Molex AT 2212 User manual

AT-2212 Air Crimp Tool Head

Doc No: ATS-640053600 Release Date: 06-24-03 UNCONTROLLED COPY Pa e 1 of 8

Revision: B Revision Date: 09-30-05

Air Powered

Crimp

Tool Head

Application Tooling

Specification Sheet Order No 64005-3600

Engineering No AT 2212

FEATURES

 Quick-chan e tool head for the 19279-0001 (AT-200)

 A precision user-friendly terminal locator stop holds terminals in the proper crimpin position

SCOPE

Products: Nylon closed end connectors 12–22 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 evaluatin the mechanical properties of the crimped connections. The

followin charts show the UL specifications for various wire sizes. The tensile stren th is shown in pounds and

indicates the minimum acceptable force to break or separate terminal from the conductor. On this style product,

only the readin from the smallest wire AWG is used. See Chart 1

Wire Size (AWG)

–

486 C

* UL – 486 C – Closed end connectors and Wire Nuts.

The followin is a partial list of the product part numbers and their specifications that this tool is desi ned to run.

We will be addin to this list and an up to date copy is available on www.molex.com.

Terminal No Terminal Eng No (REF)

Wire Size

Wire Combinations

AWG

mm²

19160

0009

2212

(3.30

0.35)

See

Chart 1

19160

0010

2212

(3.30

0.35)

See Chart 1

19160

0011

2212

(3.30

0.35)

See Chart 1

AT-2212 Air Crimp Tool Head

Doc No: ATS-640053600 Release Date: 06-24-03 UNCONTROLLED COPY Pa e 2 of 8

Revision: B Revision Date: 09-30-05

OPERATION

Refer to the instruction manual for the 19279-0001 (AT200) for

mountin this crimp tool head.

Wire Preparation

Pre-twisted wire not required for OEM applications. For Solid (OEM only) strip leads to 3/8 of an inch. Insert into

connector and crimp.

For stranded wire strip leads to approximately 3/4 of an inch. Twist the wire combination even and ti ht. Trim

stripped pre-twisted area to 3/8 of an inch and insert into connector and crimp. For more information follow the

Quality Crimpin Handbook.

CHART 1

Wire Combinations for Nylon

Insulated Closed End Connectors

Part No 191600009 (NC-2212)

Wire Type

Wire Gauge (AWG)

Rating

Stranded or Solid

1 1

UL & CSA

Stranded or Solid

1 1

UL & CSA

Stranded or Solid

1 2

UL & CSA

Stranded or Solid

1 1 1

UL & CSA

Stranded or Solid

1 1 2

UL & CSA

Stranded or Solid

1 1 1

UL & CSA

Stranded or Solid

1 1 2

UL & CSA

Stranded or Solid

1 1 3

UL & CSA

Stranded or Solid

1 1

UL & CSA

Stranded or Solid

1 2

UL & CSA

Stranded or Solid

1 3

UL & CSA

Stranded or Solid

1 1

UL & CSA

Stranded or Solid

1 2

CSA

Stranded or Solid

1 3

CSA

Stra

nded or Solid

1 4

CSA

Stranded or Solid

1 1 1 1

CSA

Stranded or Solid

UL & CSA

Stranded or Solid

UL & CSA

Stranded or Solid

2 1

UL & CSA

Stranded only

2 2

UL & CSA

Stranded or Solid

2 1

UL & CSA

Stranded or Solid

2 2

UL &

CSA

Stranded or Solid

2 1

UL & CSA

Stranded or Solid

2 2

UL & CSA

Stranded or Solid

2 3

UL & CSA

Stranded or Solid

2 1 1

UL & CSA

Stranded or Solid

2 1 1

UL & CSA

Stranded or Solid

2 1 1

UL & CSA

Stranded or Solid

1 1 2

UL & CSA

tranded or Solid

1 1

UL & CSA

Stranded or Solid

1 1

UL & CSA

Stranded or Solid

1 2

UL & CSA

Stranded or Solid

1 3

UL & CSA

Stranded or Solid

1 1

UL & CSA

Wire Combinations for Nylon

Insulated Closed End Connectors

Part No 191600009 (NC-2212)

Wire Type

Wire Gauge (AWG)

Rating

Stranded or Solid

1 2

UL & CSA

Stranded or Solid

1 3

UL & CSA

Stranded or

Solid

1 4

UL & CSA

Stranded or Solid

1 1

UL & CSA

Stranded or Solid

1 2

UL & CSA

Stranded or Solid

1 3

UL & CSA

Stranded or Solid

1 4

UL & CSA

Stranded or Solid

1 5

UL & CSA

Stranded or Solid

1 2 1

UL & CSA

Stranded or Solid

1 2 1

UL & CSA

Stranded or Solid

1 2 2

UL & CSA

Stranded or Solid

1 1 1

UL & CSA

Stranded or Solid

1 2 1

UL & CSA

Stranded or Solid

1 1 2

UL & CSA

Stranded Only

UL only

Stranded or Solid

UL & CSA

Stranded or Solid

4 1

UL & CSA

Stranded or Solid

4 1

UL & CSA

Stranded or Solid

UL & CSA

Stranded or Solid

3 1

UL & CSA

Stranded or Solid

3 2

UL & CSA

Stranded or Solid

3 1

UL & CSA

Stranded or Solid

3 2

UL & CSA

Stranded or Solid

3 3

UL & CSA

Stranded or

Solid

3 1 1

UL & CSA

Stranded or Solid

UL & CSA

Stranded or Solid

2 1

UL & CSA

Stranded or Solid

2 2

UL & CSA

Stranded or Solid

2 3

UL & CSA

Stranded or Solid

2 1

UL & CSA

Stranded or Solid

2 2

UL & CSA

Stranded or Solid

2 3

UL & CSA

Stranded or Solid

2 1 1

UL & CSA

Stranded or Solid

2 2 1

UL & CSA

3/8 “

AT-2212 Air Crimp Tool Head

Doc No: ATS-640053600 Release Date: 06-24-03 UNCONTROLLED COPY Pa e 3 of 8

Revision: B Revision Date: 09-30-05

Wire Combinations for Nylon

Insulated Closed End Connectors

Part No 191600009 (NC-2212)

Wire Type

Wire Gauge (AWG)

Rating

Stranded or Solid

2 3 1

UL & CSA

Stranded or Solid

2 1 2

UL & CSA

Stranded or Solid

2 1 3

UL & CSA

Stranded or Solid

1 1

UL & CSA

Stranded or Solid

1 2

UL &

CSA

Stranded or Solid

1 3

UL & CSA

Stranded or Solid

1 4

UL & CSA

Stranded or Solid

1 5

UL & CSA

Stranded or Solid

1 1

UL & CSA

Stranded or Solid

1 2

UL & CSA

Stranded or Solid

1 3

UL & CSA

Stranded or Solid

1 4

UL & CSA

Stran

ded or Solid

1 5

UL & CSA

Stranded or Solid

1 1 1

UL & CSA

Stranded or Solid

1 2 1

UL & CSA

Stranded or Solid

1 3 1

UL & CSA

Stranded or Solid

1 4 1

UL & CSA

Stranded or Solid

1 1 2

UL & CSA

Stranded or Solid

1 1 3

UL & CSA

Stranded o

r Solid

1 1 4

UL & CSA

Stranded or Solid

1 2 2

UL & CSA

Stranded or Solid

1 2 3

UL & CSA

Stranded or Solid

1 3 2

UL & CSA

Stranded or Solid

UL & CSA

Stranded or Solid

UL & CSA

Wire Combinations for Nylon

Insulated Closed End Connectors

Part No 191600009 (NC-2212)

Wire Type

Wire Gauge (AWG)

Rating

Stranded or Solid

5 1

UL & CSA

Stranded or Solid

UL & CSA

Stranded or Solid

4 1

UL & CSA

Stranded or Solid

4 2

UL & CSA

Stranded or Solid

UL & CSA

Stranded or Solid

3 1

UL & CSA

Stranded or Solid

3 2

UL & CSA

Stranded or Solid

3 3

UL & CSA

Stranded or Solid

UL & CSA

Stranded or Solid

2 1

UL & CSA

Stranded or Solid

2 2

UL & CSA

Stranded or Solid

2 3

UL & CSA

Stranded or Solid

2 4

UL & CSA

Stranded or Solid

1 1

UL & CSA

Stranded or Solid

1 2

UL & CSA

Stranded or Solid

1 3

UL & CSA

Stranded

or Solid

1 4

UL & CSA

Stranded or Solid

1 5

UL & CSA

Stranded or Solid

UL & CSA

Stranded or Solid

UL & CSA

Stranded or Solid

UL & CSA

Stranded or Solid

UL & CSA

Stranded or Solid

UL & CSA

Crimping Terminals

1. Hold air crimp tool with the locator as shown in Fi ure 1.

Insert the closed end connector in the locator slot. Make

sure that the shoulder of the connector is restin on the

locator plate. The connector should fit snu ly into the jaws

of the crimp tool. See Fi ure 1.

2. If necessary, adjust the jaws of the tool in the open position

so that the connector does not move or fall out of the jaws.

Usin a 3/32” Allen wrench turn the adjustin screw in the

adjustment block clockwise (CW) to close the jaws. Turn

the adjustin screw counterclockwise (CCW) to open the

jaws. See Fi ure 2.

3. Place pre-twisted wire into closed-end connector. Than

press lever (tri er) on air tool. See Fi ure 3. Release the

lever after jaws have fully closed

Caution: Never place fin ers in the tool nests.

Figure 1

JAWS OPEN

LOCATOR

PRE

TWISTED

WIRE

ADJUSTMENT

BLOCK

CONNECTOR

AT-2212 Air Crimp Tool Head

Doc No: ATS-640053600 Release Date: 06-24-03 UNCONTROLLED COPY Pa e 4 of 8

Revision: B Revision Date: 09-30-05

4. Remove the crimped connector and inspect for proper crimp location and insulation closure. It may be required

to rotate crimped connector 90° to remove from the tool. Molex offers a Crimp Inspection Handbook for closed

barrel industrial product. See our website or contact your sales en ineer.

Maintenance

It is recommended that each operator of the tool be made aware of, and responsible for, the followin

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 dama e the tool.

3. Make certain all pins; pivot points and bearin surfaces are

protected with a thin coat of hi h quality machine oil. Do not oil

excessively. This tool was en ineered for durability, but like any

fine piece of equipment it needs cleanin and lubrication for a

maximum service life of trouble-free crimpin . Use a li ht oil

such as 30 wei ht automotive oil at the oil points shown in

Fi ure 4, every 5,000 crimps or monthly will si nificantly

enhance the tool life and ensure a stable calibration.

4. When tool is not in use store the tool in a clean, dry area.

CAUTION: This crimp tool requires a re ulated air supply line with operatin pressure of 60 to 70 PSI. Hi her

pressure may cause dama e to the tool.

LUBRICATION POINTS

(BOTH SIDES) LIGHT OIL

(EVERY MONTH OR

5,000 CRIMPS)

Figure 4

ADJUSTMENT

BLOCK

CONNECTOR

Figure 2

3/32” ALLEN

WRENCH

ADJUSTING

SCREW

JAWS

OPEN

JAWS

Figure 3

LOCATOR

PRE

TWISTED

WIRE

CONDUCTOR PUNCH

CONDUCTOR

ANVIL

CONNECTOR

AT-2212 Air Crimp Tool Head

Doc No: ATS-640053600 Release Date: 06-24-03 UNCONTROLLED COPY Pa e 5 of 8

Revision: B Revision Date: 09-30-05

Tool Calibration

A Certificate of Calibration (see last pa e) was supplied with the

tool. To recalibrate this tool, pin au e 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.

Wire Range

“X” Dimension

Conductor Crimp

AWG

mm²

Mean

No Go

0.35

–

3.30

.102

.099

.106

Warranty

This tool is for electrical terminal crimpin purposes only. This tool is made of the best quality materials. All vital

components are lon -life tested. All tools are warranted to be free of manufacturin defects for a period of 30 days

Should such a defect occur, we would repair or exchan e the tool free of char e. This repair or exchan e will not

be applicable to alter, misused or dama ed tools.

CAUTION: Molex crimp specifications are valid only when used with Molex terminals, applicators and toolin .

PIN GAUGE IN

CONDUCTOR CRIMP

“ Confining ” Crimp

AT-2212 Air Crimp Tool Head

Doc No: ATS-640053600 Release Date: 06-24-03 UNCONTROLLED COPY Pa e 6 of 8

Revision: B Revision Date: 09-30-05

Figure 5

32 X 1/4”

LONG SHCS

PARTS LIST

Item

Order No

Desc

ription

Quantity

64005

Crimp Tool Head

Figure 5

64005

0120

Air Tool Head, Nose Mount

64001

3675

Locator Assembly

64001

3670

Toolin Kit

Tooling Kit Only

64001

3601

Conductor Punch

64001

3602

Conductor Anvil

AT-2212 Air Crimp Tool Head

Doc No: ATS-640053600 Release Date: 06-24-03 UNCONTROLLED COPY Pa e 7 of 8

Revision: B Revision Date: 09-30-05

Figure 6

(4)

(2)

(4)

(2)

Parts List (Continued)

Item

Order No

Description

Quantity

64005

0120

Air Tool Head, Nose Mount

Figure 6

64000

0077

Repair Kit (Sprin s, Rods Pivots, Rin s, and

Washers)

N/A

40 by 3 /8”Lon SHCS

2**

N/A

M4 by 12LG. Freedri

ve Pan Head Screw

2**

N/A

3/16” by 3/8” Lon Dowel Pin

1**

** Available from an Industrial supply company such as MSC (1

800

645

7270).

AT-2212 Air Crimp Tool Head

Doc No: ATS-640053600 Release Date: 06-24-03 UNCONTROLLED COPY Pa e 8 of 8

Revision: B Revision Date: 09-30-05

Air Powered

Crimp

Tool Head

Certificate of Calibration

Order No 64005-3600

Engineering No AT 2212

Tool Order Number_____________________

Tool En . Number______________________

Tool Revision_________________________

Serial Number________________________

Date of Manufacture____________________

Pin Gau e of Conductor Nest/Nests or Slu hei ht if the nest is the “F” Crimp style.

Ran e Conductor Nest # 1 = ____________-- Actual = ______________

Ran e Conductor Nest # 2 = ____________-- Actual = ______________

Ran e Conductor Nest # 3 = ____________-- Actual = ______________

Technician ______________

Date of Calibration ______________

Calibration should be done every 5,000 cycles or 3 months.

Tools should be lubricated durin this operation.

Visit our Web site at http://www.molex.com

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