0640052700

AT8100 Air Crimp Tool Head Air Powered Crimp Tool Head NylaKrimp  Application Tooling Specification Sheet Order No. 64005-2700 Engineering No AT 8100 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: NylaKrimp™ Splices and Funnel Entry Nylon Butt Splices also Perma-Seal Butt Splices 18 - 22 AWG. 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) 22 20 18 *UL – 486 C 8 10 10 *UL - 486 C - Butt Splices 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. Terminal No. 19202-0011 19202-0013 19202-0063 19270-0002 Wire Size: 18 – 22 AWG 0.80 – 0.35mm² Wire Strip Length Insulation Diameter Maximum Terminal Eng No. (REF) In mm In mm AS-932-DK .310 7.94 .161/.147 Funnel 4.09/3.73 AS-N-345 .281 7.14 0.13 3.302 A-945-DKJ .310 7.94 .166/.152 Funnel 4.13/3.86 AS-N-302 .281 7.14 0.12 3.048 Caution: Never operate this tool without the supplied safety shield in place. Never place fingers in the tool nests. Doc No: ATS-640052700 Revision: D Release Date: 04-14-03 Revision Date: 10-13-06 UNCONTROLLED COPY Page 1 of 6 AT8100 Air Crimp Tool Head OPERATION Refer to the instruction manual for the 19279-0001 (AT200) for mounting this crimp tool head. Crimping Terminals 1. Insert the wire into the butt splice; the wires end should butt up against the tab in the terminal. See Figure 2. Hold airhead crimp tool with the backside facing the operator. Insert the butt splice and the wire into the nest. See Figure 1. 2. Press lever on air tool. Release it after the jaws have closed. JAWS OPEN SAFETY SHIELD CONDUCTOR ANVIL WIRE BUTT SPLICE TERMINAL Figure 2 BUTT SPLICE TERMINAL WIRE 3. 4. 5. 6. TAB OF TERMINAL CONDUCTOR PUNCH Figure 1 Remove the crimped splice. Inspect for proper crimp location. Rotate the butt splice terminal 180°°, so that the opposite end of splice is in the nest. Repeat steps 1 thru 4. Molex offers a Crimp Inspection Handbook for closed barrel industrial product. See our website or contact your sales engineer. 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. Maintenance It is recommended that each operator of the tool be made aware of, and responsible for, the following maintenance steps: LUBRICATION POINTS (BOTH SIDES) LIGHT OIL (EVERY MONTH OR 5,000 CRIMPS) 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 Figure 3 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 3, 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. Doc No: ATS-640052700 Revision: D Release Date: 04-14-03 Revision Date: 10-13-06 UNCONTROLLED COPY Page 2 of 6 AT8100 Air Crimp Tool Head Tool Calibration PIN GAUGE IN CONDUCTOR CRIMP 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. X “ Confining ” Crimp Nest Color Code Red Wire Range “X” Dimension Conductor Crimp Crimp Inspection Marking AWG mm² Mean Go No Go 18 - 22 0.35 - 0.80 .080 .077 .088 o 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. Doc No: ATS-640052700 Revision: D Release Date: 04-14-03 Revision Date: 10-13-06 UNCONTROLLED COPY Page 3 of 6 AT8100 Air Crimp Tool Head PARTS LIST Item 1 2 3 4 Order No Description Quantity 64005-2780 Crimp Tool Head Figure 4 64005-0000 Basic Air Tool Head 1 64001-2770 Tooling Kit 1 Tooling Kit Only 64001-2701 Conductor Punch 1 64001-2702 Conductor Anvil 1 1 4 3 2 Doc No: ATS-640052700 Revision: D Release Date: 04-14-03 Revision Date: 10-13-06 Figure 4 UNCONTROLLED COPY Page 4 of 6 AT8100 Air Crimp Tool Head Parts List (Continued) Item 1 2 3 4 5 Order No. Description Quantity 64005-0000 Basic Air Tool Head Figure 5 64005-0103 Nose Guard 1 64000-0077 Repair Kit (Springs, Rods Pivots ,Rings, and Washers) 1 N/A M4 by 12 Long Freedrive Pan Head Screw 1** N/A M4 by 30 Long Freedrive Pan Head Screw 1** N/A 3/16” by 3/8” Long Dowel Pin 1** ** Available from an Industrial supply company such as MSC (1-800-645-7270). 2 (2) 2 (2) 2 (4) (2) 2 4 2 (4) 3 1 2 (4) 3 Figure 5 Doc No: ATS-640052700 Revision: D Release Date: 04-14-03 Revision Date: 10-13-06 UNCONTROLLED COPY Page 5 of 6 AT8100 Air Crimp Tool Head Air Powered Crimp Tool Head Avikrimp  Certificate of Calibration Order No. 64005-2700 Engineering No. AT 8100 Tool Order Number __________________ Tool Eng. Number___________________ Tool Revision______________________ Serial Number_____________________ Date of Manufacture Pin 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 Doc No: ATS-640052700 Revision: D Release Date: 04-14-03 Revision Date: 10-13-06 UNCONTROLLED COPY Page 6 of 6