AT-FIFG Air Head Crimp Tool Air Powered Crimp Tool Head Operating Instruction Sheet and Specifications Part No. 64005-4100 Eng. No. AT FIFG (Replaces 19283-0056) 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 Fully Insulated Flag Quick Disconnects (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 190780307 (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) 22 20 18 16 14 *UL 310 8 13 20 30 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. Terminal No. 19007-0001 19007-0005 19007-0009 19007-0011 19007-0015 19007-0017 Wire Size: 18 - 22 AWG 0.80 - 0.35 mm Wire Strip Length Terminal Eng No. (REF) In. mm AA-2220 .344 8.73 AA-2220X .344 8.73 AA-2222 .344 8.73 AA-2222X .344 8.73 AA-2223 .344 8.73 AA-2223X .344 8.73 Insul. Dia. Max. In. mm .176 4.47 .240 6.10 .176 4.47 .240 6.10 .176 4.47 .240 6.10 Doc No. 64005-4100 Release Date: 09-22-03 Revision: A Revision Date: 09-22-03 Terminal No. 19007-0021 19007-0025 19007-0029 19007-0031 19007-0035 19007-0037 Wire Size: 14 - 16 AWG 2.00 - 1.30 mm Terminal Eng No. (REF) Wire Strip Length In. mm BB-2221 .313 7.94 BB-2221X .313 7.94 BB-2224 .313 7.94 BB-2224X .313 7.94 BB-2225 .313 7.94 BB-2225X .313 7.94 UNCONTROLLED COPY Insul. Dia. Max. In. mm .200 5.08 .265 6.73 .200 5.08 .265 6.73 .200 5.08 .265 6.73 Page 1 of 6 AT-FIFG Air Head Crimp Tool LOCATO Operation 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). CONDUCTO R JAWS OPEN TERMINA Figure 1 WIRE LOCATOR SAFETY SHIELD TERMINA Figure 2 TERMINAL WIRE CONDUCTO R Figure 3 Caution: 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. 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 LUBRICATION clean brush, or soft, lint-free cloth. POINTS (BOTH SIDES) 2. Do not use any abrasive materials that could damage LIGHT OIL the tool. 3. Make certain all pins; pivot points and bearing Figure 4 surfaces are protected with a thin coat of high quality machine oil. Do not oil excessively. The 64005-4100 (AT-FIFG) 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 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. Doc No. 64005-4100 Release Date: 09-22-03 Revision: A Revision Date: 09-22-03 UNCONTROLLED COPY Page 2 of 6 AT-FIFG Air Head Crimp Tool Tool Calibration 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. " NOT POSSIBLE TO PIN GAUGE, MEASURE A X" *SOLDER, LEAD OR Nest Color Code Blue Red Wire Range AWG mm 14 - 16 2.00 - 1.30 18 - 22 0.80 - 0.35 "X" Dimension Conductor Crimp Mean Go No Go .078 .076 .088 .068 .066 .070 Crimp Inspection Marking ----- 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. 64005-4100 Release Date: 09-22-03 Revision: A Revision Date: 09-22-03 UNCONTROLLED COPY Page 3 of 6 AT-FIFG Air Head Crimp Tool PARTS LIST Item 1 2 3 4 5 Order No Description 64005-4100 Crimp Tool Head 64005-0000 Basic Air Tool Head 64001-4175 Locator Assembly 64001-4170 Tooling Kit Tooling Kit Only 64001-4102 Conductor Punch 64001-4101 Conductor Anvil Quantity (Fig. 5) 1 1 1 1 1 2 M4 LOCKNUT W/ HEX NYLON 4 1 5 M4 X 20LG PAN HEAD 3 Figure 5 Doc No. 64005-4100 Release Date: 09-22-03 Revision: A Revision Date: 09-22-03 UNCONTROLLED COPY Page 4 of 6 AT-FIFG Air Head Crimp Tool Parts List (Continued) Item 1 2 3 4 5 Order No. 64005-0000 64005-0103 64000-0077 N/A N/A N/A 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. 64005-4100 Release Date: 09-22-03 Revision: A Revision Date: 09-22-03 UNCONTROLLED COPY Page 5 of 6 AT-FIFG 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 = -------------------- 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. 64005-4100 Release Date: 09-22-03 Revision: A Revision Date: 09-22-03 UNCONTROLLED COPY Page 6 of 6