Air Crimp Tool Head Tool for AviKrimp ™ FQD Terminals
Doc. No. ATS-640057300 Release Date: 01-22-07 UNCONTROLLED COPY Page 1 of 6
Revision: A Revision Date: 01-22-07
Air Powered
Crimp Tool Head
AviKrimp
Application Tooling
Specification Sheet Order No. 64005-7300
Engineering No. AT 2210
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
Products: AviKrimp ™ Female Quick Disconnect 10-12 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
1
2
7
0
*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: 10
–
12 AWG 5.00
–
3.30mm²
Terminal No.
Terminal
Eng No. (REF)
Wire Strip Length
Ins
ul
ation
Dia
meter
Max.
►
Available in Reel form only
In
mm
In
mm
190
19
-
00
37
C
-
8143
.3
75
9.53
.
1
50
3.81
►
190
19
-
00
38
C
-
8143T
.3
75
9.53
.
1
50
3.81
Air Crimp Tool Head Tool for AviKrimp ™ FQD Terminals
Doc. No. ATS-640057300 Release Date: 01-22-07 UNCONTROLLED COPY Page 2 of 6
Revision: A Revision Date: 01-22-07
WIRE
TERMINAL
Figure 2
TAB
LOCATOR
TERMINAL
BARREL
WIRE STOP BUILT
INTO TERMINAL
2
ND
TAB
LOCATOR
WIRE
CONDUCTOR
PUNCH
INSULATION
ANVIL
Figure 3
INSULATION
PUNCH
CONDUCTOR ANVIL
LOCATOR
TERMINAL
OPERATION
Refer to the instruction manual for the 19279-0001 (AT-200) for
mounting this crimp tool head.
Crimping Terminals
1. There are 2 tab locator blades supplied with the tool. One is
for .187 and .250 tabs; the other is for .205 tabs and .110 tabs.
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. Insert the wire into the terminal. Push the terminal and 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.
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 wires 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, and check for insulation closure. 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.
TERMINAL
SAFETY
SHIELD
TAB LOCATOR
Figure 1
LOCATOR
JAWS
OPEN
Air Crimp Tool Head Tool for AviKrimp ™ FQD Terminals
Doc. No. ATS-640057300 Release Date: 01-22-07 UNCONTROLLED COPY Page 3 of 6
Revision: A Revision Date: 01-22-07
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. The 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 is 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 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
Yellow
10
-
12
5.00
-
3.30
.145
.140
.148
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.
CAUTION: Molex crimp specifications are valid only when used with Molex terminals, applicators and tooling.
PIN GAUGE IN
CONDUCTOR CRIMP
“Confining” Crimp
X
LOOSEN
M4 SCREW
LUBRICATION POINTS
(BOTH SIDES)
LIGHT OIL (EVERY MONTH
OR 5,000 CRIMPS)
Figure 4
3/32” HEX
WRENCH
Air Crimp Tool Head Tool for AviKrimp ™ FQD Terminals
Doc. No. ATS-640057300 Release Date: 01-22-07 UNCONTROLLED COPY Page 4 of 6
Revision: A Revision Date: 01-22-07
3
2
1
Figure 5
M4 LOCKNUT W/HEX
NYLON INSERT
M4 FLAT WASHER
4
5
9
6
7
8
(2)
PARTS LIST
Item
Order No
Description
Quantity
64005
-
Crimp Tool Head
Fig
ure
5
1
64005
-
0000
Basic Air Tool Head
1
2
64001
-
0275
Locator Assembly
1
3
64001
-
Tooling Kit
1
Tooling Kit Only
4
64001
-
7301
Conductor Punch
1
5
64001
-
7302
Conductor Anvil
1
6
64001
-
7304
Insulation Punch
1
7
64001
-
7303
Insulation Anvil
1
8
N/A
4 mm Dia. by 5.0mm L
g
Roll Pins
2**
9
N/A
#10
-
32 by 5/16” L
on
g Cup P
oin
t Set Screw
1**
** Available from an Industrial supply company such as MSC (1
-
800
-
645
-
7270).
Air Crimp Tool Head Tool for AviKrimp ™ FQD Terminals
Doc. No. ATS-640057300 Release Date: 01-22-07 UNCONTROLLED COPY Page 5 of 6
Revision: A Revision Date: 01-22-07
Figure 6
3
3
2
2
2
4
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 comp
any such as MSC (1
-
800
-
645
-
7270).
Air Crimp Tool Head Tool for AviKrimp ™ FQD Terminals
Doc. No. ATS-640057300 Release Date: 01-22-07 UNCONTROLLED COPY Page 6 of 6
Revision: A Revision Date: 01-22-07
Air Powered
Crimp Tool Head
Avikrimp
Certificate of Calibration
Order No. 64005-7300
Engineering No. AT 2210
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 = ____________-
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