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

In.

19160-0024

NC-8

Varies

See Chart 1

19160-0144

NC-8

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

*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

Stranded only

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

Stranded only

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

Stranded only

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

Stranded only

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

Stranded only

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

Stranded only

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

Stranded only

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 only

Stranded only

UL & CSA

Stranded only

UL & CSA

Stranded only

UL & CSA

Stranded only

UL & CSA

Stranded only

UL & CSA

Wire Combinations for Nylon-Insulated

Closed-End Connectors

Part No. 191600024 (NC-8)

Wire Type

Wire Gauge (AWG)

Rating

Stranded only

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

Stranded only

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

Stranded only

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

Stranded only

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

Stranded only

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

Stranded only

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

Stranded only

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

Stranded only

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

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

Stranded only

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

Wire Combinations for Nylon-Insulated

Closed-End Connectors

Part No. 191600024 (NC-8)

Wire Type

Wire Gauge (AWG)

Rating

Stranded only

UL & CSA

Stranded only

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

No-Go

8.50

.140

.136

.146

PIN GAUGE IN

CONDUCTOR CRIMP

“Confining” Crimp

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

Figure 5

M4 LOCKNUT W/

HEX NYLON INSERT

PARTS LIST

Item

Order No.

Description

Quantity

64005-2500

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 Punch

64001-2502

Conductor Anvil

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

(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 Pivots ,Rings, and Washers)

—

M4 by 12 Long Freedrive Pan Head Screw

—

M4 by 30 Long Freedrive Pan Head Screw

—

3/16” by 3/8” Long Dowel Pin

*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

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