molex AT-200 User manual

AT2080 Air Crimp Tool Head
Doc No: ATS-640052500 Release Date: 01-20-03 UNCONTROLLED COPY age 1 of 8
Revision: B Revision Date: 09-02-03
Air Powered
Crimp Tool Head
Application Tooling
Specification Sheet Order No 64005-2500
Engineering No AT 2080
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
 neumatic powered crimp tools help reduce fatigue and discomfort from repetitive manual crimping
SCOPE
roducts: Nylon closed end connectors 8 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
–
486 C
8
45
* UL – 486 C – Closed end connectors and Wire Nuts
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: 8 AWG 8 50 mm²
Terminal No Terminal Eng No (REF)
Wire Strip Length
Wire Combinations
In
mm
19160
-
0024
NC
-
8
Varies
Varies
See Chart 1

AT2080 Air Crimp Tool Head
Doc No: ATS-640052500 Release Date: 01-20-03 UNCONTROLLED COPY age 2 of 8
Revision: B Revision Date: 09-02-03
OPERATION
Refer to the instruction manual for the 19279-0001 (AT200) for
mounting this crimp tool head.
Wire Preparation
For stranded wire strip leads to approximately 7/8 of an inch. Twist the wire combination even and tight. Trim
stripped pre-twisted area to 1/2 of an inch and insert into connector and crimp. For more information follow the
Quality Crimping Handbook.
CHART 1
Wire Combinations for Nylon
-
Insulated
Closed End Connectors
Part No 191600024 (NC-8)
Wire Type
Wire Gauge (AWG)
Rating
8
10
12
14
16
18
Stranded only
1 1
UL
& CSA
Stranded only
1 1
UL & CSA
Stranded only
1 1
UL & CSA
Stranded only
1 2
UL & CSA
Stranded only
2
UL & CSA
Stranded only
1 1
UL & CSA
Stranded only
1 1
UL & CSA
Stranded only
1 2
UL & CSA
Stranded only
1 4
UL &
CSA
Stranded only
1 2
UL & CSA
Stranded only
1 1
UL & CSA
Stranded only
1 6
UL & CSA
Stranded only
1 5
UL & CSA
Stranded only
1 4
UL & CSA
Stranded only
1 3
UL & CSA
Stranded only
1 2
UL & CSA
Stranded only
1 1
UL &
CSA
Stranded only
3
UL & CSA
Stranded only
2
UL & CSA
Stranded only
2 2
UL & CSA
Stranded only
2 3
UL & CSA
Stranded only
2 2
UL & CSA
Stranded only
2 1
UL & CSA
Stranded only
2 4
UL & CSA
Stranded only
2 3
UL & C
SA
Stranded only
2 2
UL & CSA
Stranded only
2 1
UL & CSA
**
Stranded only
1 4
UL & CSA
Stranded only
1 3
UL & CSA
Stranded only
1 2
UL & CSA
Stranded only
1 1
UL & CSA
Stranded only
1 5
UL & CSA
Stranded only
1 4
UL &
CSA
Stranded only
1 3
UL & CSA
Stranded only
1 2
UL & CSA
Wire Combinations for Nylon
-
Insulated
Closed End Connectors
Part No 191600024 (NC-8)
Wire Type
Wire Gauge (AWG)
Rating
8
10
12
14
16
18
Stranded only
1 8
UL & CSA
Stranded only
1 7
UL & CSA
Stranded only
1 6
UL & CSA
Stranded only
1 5
UL & CSA
Stranded only
1 4
UL & CSA
Stranded only
1 3
UL &
CSA
Stranded only
5
UL & CSA
Stranded only
4
UL & CSA
Stranded only
4 2
UL & CSA
Stranded only
4 1
UL & CSA
Stranded only
3
UL & CSA
Stranded only
3 3
UL & CSA
Stranded only
3 2
UL & CSA
Stranded Only
3 1
UL only
Stranded only
3 5
UL & CSA
Stranded only
3 4
UL & CSA
Stranded only
3 3
UL & CSA
Stranded only
3 2
UL & CSA
Stranded only
3 1
UL & CSA
Stranded only
2 4
UL & CSA
Stranded only
2 3
UL & CSA
Stranded only
2 2
UL & CSA
Stranded only
2 1
UL & CSA
Stranded only
2 7
UL & CSA
Stranded only
2 6
UL & CSA
Stranded only
2 5
UL & CSA
Stranded only
2 4
UL & CSA
Stranded only
2 3
UL & CSA
Stranded only
2 2
UL & CSA
Stranded only
1 6
UL & CSA
Stranded only
1 5
UL & CSA
Stranded only
1 4
UL & CSA
Stranded only
1 3
UL & CSA
Stranded only
1 10
UL & CSA
Stranded only
1 9
UL & CSA
Stranded only
1 8
UL & CSA
Stranded only
1 7
UL & CSA
1/2 “

AT2080 Air Crimp Tool Head
Doc No: ATS-640052500 Release Date: 01-20-03 UNCONTROLLED COPY age 3 of 8
Revision: B Revision Date: 09-02-03
JAWS SLIGHTLY
CLOSED
CONNECTOR
Figure 2
PRE
-
TWISTED
WIRE
CONNECTOR
LOCATOR
JAWS
OPEN
Figure 1
DROP IN
THIS SIDE
Wire Combinations for Nylon
-
Insulated
Closed End Connectors
Part No 191600024 (NC-8)
Wire Type
Wire Gauge (AWG)
Rating
8
10
12
14
16
18
Stranded only
1 6
UL & CS
A
Stranded only
1 5
UL & CSA
Stranded only
1 4
UL & CSA
Stranded only
7
UL & CSA
Stranded only
7 1
UL & CSA
Stranded only
6
UL & CSA
Stranded only
6 3
UL & CSA
Stranded only
6 2
UL & CSA
Stranded only
6 1
UL & CSA
Stranded only
5
UL & CSA
Stranded only
5 4
UL & CSA
Stranded only
5 3
UL & CSA
Stranded only
5 2
UL & CSA
Stranded only
5 1
UL & CSA
Stranded only
4
UL & CSA
Stranded only
4 6
UL & CSA
Stranded only
4 5
UL & CSA
S
tranded only
4 4
UL & CSA
Stranded only
4 3
UL & CSA
Stranded only
4 2
UL & CSA
Stranded only
4 1
UL & CSA
Stranded only
3 8
UL & CSA
Stranded only
3 7
UL & CSA
Stranded only
3 6
UL & CSA
Stranded only
3 5
UL & CSA
Wire Combinations for Nylon
-
Insulated
Closed End Connectors
Part No 191600024 (NC-8)
Wire Type
Wire Gauge (AWG)
Rating
8
10
12
14
16
18
S
tranded only
3 4
UL & CSA
Stranded only
3 3
UL & CSA
Stranded only
3 2
UL & CSA
Stranded only
2 9
UL & CSA
Stranded only
2 8
UL & CSA
Stranded only
2 7
UL & CSA
Stranded only
2 6
UL & CSA
Stranded only
2 5
UL & CSA
S
tranded only
2 4
UL & CSA
Stranded only
1 11
UL & CSA
Stranded only
1 10
UL & CSA
Stranded only
1 9
UL & CSA
Stranded only
1 8
UL & CSA
Stranded only
1 7
UL & CSA
Stranded only
1 6
UL & CSA
Stranded only
1 5
UL & CSA
Stranded only
12
UL & CSA
Stranded only
11
UL & CSA
Stranded only
10
UL & CSA
Stranded only
9
UL & CSA
Stranded only
8
UL & CSA
Stranded only
7
UL & CSA
** - Rated 300 Volts all others 600 Volts
Crimping Terminals
1. Hold airhead crimp tool with the locator facing up. Insert the closed end connector in the slot (8). Make sure
that the shoulder of the connector is resting on the locator plate. See Figure 1.

AT2080 Air Crimp Tool Head
Doc No: ATS-640052500 Release Date: 01-20-03 UNCONTROLLED COPY age 4 of 8
Revision: B Revision Date: 09-02-03
LUBRICATION POINTS
(BOTH SIDES)
LIGHT OIL (EVERY MONTH
OR 5,000 CRIMPS)
Figure 4
2. lace pre-twisted wire into closed-end connector, and then press lever on air tool. See Figure 2 and 3.
Release the lever after jaws have closed.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
Caution Never operate this tool without the supplied safety shield in place. Never place fingers in the tool nest.
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.
3. 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.
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. This 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 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.
Figure 3
LOCATOR
PRE
-
TWISTED
WIRE
CONDUCTOR
PUNCH
CONDUCTOR
ANVIL
CONNECTOR

AT2080 Air Crimp Tool Head
Doc No: ATS-640052500 Release Date: 01-20-03 UNCONTROLLED COPY age 5 of 8
Revision: B Revision Date: 09-02-03
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.
Wire Range
“X” Dimension
Conductor Crimp
Awg
mm²
Mean
Go
No Go
8
8.50
.140
.136
.146
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 alter, 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

AT2080 Air Crimp Tool Head
Doc No: ATS-640052500 Release Date: 01-20-03 UNCONTROLLED COPY age 6 of 8
Revision: B Revision Date: 09-02-03
2
3
1
Figure 5
M4 LOCKNUT W/
HEX NYLON INSERT
4
5
PARTS LIST
Item
Order No
Description
Quanti
ty
64005
-
25
00
Crimp Tool Head
Figure 5
1
64005
-
0000
Basic Air Tool Head
1
2
64001
-
2575
Locator Assembly
1
3
64001
-
2570
Tooling Kit
1
Tooling Kit Only
4
64001
-
2501
Conductor unch
1
5
64001
-
2502
Conductor Anvil
1

AT2080 Air Crimp Tool Head
Doc No: ATS-640052500 Release Date: 01-20-03 UNCONTROLLED COPY age 7 of 8
Revision: B Revision Date: 09-02-03
Figure 6
3
4
2
2
2
5
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 ivots ,Rings, and Washers)
1
3
N/A
M4 by 12 Long Freedrive an Head Screw
1**
4
N/A
M4 by
30 Long Freedrive an Head Screw
1**
5
N/A
3/16” by 3/8” Long Dowel in
1**
** Available from an Industrial supply company such as MSC (1
-
800
-
645
-
7270).

AT2080 Air Crimp Tool Head
Doc No: ATS-640052500 Release Date: 01-20-03 UNCONTROLLED COPY age 8 of 8
Revision: B Revision Date: 09-02-03
Air Powered
Crimp
Tool Head
Certificate of Calibration
Order No 64005-2500
Engineering No AT 2080
Tool Order Number __________________
Tool Eng. Number___________________
Tool Revision______________________
Serial Number_____________________
Date of Manufacture
in 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