117 B-840-38HD 0.38 9.53 0.23 5.72 19058-0155 TT-1614HD 0.38 9.53 0.21 5.38 19142-0037 B-241-10HDX 0.31 7.94 0.25 6.35 Terminal No. 19142-0040 19197-0020 19197-0023 19197-0038 19197-0041 Wire Size: 14 – 16 AWG 2.00 – 1.30 mm² Terminal Wire Strip Length Insul. Dia. Max. In. mm In. mm B-268-14HDX 0.31 7.94 0.25 6.35 B-841-08HD 0.38 9.53 0.23 5.72 B-841-10HD 0.38 9.53 0.23 5.72 B-841-08HDX 0.28 7.14 0.23 5.72 B-841-10HDX 0.28 7.14 0.23 5.72 OPERATION JAWS OPEN Refer to the instruction manual for the 19279-0001 (AT-200) for mounting this crimp tool head. SAFETY SHIELD 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. FRONT EDGE OF BARREL TERMINAL Caution: Never operate this tool without the supplied safety shield in place. Never place fingers in the tool nests. LOCATOR PUSH UP Figure 1 3. Push on wire to assure it is still fully seated in the terminal. (See Figure 2 and 3). Cycle the tool. CONDUCTOR PUNCH LOCATOR TERMINAL Figure 2 TERMINAL BARREL WIRE WIRE TERMINAL INSULATION PUNCH CONDUCTOR ANVIL INSULATION ANVIL Figure 3 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. 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 4). 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. Doc. No. 64005-1600 Revision: A Release Date: 01-17-03 Revision Date: 06-25-03 UNCONTROLLED COPY Page 2 of 6 AT2200HD Air Head Crimp Tool 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 LUBRICATION POINTS (BOTH SIDES) contaminants with a clean brush, or soft, LIGHT OIL (EVERY MONTH OR 5,000 lint-free cloth. CRIMPS) 2. Do not use any abrasive materials that could damage the tool. 3. Make certain all pins, pivot points and LOOSEN M4 bearing surfaces are protected with a SCREW thin coat of high quality machine oil. Do not oil excessively. The 64005-1600 3/32” HEX WRENCH (AT-2200HD) was engineered for durability, but like any fine piece of Figure 3 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. 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 Yellow Wire “X” Dimension Crimp Range Conductor Crimp Inspection AWG mm² Mean Go No Go Marking 14 - 16 2.00 – 1.30 .151 .150 .153 o 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. 64005-1600 Revision: A Release Date: 01-17-03 Revision Date: 06-25-03 UNCONTROLLED COPY Page 3 of 6 AT2200HD Air Head Crimp Tool PARTS LIST Item 1 2 3 Order No 64005-1600 64005-0000 64001-1675 64001-1670 4 5 6 7 8 9 64001-1602 64001-1601 64001-1606 64001-1505 N/A N/A Description Quantity Crimp Tool Head (Fig. 5) 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 5 8 9 (2) 6 7 3 Figure 5 Doc. No. 64005-1600 Revision: A Release Date: 01-17-03 Revision Date: 06-25-03 UNCONTROLLED COPY Page 4 of 6 AT2200HD Air Head Crimp Tool Parts List (Continued) Item Order No. 64005-0000 64005-0103 64000-0077 N/A N/A N/A 1 2 3 4 5 Description Basic Air Tool Head Nose Guard Repair Kit (Springs, Rods Pivots ,Rings, and Washers) M4 by 12LG. Freedrive Pan Head Screw M4 by 30LG. Freedrive Pan Head Screw 3/16” by 3/8” Long Dowel Pin Quantity (Fig. 6) 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 3 2 (4) Figure 6 Doc. No. 64005-1600 Revision: A Release Date: 01-17-03 Revision Date: 06-25-03 UNCONTROLLED COPY Page 5 of 6 AT2200HD 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. 64005-1600 Revision: A Release Date: 01-17-03 Revision Date: 06-25-03 UNCONTROLLED COPY Page 6 of 6