molex AT 2080 User guide

AT2080 Air Crimp Tool Head
Doc No: ATS-640052500 Release Date: 01-20-03 UNCONTROLLED COPY Page 1 of 7
Revision: C Revision Date: 06-23-21
Application Tooling Specification
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
Products: Nylon closed-end connectors 8 AWG. This tool head is intended for use in the 19279-0001
(AT-200), either handheld or with optional bench adapter 19078-0307 (ATBA) and foot switch.
Wire Size: 8 AWG, 8.50mm²
Terminal Order No.
Terminal Engineering No. (Ref.)
Wire Strip Length
Wire Combinations
mm
In.
19160-0024
NC-8
Varies
Varies
See Chart 1
19160-0144
NC-8
Varies
Varies
See Chart 1
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)
*UL486 C
8
45
*UL486 C: Closed-end connectors and wire nuts
Order Number
64005-2500
Engineering No.
AT 2080

AT2080 Air Crimp Tool Head
Doc No: ATS-640052500 Release Date: 01-20-03 UNCONTROLLED COPY Page 2 of 7
Revision: C Revision Date: 06-23-21
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”. 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 & CSA
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
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
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
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
Stranded only
1
6
UL & CSA
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
Stranded 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
Stranded 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
Stranded 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
1/2”

AT2080 Air Crimp Tool Head
Doc No: ATS-640052500 Release Date: 01-20-03 UNCONTROLLED COPY Page 3 of 7
Revision: C Revision Date: 06-23-21
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
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
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
8
UL & CSA
Stranded only
7
UL & CSA
**Rated 300 Volts. All others 600 Volts.
Crimping Terminals
1. Hold the airhead crimp tool with the locator facing up. Insert the closed-end connector in the
slot (8). Make sure the shoulder of the connector is resting on the locator plate. See Figure 1.
2. Place the pre-twisted wire into the closed-end connector, and then press the lever on the air
tool. See Figures 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 because 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.
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 Page 4 of 7
Revision: C Revision Date: 06-23-21
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 a 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. Using 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 the 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.
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, Molex 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.
Wire Range
“X” Dimension Conductor Crimp
AWG
mm²
Mean
Go
No-Go
8
8.50
.140
.136
.146
PIN GAUGE IN
CONDUCTOR CRIMP
“Confining” Crimp
X
LUBRICATION POINTS
(BOTH SIDES)
LIGHT OIL (EVERY MONTH
OR 5,000 CRIMPS)
Figure 4

AT2080 Air Crimp Tool Head
Doc No: ATS-640052500 Release Date: 01-20-03 UNCONTROLLED COPY Page 5 of 7
Revision: C Revision Date: 06-23-21
2
3
1
Figure 5
M4 LOCKNUT W/
HEX NYLON INSERT
4
5
PARTS LIST
Item
Order No.
Description
Quantity
64005-2500
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 Punch
1
5
64001-2502
Conductor Anvil
1

AT2080 Air Crimp Tool Head
Doc No: ATS-640052500 Release Date: 01-20-03 UNCONTROLLED COPY Page 6 of 7
Revision: C Revision Date: 06-23-21
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 Pivots ,Rings, and Washers)
1
3
—
M4 by 12 Long Freedrive Pan Head Screw
1*
4
—
M4 by 30 Long Freedrive Pan Head Screw
1*
5
—
3/16” by 3/8” Long Dowel Pin
1*
*Available from an industrial supply company.

AT2080 Air Crimp Tool Head
Doc No: ATS-640052500 Release Date: 01-20-03 UNCONTROLLED COPY Page 7 of 7
Revision: C Revision Date: 06-23-21
Certificate of Calibration
Tool Order Number: ___________________
Tool Eng. Number: ___________________
Tool Revision: ___________________
Serial Number: ___________________
Date of Manufacture: ___________________
Handle Load Range at 1 inch from the Tips = ________________
Actual = ________________
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 = ______________
Range Conductor Nest # 3 = ____________ —Actual = ______________
Technician: ______________
Date of Calibration: ______________
Calibration should be done every 5,000 cycles or every 3 months. Tools should be lubricated during
this operation.
Application Tooling Support
Phone: (402) 458-TOOL (8665)
E-Mail: [email protected]
Website: www.molex.com/applicationtooling
Molex is a registered trademark of Molex, LLC in the United States of America and may be registered in other countries; all other
trademarks listed herein belong to their respective owners.
Order Number
64005-2500
Engineering No.
AT 2080