molex AT 1610 User manual

AT-1610 Head Crimp Tool
Doc No: ATS-640053500 Release Date: 09-05-05 UNCONTROLLED COPY Pa e 1 of 7
Revision: D Revision Date: 07-08-16
Air Powered
Crimp
Tool Head
Application Tooling
Specification Sheet
Order No 64005-3500
Engineering No AT 1610
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 10 - 18 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)
*UL
–
486 C
18
10
16
15
14
25
12
35
10
40
* 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
-
0002
NC
-
1610
10
-
16
(5.00
-
1.30)
See Chart 1
19160
-
0003
NC
-
1610
-
BA
10
-
16
(5.00
-
1.30)
See Chart 1
19160
-
0004
NC
-
1610
-
L
10
-
16
(5.00
-
1.30)
See Chart 1
19160
-
0006
NC
-
1610
-
Y
10
-
16
(5.00
-
1.30)
See Chart 1
19160
-
0030
NC
-
S1610
10
-
16
(5.00
-
1.30)
See Chart 1

AT-1610 Head Crimp Tool
Doc No: ATS-640053500 Release Date: 09-05-05 UNCONTROLLED COPY Pa e 2 of 7
Revision: D Revision Date: 07-08-16
OPERATION
Refer to the instruction manual for the 19279-0001 (AT200) for mountin this crimp tool head.
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.
Wire Preparation
Pre-twisted wire not required for OEM applications. For Solid
wire (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 191600002 (NC-1610)
Wire Type
Wire Gauge (AWG)
Rating
12
14
16
17
18
20
Stranded or Solid
1 1
UL & CSA
Stranded or Solid
1 1
UL & CSA
Stranded or Solid
1 2
UL & CSA
Stranded or Solid
2
UL & CSA
Stranded or Solid
1 2
UL & CSA
Stranded or Solid
1 1
UL & CSA
Stranded or Solid
1 1 1
UL & CSA
Stranded or Solid
1 3
UL & CSA
Stranded or Solid
1 2
UL & CSA
Stranded or Solid
1 1
UL & CSA
Stranded or Solid
3 1
UL & CSA
Stranded or Solid
3
UL & CSA
Stranded or Solid
2 3
UL & CSA
Stranded or Solid
2 2
UL & CSA
Stranded or Solid
2 1
UL &
CSA
Wire Combinations for Nylon
Insulated Closed End Connectors
Part No 191600002 (NC-1610)
Wire Type
Wire Gauge (AWG)
Rating
12
14
16
17
18
20
Stranded or Solid
2
UL & CSA
Stranded or Solid
1 4
UL & CSA
Stranded or Solid
1 3
UL & CSA
Stranded or Solid
1 2
UL & CSA
Stranded or Solid
1
UL & CSA
Stranded or Solid
6
UL & CSA
Stranded or Solid
5
UL & CSA
Stranded or Solid
4
UL & CSA
Stranded or Solid
3
UL & CSA
Stranded only
2 1
UL
Stranded only
3 2
UL
Solid only
1 3
CSA
Stranded or Solid
3
UL
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.
3/8 “
Figure 1
JAWS OPEN
LOCATOR
PRE
-
TWISTED
WIRE
ADJUSTMENT BLOCK
CONNECTOR

AT-1610 Head Crimp Tool
Doc No: ATS-640053500 Release Date: 09-05-05 UNCONTROLLED COPY Pa e 3 of 7
Revision: D Revision Date: 07-08-16
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.
4. Remove the crimped connector and inspect for proper crimp location and insulation closure. 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 crimp 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.
ADJUSTMENT
BLOCK
CONNECTOR
Figure 2
3/32” ALLEN
WRENCH
ADJUSTING
SCREW
CLOSE
JAWS
OPEN
JAWS
Figure 3
LOCATOR
PRE
-
TWISTED
WIRE
CONDUCTOR PUNCH
CONDUCTOR ANVIL
CONNECTOR
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY MONTH OR
5,000 CRIMPS)
Figure 4

AT-1610 Head Crimp Tool
Doc No: ATS-640053500 Release Date: 09-05-05 UNCONTROLLED COPY Pa e 4 of 7
Revision: D Revision Date: 07-08-16
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” Dimens
ion
Conductor Crimp
Awg
mm²
Mean
Go
No Go
10
-
16
1.30
-
5.00
.120
.116
.128
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
X

AT-1610 Head Crimp Tool
Doc No: ATS-640053500 Release Date: 09-05-05 UNCONTROLLED COPY Pa e 5 of 7
Revision: D Revision Date: 07-08-16
3
2
1
Figure 5
#6
-
32 X 1/4”
LONG SHCS
4
5
PARTS LIST
Item
Order No
Description
Quantity
64005
-
3500
Crimp Tool Head
Fig
ure
5
1
64005
-
0120
Air Tool Head, Nose Mount
1
2
64001
-
3575
Locator
Assembly
1
3
64001
-
3570
Toolin Kit
1
Tooling Kit Only
4
64001
-
3501
Conductor Punch
1
5
64001
-
3502
Conductor Anvil
1

AT-1610 Head Crimp Tool
Doc No: ATS-640053500 Release Date: 09-05-05 UNCONTROLLED COPY Pa e 6 of 7
Revision: D Revision Date: 07-08-16
Figure 6
3
2
1
1
1
4
2
(4)
(4)
(2)
(4)
1
1
(2)
(2)
1
(2)
Parts List (Continued)
Item
Order No
Description
Quantity
64005
-
0120
Air Tool Head, Nose Mount
Figure 6
1
64000
-
0077
Repair Kit (Sprin s, Rods Pivots, Rin s, and
Washers)
1
2
N/A
#4
-
40 by 3 /8”Lon SHCS
2**
3
N/A
M4 by 12LG. Freedrive Pan Head Screw
2**
4
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-1610 Head Crimp Tool
Doc No: ATS-640053500 Release Date: 09-05-05 UNCONTROLLED COPY Pa e 7 of 7
Revision: D Revision Date: 07-08-16
Air Powered
Crimp
Tool Head
Certificate of Calibration
Order No 64005-3500
Engineering No AT 1610
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 = ______________
Technician ______________
Date of Calibration ______________
Calibration should be done every 5,000 cycles or 3 months.
Tools should be lubricated durin this operation.
Application Tooling Support
2200 Wellin ton Court
Lisle, IL 60532 USA
Phone: [phone]-TOOL (8665)
E-mail: applicationtoolin @molex.com
Visit our Website at www.molex.com/applicationtoolin