0640074400

AT-1080 Hand Crimp Tool Air Powered Crimp Tool Head VersaKrimp  Application Tooling Specification Sheet Order No. 64007-4400 Engineering No. AT1080 FEATURES Quick-change tool head for the 19279-0001 (AT-200) Tooling kit is interchangeable with other kits in the 64001 and 64003 Series Pneumatic powered crimp tools help reduce fatigue and discomfort from repetitive manual crimping SCOPE Products: VersaKrimp™ Ring Tongue Terminals and Splices 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) 8 *UL - 486 A 90 *UL – 486 C 45 *UL – 310 N/A *UL - 486 A - Terminals (Copper conductors only) *UL - 486 C - Butt Splices, Parallel 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 Wire Size: 8 AWG 8.50mm² Wire Strip Length Terminal Terminal Order No. Eng. No. (REF) In mm 19193-0143 D-350-06 .438 11.11 19193-0144 D-350-06R90 .438 11.11 19193-0146 D-350-08 .438 11.11 19193-0147 D-350-08R90 .438 11.11 19193-0149 D-350-10 .438 11.11 19193-0152 D-350-14 .438 11.11 19193-0154 D-350-14R90 .438 11.11 19193-0157 D-350-56 .438 11.11 19193-0159 D-351-10 .438 11.11 19193-0161 D-351-10R90 .438 11.11 19193-0163 D-351-14 .438 11.11 19193-0165 D-351-14R90 .438 11.11 19193-0167 D-351-38 .438 11.11 Doc No. ATS-640074400 Revision: B Release Date: 02-15-06 Revision Date: 10-13-06 Wire Size: 8 AWG 8.50mm² Wire Strip Length Terminal Terminal Order No. Eng. No. (REF) In mm 19193-0171 D-351-56 .438 11.11 19193-0175 D-351-76 .438 11.11 19193-0178 D-352-10 .438 11.11 19193-0179 D-352-12 .438 11.11 19193-0182 D-352-14 .438 11.11 19193-0184 D-352-38 .438 11.11 19193-0185 D-352-56 .438 11.11 19193-0186 D-352-58 .438 11.11 19193-0187 D-352-76 .438 11.11 19193-0190 D-353-12 .438 11.11 19193-0191 D-353-14 .438 11.11 19193-0192 D-353-34 .438 11.11 19193-0193 D-353-38 .438 11.11 UNCONTROLLED COPY Page 1 of 6 AT-1080 Hand Crimp Tool Wire Size: 8 AWG 8.50mm² Wire Strip Length Terminal Terminal Order No. Eng. No. (REF) In mm 19193-0194 D-353-56 .438 11.11 19193-0195 D-353-58 .438 11.11 19193-0196 D-353-76 .438 11.11 19193-0198 D-356-06 .438 11.11 19193-0200 D-356-08 .438 11.11 19193-0202 D-356-10 .438 11.11 19193-0204 D-356-14 .438 11.11 19193-0506 D-356-14R90 .438 11.11 Wire Size: 8 AWG 8.50mm² Wire Strip Length Terminal Terminal Order No. Eng. No. (REF) In mm 19193-0527 D-351-56R90 .438 11.11 19203-0244 D-T-350-10 19203-0245 D-T-350-14 19205-0004 D-355 .312 7.92 19215-0034 D-354 .375 9.53 19215-0037 DC-354 .375 9.53 OPERATION Refer to the instruction manual for the 19279-0001 (AT200) for mounting this crimp tool head. CAUTION: Never operate this tool without the supplied safety shield in place. Never place fingers in the tool nests. CONDUCTOR ANVIL JAWS OPEN SAFETY SHIELD TERMINAL TERMINAL BARREL Figure 1 TERMINAL WIRE WIRE Figure 2 CONDUCTOR PUNCH Crimping Terminals 1. Insert the wire into the terminal. Then insert the terminal in the nest with the barrel up and centered in the nest. 2. Push on wire to assure it is still fully seated in the terminal. See Figure 2 and 3. Cycle the tool. 3. When crimping butt splices, insert the wire into the butt splice. Position the splice and the wire into the nest with conductor crimp on the conductor barrel of the splice. The splice should be approximately centered inside the tooling nests. See Figure 3. Cycle the tool. 4. Remove the crimp and inspect for proper crimp location. 5. Molex offers a Crimp Inspection Handbook for closed barrel industrial product. See our website or contact your sales engineer. Note: Whenever crimping unbrazed product, make sure the seam of the terminal is oriented up or down in the tool. This will provide higher pull force values. 6. When crimping parallel splices insert the first wire into one end of splice then insert the second wire into the opposite end of the parallel splice. This procedure will crimp both wires at the same time. Make sure the wires are fully seated into the parallel splice. Position the splice and the wires in the nest with conductor crimp on the conductor barrel of the splice The splice should be approximately centered inside the tooling nests. See Figure 4. Cycle the tool. Doc No. ATS-640074400 Revision: B Release Date: 02-15-06 Revision Date: 10-13-06 UNCONTROLLED COPY Page 2 of 6 AT-1080 Hand Crimp Tool CONDUCTOR ANVIL VISUALLY CENTER SPLICE BARREL WIRE BUTT SPLICE Figure 3 CONDUCTOR ANVIL VISUALLY CENTER SPLICE BARREL PARALLEL SPLICE 1ST WIRE 2ND WIRE CONDUCTOR PUNCH CONDUCTOR PUNCH Figure 4 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 troublefree crimping. A light oil, such as 30 weight automotive oil used at the oil points shown in Figure 5, 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. LUBRICATION POINTS (BOTH SIDES) LIGHT OIL (EVERY MONTH OR 5,000 CRIMPS) Figure 5 Tool Calibration A Certificate of Calibration (See last page) was supplied with the tool. To recalibrate this tool, measurements should be taken from each conductor nest and compared to this chart. The tool should be lubricated prior to recalibration to ensure consistent measurements. Nest Color Code N/A Wire Range AWG mm² 8 13.30 X PIN GAUGE IN CONDUCTOR CRIMP “X” Dimension Conductor Crimp Mean Go No Go .115 .109 .122 “INDENTOR” CRIMP Crimp Inspection Marking 8 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 altered, misused or damaged tools. CAUTION: Molex crimp specifications are valid only when used with Molex terminals, applicators and tooling. Doc No. ATS-640074400 Revision: B Release Date: 02-15-06 Revision Date: 10-13-06 UNCONTROLLED COPY Page 3 of 6 AT-1080 Hand Crimp Tool PARTS LIST Item 1 2 3 4 Order No Description 64007-4400 Crimp Tool Head 64005-0000 Basic Air Tool Head 64003-4470 Tooling Kit Tooling Kit Only 64003-4402 Conductor Anvil 64003-4401 Conductor Punch Quantity Figure 6 1 1 1 1 1 3 4 2 Doc No. ATS-640074400 Revision: B Release Date: 02-15-06 Revision Date: 10-13-06 Figure 6 UNCONTROLLED COPY Page 4 of 6 AT-1080 Hand Crimp Tool Parts List (Continued) Item 1 2 3 4 Order No. Description Quantity 64005-0000 Basic Air Tool Head Figure 7 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 2** 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 7 Doc No. ATS-640074400 Revision: B Release Date: 02-15-06 Revision Date: 10-13-06 UNCONTROLLED COPY Page 5 of 6 AT-1080 Hand Crimp Tool Air Powered Crimp Tool Head VersaKrimp  Certificate of Calibration Order No. 64007-4400 Engineering No. AT1080 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-640074400 Revision: B Release Date: 02-15-06 Revision Date: 10-13-06 UNCONTROLLED COPY Page 6 of 6