molex AT-200 Manual

AT-200 Air-Powered Crimping Tool
Doc No: TM-192790001 Release Date: 07-01-02 UNCONTROLLED COPY Page 1 o 18
Revision: D Revision Date:11-10-09
AT-200 AIR-POWERED CRIMPING TOOL
Operating and Maintenance Instr ctions with
Optional Bench Adapter and Foot Switch
Order No. 19279-0001
 Description
 Operation
 Maintenance

AT-200 Air-Powered Crimping Tool
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Revision: D Revision Date:11-10-09
WARNING
NEVER USE THIS TOOL WITHOUT GUARDS OR SAFETY DEVICES THAT ARE
INTENDED TO PREVENT HANDS FROM REMAINING IN THE DIE SPACE.
NEVER OPERATE, SERVICE, INSTALL OR ADJUST THIS TOOL WITHOUT PROPER
INSTRUCTION AND WITHOUT FIRST READING AND UNDERSTANDING THE
INSTRUCTIONS IN THIS MANUAL AND ALL APPLICABLE AIR POWERED
CRIMPING TOOL MANUALS.
NEVER INSTALL OR SERVICE THIS MACHINE WHILE CONNECTED TO THE
COMPRESSED AIR SOURCE.
CAUTION THE MOLEX AT-200 AIR POWERED CRIMPING TOOL IS DESIGNED TO BE
USED WITH AIR POWERED CRIMP TOOLS HEADS AND TOOLING SUPPLIED
BY MOLEX. USE OF TOOL HEADS OR TOOLING FROM ANY OTHER SOURCE
MAY RESULT IN DAMAGE OR INJURY. MOLEX WILL NOT BE LIABLE FOR ANY
DAMAGE OR INJURY FROM USE OF NON-MOLEX COMPONENTS IN THIS
TOOL.
WORK SAFELY AT ALL TIMES
For Service, Contact Yo r
Local Molex Sales Office
Molex Application Tooling Gro p
2200 Wellington Court
Lisle, Illinois 60532
Tel: [phone]
Fax: [phone]

AT-200 Air-Powered Crimping Tool
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Revision: D Revision Date:11-10-09
Table of Contents
1. General Description and Operation
2. Changing Crimping Heads
3. Parts List, Assembly Drawings
Appendix
A Options

AT-200 Air-Powered Crimping Tool
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Revision: D Revision Date:11-10-09
General Description
Description
The AT-200 Air-Powered Crimping Tool is a hand
held pneumatic tool weighting less than two pounds.
It is designed to crimp high quality and consistent
crimped terminals. This tool operates on standard
shop air (85 to 95 PSI) and crimps wire ranges rom
26 to 8AWG.
Feat res
 Crimping dies are easily and quickly
interchanged to reduce production down time.
 Complete portable system that allows tool to be
moved and stored easily.
 Tool may be used as a Potable tool, suspended
over head or bench mounted.
 Higher volume output with less operator atigue.
Technical Specification
Pne matic:
Supply Pressure: 100 PSI (6.9 Bars) max
Cycle Time:
15 seconds
Weight
0.9kg (2lbs)
Delivery Check
Care ully remove the AT-200 Air-Powered
Crimping Tool rom its shipping container and
determine that the ollowing items are included in
the package.
 19279-0001 Air-Powered Crimping
Tool
 19279-0140 Air Hose 1/8 NPT Male
 TM-192790001 Instruction Manual
Tools
The ollowing tools are recommended or setup
and adjustments to this tool.
1. Metric standard hex wrench set
2. Inch standard hex wrench set
3. Adjustable wrench
4. Wire stripper / cutter
5. Screw driver
Can Also Be Used With:
19078-0307 Bench Adapter Assembly with
Foot Switch
64001-4000 Electrical Control Box
Specification Sheets
Molex ships speci ication sheets with every Air
Crimp Tool Head. These Tool Heads are not
included with the AT-200 Air-Powered Crimp Tool.
They are ordered separately. The speci ication
sheet contains the ollowing:
Terminal numbers
Wire AWG ranges
Insulation diameter ranges
Strip lengths
Pull Force
Crimp heights
Bell mouth
Bend, twist and roll limits
Tooling parts list and assembly
These are available on the Molex website
(www.molex.com).

AT-200 Air-Powered Crimp Tool
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Revision: D Revision Date:11-10-09
FILTER REGULATOR
(NOT SUPPLIED)
FOOT
SWITCH
OPTIONAL BENCH
ADAPTER
TO AIR
SUPPLY
SECURE AIR CRIMPING
TOOL IN POSTION
CONNECT TUBING FROM
FOOT SWITCH
WITHOUT FITTING
Fig re 2
CONNECT TUBING FROM
FOOT SWITCH
WITH FITTING
(NOT SUPPLIED)
TRIGGER SAFETY
AIR HOSE
(19279-0140)
FILTER REGULATOR
(NOT SUPPLIED)
TO AIR
SUPPLY
TRIGGER
Fig re 1
Operation
1. Read the ollowing instructions be ore attempting to operate tool.
2. Connect the air hose to the tool and to the air supply 85 to 95 PSI. Do not exceed 100 PSI. May ca se inj ry
or damage to the tool. Air supply must be equipped with a 1/4NPT air ilter /regulator which is not supplied by
Molex. See Figure 1. (Available rom any Industrial supply co.)
I changing to the Optional bench adapter (Order No. 19078-0307) remove the air hose (Order No. 19279-0140) rom
the Air-Powered Crimp Tool and connect the tubing rom the ootswitch. See Figure 2. I using the Optional Electrical
Controls (Order No. 64001-4000), see Appendix A.

AT-200 Air-Powered Crimp Tool
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SAFETY
(UNLOCKED)
SAFETY
(LOCKED)
TRIGGER
TRIGGER
PULL
OUT
PUSH IN
Fig re 3
3. Lock the trigger by engaging the red aluminum sa ety. Pull the sa ety outward rom the end o the trigger and
rotate it until the next detent position engages. See Figure 3.
Note: Always use the sa ety or disconnect air supply when changing crimping heads.
4. For the proper crimping head, use the order number located on the label o the terminal/connector container.
5. Strip the proper wire to the minimum length located on the label o terminal/connector container or on the air
powered crimp tool head speci ication sheet.

AT-200 Air-Powered Crimp Tool
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Revision: D Revision Date:11-10-09
Section 2
2.1 Changing Crimp Tool Heads
2.2 Insulation Support Crimp Adjustment
(Older style ixed jaw air powered crimp tools heads)
2.3 Insulation Support Crimp Adjustment
(Newer style insertion air powered crimp tools heads)
2.4 Terminal Crimping
2.5 Maintenance

AT-200 Air-Powered Crimp Tool
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CRIMPIMG HEAD
JAW ASSY
TRIGGER SAFETY
(LOCKED)
#1/4
–
20 SLOTTED
SCREWS (2)
PULL OUT
Fig re 4
TURN
CLOCKWISE
(CW)
TRIGGER SAFETY
(LOCKED)
CAM
INCORRECT CAM
ALIGNMENT
#1/4
-
20 HOLE
CORRECT CAM
ALIGNMENT
Fig
re 5
TRIGGER SAFETY
(LOCKED)
CAM
#1/4
-
20 HOLE
2.1 Changing Crimp Tool Heads
1. Engage the trigger sa ety or disconnect the air supply.
2. Remove the (2) #1 /4-20 slotted screws on both sides o the power unit. Pull the crimp tool head jaw assembly
out o the tool. See Figure 4.
3. Be ore attempting to replace the dies, make sure the wedge points o the cam line up with the (2) #1/4-20 holes
in the ront o power unit. See Figure 5.

AT-200 Air-Powered Crimp Tool
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Revision: D Revision Date:11-10-09
I the cam is not lined up, use the ollowing
procedure.
a) Disconnect the air supply with the cam
in the retracted position trigger is up.
b) Grasp the center section o the cam
with a long nose plier and rotate the
cam clockwise (CW) until the center
line o the wedge line up with (2) #1/4-
20 holes in power unit. See Figure 5
or the correct alignment.
c) Replace the head be ore cycling the
tool. Be sure both screws are in place
and tightened.
4. To replace the crimp tool head, hold power
unit in le t hand as shown in Figure 6.
5. Grasp the crimp tool head with the right
hand and with the terminal locator acing
you. Slide the crimp tool head assembly
into the body o the power unit until the side
plates o the crimp tool head butt against
the steps in the power unit. Be sure the jaw return springs clear the cam in the power unit. See Figure 6.
6. Line up the holes in the crimp tool head with the holes in the housing o the power unit.
7. Replace the (2) #1/4-20 screws and tighten securely. The tool is now ready or use.
2.2 Ins lation S pport Crimp Adj stment
(Older style fixed jaw air powered crimp tools heads)
1. The crimp tool heads or the insulated terminals and
the connectors eature an adjustable insulation
support crimp to accommodate varying wire insulation
diameters (See Figure 7) or old style crimp tool head.
2. The adjustment screw on each crimp head tool is set
at the actory at the M position. This setting will give
the best crimp on most wires. Two other adjustment
settings are available: S, the smallest con iguration
and L, the largest con iguration.
3. Crimp a terminal or connector and inspect the
insulation support sleeve crimp or con iguration. A
properly crimped sleeve snugly grasps the wire
insulation.
4. I the crimp con iguration is too loose, change the
adjustment setting by removing the air powered crimp
tool head rom the AT-200 and setting adjustment screw to the S position. Re-insert the air powered crimp tool
head into the AT-200 and crimp, and inspect the insulation support sleeve.
5. I crimp con iguration is too tight, change adjustment setting by removing the air powered crimp tool head rom
the AT-200 and setting adjustment screw to the L position. Re-insert the air powered crimp tool head into the
AT-200 and crimp, and inspect insulation support sleeve.
CRIMPING HEAD
BUTTS UP AGAINST STEPS
#1/ 4
-
20 SCREWS (2)
TERMINAL LOCATOR
SLIDE IN
POWER UNIT
Fig re 6
LUBRICATION POINTS
LIGHT OIL (EVERY MONTH
OR 5,000 CRIMPS)
INSULATION CRIMPING
ADJUSTMENT SCREWS
Fig re 7

AT-200 Air-Powered Crimp Tool
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LOOSEN THE
M4 SCREW
LUBRICATION POINTS
(BOTH SIDES)
LIGHT OIL (EVERY MONTH
OR 5,000 CRIMPS)
Fig re 8
3/32” HE
X
WRENCH
2.3 Ins lation S pport Crimp Adj stment
(Newer style insertable jaw air powered crimp tools)
For the new style crimp head tools, i the insulation part o the crimp needs to be adjusted, irst loosen the M4
screw on the bottom tool jaw, then insert a 3/32” Hex wrench (supplied) into the bottom o the lower die. See
Figure 4. A clockwise (CW) rotation decreases the insulation crimp while a counter-clockwise (CCW) rotation
increases the insulation crimp. A ter adjusting retighten the M4 screw.
2.4 Terminal Crimping
Speci ications and Instructions or crimping are included with the individual air powered crimp tool heads.
2.5 Maintenance
CAUTION: Always disconnect air supply be ore all maintenance.
It is recommended that each operator o the tool be made aware o , and responsible or, the ollowing
maintenance steps:
1. Remove dust, moisture and other contaminants with a clean brush, or so t, lint- ree cloth.
2. Do not use any abrasive materials that could damage the tool.
3. Make certain all pins; pivot points and bearing sur aces are protected with a thin coat o high quality machine
oil. Do not oil excessively. This tool needs cleaning and lubrication or a maximum service li e o trouble- ree
crimping. A light oil, such as 30
weight automotive oil used at the oil
points shown in Figure 8, every
5,000 crimps or monthly will
signi icantly enhance the tool li e and
ensure a stable calibration.
4. When tool is not in use store the tool
in a clean, dry area.
Warranty
This tool is or electrical terminal crimping
purposes only. This tool is made o the
best quality materials. All vital components are long-li e tested. All tools are warranted to be ree o manu acturing
de ects or a period o 30 days. Should such a de ect occur, we would repair or exchange the tool ree o charge.
This repair or exchange will not be applicable to altered, misused or damaged tools.
I seals are damaged the warranty is invalid.
CAUTION: Molex crimp speci ications are valid only when used with Molex terminals and tooling.

AT-200 Air-Powered Crimp Tool
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Revision: D Revision Date:11-10-09
Section 3
3.1 Parts Lists and Assembly Drawings

AT-200 Air-Powered Crimp Tool
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2
6
3
1
4
5
(2)
Fig re 9
3.1 Parts List and Assembly Drawings
19279-0001-Air Power Crimp Tool Assembly Fig re 9
Item Order No. Engineering No. Description Qty Notes
1 19279-0080 19279-0080 Cam For AT-200 Air Tool 1
2 19279-0135 19279-0135 AT-200 Air Powered Crimping Tool 1 Figure 10
3 19279-0140 19279-0140 Air Hose 1/8 NPT Male FTG 1
4 19279-0161 19279-0161 Screw Silver Slotted 2
5 N/A N/A #1/4-1/8 Hex Bushing 1**
6 N/A N/A #1/4-28 by 3/4 Cup Point SSS 1**
** Available rom an industrial supply company such as MSC (1-800-645-7270).

AT-200 Air-Powered Crimp Tool
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3.1 Parts List and Assembly Drawings
19279-0135-AT-200 Air Powered Crimping Tool Fig re 10
Item Order No. Eng. No. Description Qty
1 N/A N/A 1/4 ID by 3/8 OD by 1/16” Cross Section Buna O-Ring 4**
2 N/A N/A 5/32 ID by 9/32 OD by 1/16” Cross Section Buna O-Ring 2**
3 N/A N/A 3/8 ID by 1/2 OD by 1/16” Cross Section Buna O-Ring 2**
4 N/A N/A 1/2 ID by 11/16 OD by 3/32” Cross Section Buna O-Ring 1**
5 N/A N/A 1.0 ID by 1-13/16 OD by 3/32” Cross Section Buna O-Ring 4**
6 N/A N/A 1-5/8 ID by 1-3/4OD by 1/16” Cross Section Buna O-Ring 3**
7 N/A N/A .180 OD by .016 WD by .25” FL Compression Spring 1**
8 N/A N/A .455 OD by .038 WD by .625” FL Compression Spring 1**
9 N/A N/A Retaining Ring 2.012 OD by .062” Thick 5**
10 N/A N/A #4-40 by .50 Long SHCS 1**
11 N/A N/A #6-32 by .25” Long Flat Head Phillips 1**
12 N/A N/A #6-32 by .88“ Long Flat Head Phillips 2**
13 N/A N/A #8-32 by .375” Long Round Head Phillips 2**
14 N/A N/A 1/16 Diameter by .187” Long Dowel Pin 1**
15 N/A N/A 1/16 Diameter by .25” Long Dowel Pin 1**
16 N/A N/A 1/8 Diameter by .75” Long Spring Pin 1**
** Available rom an industrial supply company such as MSC (1-800-645-7270).

AT-200 Air-Powered Crimp Tool
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Revision: D Revision Date:11-10-09
9
5
4
5
5
6
9
9
3
(4)
1
8
11
12
6
3
6
2
2
13
10
7
15
14
16
5
9
9
(2)
(2)
Fig re 10
3.1 Parts List and Assembly Drawings

AT-200 Air-Powered Crimp Tool
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3
6
7
4
2
3
5
1
(2)
(2)
Fig re 11
3.1 Parts List and Assembly Drawings
19078-0307-Optional Bench Adapter Fig re 11
Item Order No. Engineering No. Description Qty
1 N/A N/A Dual Air Hose (1/8 ID by 8’) 1**
2 N/A N/A Air Foot Switch (3B – 30A2 – S) 1**
3 N/A N/A 1/8” NPT – M Fitting, by 1/8 Barb 3**
4 N/A N/A 1/8” Close Nipple (M/M) 1**
5 N/A N/A Clippard Thread on Hose Clamp 2**
6 N/A N/A 1/8” Fitting Brass Pipe Tee M/F/F 1**
7 N/A N/A 1/8” Brass Coupling - 1/8 (F/F) 1**
** Available rom an industrial supply company such as MSC (1-800-645-7270).

AT-200 Air-Powered Crimp Tool
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Revision: D Revision Date:11-10-09
Appendix A
Options
1. Accessories
64001-4000 - Full Cycle/Pressure Electrical Control Box Instruction Sheet

AT-200 Air-Powered Crimp Tool
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Accessory
F ll Cycle/Press re Electrical Control Box
Instr ction Sheet
Order No. 64001-4000
Feat res
 The 64001-400 Full Cycle Electrical Control Box is an option or use on Air Power Crimp Tool (AT200) Order
No.19279-0001 equipped with Bench Adapter Order No.19078-0307.
 This control box will assure that the air tool completes a ull crimp cycle. Applying the air pressure or a long
enough cycle to assure a success ully completed crimp.
 Prevents actuation i su icient pneumatic pressure is not available to produce good crimps.
 Eliminates the operators’ judgment and low line pressure as sources o variability or critical applications.
OPERATION
1. To install the control box remove the
pneumatic oot switch and all o the
tubing.
2. Replace with the components,
ittings and the tubing. See Figures
1 and 3.
3. Make sure they are correctly
connected in the right positions,
which are clearly marked on the
each side o the Cycle Box in Figure
1.
4. The power is on i the “Green“ indicator light is on.
5. I the “Yellow“ indicator light turns on, the air pressure is low (90 PSI – Min.). Check the pressure
gauge and reset i necessary.
6. To change the cycle time, the timer has to be
readjusted. This is done by removing the (4) screws
on the top cover. Place the cover aside and locate
the timer. See Figure 2. Using a Phillips
screwdriver insert it in the slot on top o the timer.
Turn the timer clockwise (CW) to increase time or
counterclockwise (CCW) to decrease time. The dial
can be turned by hand i a screwdriver is not
available. Place the cover back and re-install the
(4) screws.
7. Push the oot switch to start the crimp cycle.
8. When the crimp cycle is complete the circuit will
release and the jaws o the air tool will open.
9. To stop the cycle be ore complete, push the emergency stop button. To reset, rotate the button
clockwise (CW) as indicated by the arrows on the button.
Fig re 1
POWER SUPPLY
FILTER REGULATOR
AIR CRIMP
TOOL
BENCH ADAPTER
ACTUATOR
FOOTSWITCH
ASSEMBLY
TIMER
Fig re 2
S
LOT

AT-200 Air-Powered Crimp Tool
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Revision: D Revision Date:11-10-09
3
6
4
7
1
2
9
1
5
5
Fig re 3
REF
EMERGENCY
STOP
TO AIR
SUPPLY
TO
120 VAC
NOT SUPPLIED
1/4 NPT by 1/4 TUBE
FITTING (REF)
8
Parts List
64001-4000-Electrical Control Box (Timed Cycle) Fig re 3
Item Order No. Description Qty
1 64001-4000 Electrical Controls Re
2 62500-1265 Power Supply 1
3 63800-8394 Footswitch Assembly 1
4 69018-6237 Power Cord 1
5 N/A 1/4“ OD Tubing **
6 N/A 1/8 NPT by 1/4 Tube Fitting **
7 19078-0307 Bench Adapter Re
8 19279-0001 Air Power Crimp Tool Re
9 N/A Filter Regulator Re
** Available rom an industrial supply company such as MSC (1-800-645-7270).
Americas Headq arters
Lisle, Illinois 60532 U.S.A.
1-800-78MOLEX
amerin [email protected]
Far East North Headq arters
Yamato, Kanagawa, Japan
81-462-65-2324
enin [email protected]
Far East So th Headq arters
Jurong, Singapore
65-6-268-6868
esin [email protected]
E ropean Headq arters
Munich, Germany
49-89-413092-0
eurin [email protected]
Corporate Headq arters
2222 Wellington Ct.
Lisle, IL 60532 U.S.A.
630-969-4550
Fax: [phone]
Visit o r Web site at http://www.molex.com