AT8100 Air Crimp Tool Head
Doc No: ATS-640052700 Release Date: 04-14-03 UNCONTROLLED COPY Page 1 of 6
Revision: D Revision Date: 10-13-06
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)
*UL
–
486 C
22
8
20
10
18
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.
Wire Size: 18
–
–
0.35mm²
Terminal No. Terminal Eng No. (REF)
Wire Strip Length
Insul
ation
Dia
meter
Max
imum
In
mm
In
mm
19202
-
001
1
AS
-
932
-
DK
.310
7.94
.161/.147 Funnel
4.09/3.73
19202
-
0013
AS
-
N
-
345
.281
7.14
0.13
3.302
19202
-
0063
A
-
945
-
DKJ
.310
7.94
.166/.152 Funnel
4.13/3.86
19270
-
0002
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.
AT8100 Air Crimp Tool Head
Doc No: ATS-640052700 Release Date: 04-14-03 UNCONTROLLED COPY Page 2 of 6
Revision: D Revision Date: 10-13-06
LUBRICATION POINTS
(BOTH SIDES)
LIGHT OIL (EVERY MONTH
OR 5,000 CRIMPS)
Figure
3
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.
3. Remove the crimped splice. Inspect for proper crimp location.
4. Rotate the butt splice terminal 180°
°°
°, so that the opposite end of splice is in the nest.
5. Repeat steps 1 thru 4.
6. 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:
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 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.
Figure 2
WIRE
CONDUCTOR
PUNCH
CONDUCT
OR
ANVIL
BUTT SPLICE
TERMINAL
TAB OF
TERMINAL
JAWS OPEN
BUTT SPLICE
TERMINAL
Figure 1
WIRE
SAFETY
SHIELD
AT8100 Air Crimp Tool Head
Doc No: ATS-640052700 Release Date: 04-14-03 UNCONTROLLED COPY Page 3 of 6
Revision: D Revision Date: 10-13-06
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.
Nest Color Code
Wire Range
“X” Dimension Conductor Crimp
Crimp Inspection Marking
AWG
mm²
Mean
Go
No Go
Red
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.
PIN GAUGE IN
CONDUCTOR CRIMP
“ Confining ” Crimp
X
AT8100 Air Crimp Tool Head
Doc No: ATS-640052700 Release Date: 04-14-03 UNCONTROLLED COPY Page 4 of 6
Revision: D Revision Date: 10-13-06
PARTS LIST
Item
Order No
Description
Quantity
64005
-
2780
Crimp Tool Head
Fig
ure
4
1
64005
-
0000
Basic Air Tool Head
1
2
64001
-
2770
Tooling Kit
1
Tooling Kit Only
3
64001
-
2701
Conductor Punch
1
4
64001
-
2702
Conductor Anvil
1
3
1
Figure 4
4
2
AT8100 Air Crimp Tool Head
Doc No: ATS-640052700 Release Date: 04-14-03 UNCONTROLLED COPY Page 5 of 6
Revision: D Revision Date: 10-13-06
Figure 5
3
3
2
2
2
4
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
5
1
64005
-
0103
Nose Guard
1
2
64000
-
0077
Repair Kit (Springs, Rods Pivots ,Rings, and Washers)
1
3
N/A
M4 by 12 Long F
reedrive Pan Head Screw
1**
4
N/A
M4 by 30 Long Freedrive Pan Head Screw
1**
5
N/A
3/16” by 3/8” Long Dowel Pin
1**
** Available from an Industrial supply company such as MSC (1
-
800
-
645
-
7270).
AT8100 Air Crimp Tool Head
Doc No: ATS-640052700 Release Date: 04-14-03 UNCONTROLLED COPY Page 6 of 6
Revision: D Revision Date: 10-13-06
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