Molex AT-200 Bedienungsanleitung

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)

–

486 C

* 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

19160

0024

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

Stranded only

& CSA

Stranded only

UL & CSA

Stranded only

UL & CSA

Stranded only

UL & CSA

Stranded only

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

UL & CSA

Stranded only

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

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

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

UL & CSA

Stranded only

UL & CSA

Stranded only

4 2

UL & CSA

Stranded only

4 1

UL & CSA

Stranded only

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

Stranded only

1 6

UL & CS

Stranded only

1 5

UL & CSA

Stranded only

1 4

UL & CSA

Stranded only

UL & CSA

Stranded only

7 1

UL & CSA

Stranded only

UL & CSA

Stranded only

6 3

UL & CSA

Stranded only

6 2

UL & CSA

Stranded only

6 1

UL & CSA

Stranded only

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

UL & CSA

Stranded only

4 6

UL & CSA

Stranded only

4 5

UL & CSA

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

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

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

UL & CSA

Stranded only

UL & CSA

Stranded only

UL & CSA

Stranded only

UL & CSA

Stranded only

UL & CSA

Stranded only

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

No Go

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

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

Figure 5

M4 LOCKNUT W/

HEX NYLON INSERT

PARTS LIST

Item

Order No

Description

Quanti

64005

Crimp Tool Head

Figure 5

64005

0000

Basic Air Tool Head

64001

2575

Locator Assembly

64001

2570

Tooling Kit

Tooling Kit Only

64001

2501

Conductor unch

64001

2502

Conductor Anvil

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

(4)

(2)

(4)

(2)

Parts List (Continued)

Item

Order No

Description

Quantity

64005

0000

Basic Air Tool Head

Figure 6

64005

0103

Nose Guard

64000

0077

Repair Kit (Springs, Rods ivots ,Rings, and Washers)

N/A

M4 by 12 Long Freedrive an Head Screw

1**

N/A

M4 by

30 Long Freedrive an Head Screw

1**

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

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