molex AT-200 Manual

AT-200Air-PoweredCrimpTool
OrderNo.19279-0001 ReleaseDate:07-01-02 UNCONTROLLED COPY Page1of19
Revision:B RevisionDate:06-18-03
AT-200 AIR-POWERED CRIMPING TOOL
Operating and Maintenance Instructions with
Optional Bench Adapter and Foot Switch
§Description
§Operation
§Maintenance

AT-200Air-PoweredCrimpTool
OrderNo.19279-0001 ReleaseDate:07-01-02 UNCONTROLLED COPY Page2of19
Revision:B RevisionDate:06-18-03
WARNING
NEVER USETHISTOOLWITHOUTGUARDS ORSAFETYDEVICESTHATAREINTENDEDTOPREVENTHANDSFROM
REMAININGINTHEDIESPACE.
NEVER OPERATE,SERVICE,INSTALLORADJUST THIS TOOL WITHOUT PROPERINSTRUCTIONANDWITHOUTFIRST
READINGANDUNDERSTANDING THE INSTRUCTIONSIN THIS MANUAL ANDALL APPLICABLEAIR
POWEREDCRIMPING TOOL MANUALS.
NEVER INSTALLORSERVICETHISMACHINE WHILE CONNECTED TO THECOMPRESSEDAIRSOURCE.
CAUTION THEMOLEX AT-200AIR POWERED CRIMPINGTOOL IS DESIGNEDTO BE USEDWITH AIRPOWERED CRIMP
TOOLSHEADS ANDTOOLINGSUPPLIEDBY MOLEX. USE OF TOOL HEADSORTOOLINGFROMANY OTHER
SOURCEMAYRESULTIN DAMAGE ORINJURY. MOLEX WILL NOT BE LIABLEFORANYDAMAGE OR
INJURYFROM USEOFNON-MOLEX COMPONENTSIN THISTOOL.
WORK SAFELY AT ALL TIMES
For Service, Contact Your
Local Molex Sales Office
Molex Application Tooling Group
1150 E. Diehl Road
Naperville, Illinois 60532
Tel: [phone]
Fax: [phone]

AT-200Air-PoweredCrimpTool
OrderNo.19279-0001 ReleaseDate:07-01-02 UNCONTROLLED COPY Page3of19
Revision:B RevisionDate:06-18-03
Table of Contents
1GeneralDescription
2ChangingCrimping Heads
3PartsList, Assembly Drawings and Maintenance
Appendix
AOptions

AT-200Air-PoweredCrimpTool
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Revision:B RevisionDate:06-18-03
General Description
1. Readthefollowinginstructionsbeforeattemptingtooperatetool.
2. Connectairhosetotoolandtoairsupply85to95PSI. Donotexceed100PSI.May cause injuryor damage to the tool.
Airsupplymustbeequippedwitha1/4NPTairfilter/regulatorwhichisnotsuppliedbyMolex(SeeFigure1).(Availablefrom
anyIndustrialsupplyco.)
IfchangingtotheOptionalbenchadapter(PartNo.19078-0307)remove theairhose(19279-0140)andconnectthetubingfrom
thefootswitch(SeeFigure2). IfusingtheOptionalElectricalControls(PartNo. 64001-4000),seeAppendixA.
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
Figure 2
CONNECT TUBING FROM FOOT
SWITCH
WITH FITTING
(NOT SUPPLIED)
TRIGGER
SAFETY
AIR HOSE
(19279
-
0140)
FILTER REGULATOR
(NOT SUPPLIED)
TO AIR
SUPPLY
TRIGGER
Figure 1

AT-200Air-PoweredCrimpTool
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3. Locktriggerbyengagingred aluminumsafety. Pullthesafetyoutwardfromendoftriggerandrotateuntilnextdetentpositionengages
(SeeFigure3).
4. Propercrimpinghead: Usepartnumber locatedonlabelofterminal/connectorcontainer.
5. Stripproperwiretominimumlengthlocatedonlabelofterminal/connectorcontainerorontheairpoweredcrimptoolheadspecification
sheet.
SAFETY
(UNLOCKED)
SAFETY
(LOCKED)
TRIGGER
TRIGGER
PULL OUT PUSH IN
Figure 3
Note: Always use the safety or disconnect air supply when changing crimping Heads.

AT-200Air-PoweredCrimpTool
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Revision:B RevisionDate:06-18-03
Section 2
2.1 ChangingCrimp Tool Heads
2.2 InsulationSupport Crimp Adjustment (Older style fixed jaw air powered crimp toolsheads)
2.3 InsulationSupport Crimp Adjustment (Newer style insertion air powered crimp tools heads)
2.4 TerminalCrimping

AT-200Air-PoweredCrimpTool
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Revision:B RevisionDate:06-18-03
CRIMPIMG HEAD
JAW ASSY
TRIGGER SAFETY
(LOCKED)
1/4” –20 SLOTTED
SCREWS (2)
PULL
OUT
Figure 4
2.1 Changing Crimp Tool Heads
1. Engagetriggersafetyor
disconnectairsupply.
2. Removethetwo1/4”–20
slottedscrews onboth sides
ofpowerunit. Pullcrimp
toolhead jawassemblyout
oftool(SeeFigure4).
3. Beforeattemptingtoreplacedies,checktoseethatwedgepointofcamlinesupwiththetwo1/4”holesinfrontofpowerunit
(SeeFigure5).
TURN
CLOCKWISE
(CW)
TRIGGER
SAFETY
(LOCKED)
1/4” –20
HOLES
CAM
INCORRECT CAM
ALIGNMENT
1/4” –20
HOLES
CORRECT CAM
ALIGNMENT
Figure 5
TRIGGER
SAFETY
(LOCKED)
CAM

AT-200Air-PoweredCrimpTool
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Revision:B RevisionDate:06-18-03
CRIMPING HEAD
BUTTS UP AGAINST STEPS
1 / 4” –20
SCREWS (2)
TERMINAL LOCATOR
SLIDE IN
POWER UNIT
Figure 6
Ifcamisnotlinedup,usethefollowingprocedure.
a) Disconnectairsupplywithcam intheretractedposition,whichistriggerup.
b) Graspcentersectionof camwithlongnosepliersandrotatecamclockwise(CW)untilcenterlineof wedgelinesup with1 /4”
holesinpowerunit. SeeFigure5forcorrectalignment.
c) Replaceheadbeforecyclingthetool.Besurebothscrewsarein placeandtightened.
4. Toreplacethecrimptool head,holdpowerunitin lefthand asshownin Figure6.
5. Graspcrimptoolheadinrighthandwithterminallocatorfacingyou. Slidecrimptoolheadassemblyintobodyofpowerunituntil
sideplatesof thecrimptool headbuttagainst stepsinthe powerunit. Besurejawreturnspringsclearthecaminpowerunit(See
Figure 6).
6. Lineupholesincrimptoolheadwiththoseinhousingofpowerunit.
7. Replace1 /4”–20screwsandtightensecurely. Tool isnowreadyforuse.
2.2 Insulation Support Crimp Adjustment
(Older style fixed jaw air powered crimp tools heads)
1. Thecrimptoolheadsforinsulatedterminalsandconnectorsfeatureanadjustableinsulationsupportcrimptoaccommodatevarying
wireinsulationdiameters (SeeFigure7) foroldstyle crimptoolhead.

AT-200Air-PoweredCrimpTool
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Revision:B RevisionDate:06-18-03
LUBRICATION POINTS
LIGHT OIL (EVERY MONTH
OR 5,000 CRIMPS)
INSULATION CRIMPING
ADJUSTMENT SCREWS
Figure 7
2. Theadjustmentscrewoneachcrimpheadtoolis setatthe factoryattheMposition. This settingwillgive thebestcrimponmost
wires. Twootheradjustmentsettingsareavailable:S,thesmallestconfigurationandL,thelargestconfiguration.
3. Crimp a terminal or connector and
inspectthe insulationsupportsleeve
crimporconfiguration. A properly
crimpedsleeve snugly grasps thewire
insulation.
4. Ifcrimpconfiguration istooloose,
changeadjustmentsettingbyremoving
fromtheAT-200and settingadjustment
screwtotheSposition. Re-insertthe air
poweredcrimptoolheadintotheAT-
200andcrimp,andinspectinsulation
supportsleeve.
5. Ifcrimpconfiguration istootight,
changeadjustmentsettingbyremoving
theairpoweredcrimptoolheadfrom
theAT-200andsettingadjustment
screwtotheLposition. Re-inserttheair
poweredcrimptoolheadintotheAT-
200andcrimp,andinspectinsulation
supportsleeve.
2.3. Insulation Support Crimp Adjustment
(Newer style insertable jaw air powered crimp tools)
For new style crimp headtools,ifthe
insulationpartof thecrimpneeds to
beadjusted,firstloosentheM4screw
onthebottomtooljaw,theninserta
3/32Hexwrench (supplied)intothe
bottomofthe lowerdie(See Figure
4). Aclockwise(CW)rotation
decreasesinsulationcrimpwhilea
counter-clockwise(CCW)rotation
increasesinsulation crimp.After
adjustingretightentheM4screw.
2.4 Terminal Crimping
SpecificationsandInstructionsforcrimpingareincludedwiththeindividualairpowered crimptoolheads.
LOOSEN M4
SCREW
LUBRICATION POINTS (BOTH SIDES)
LIGHT OIL (EVERY MONTH
OR 5,000 CRIMPS)
Figure 8
3/32” HEX
WRENCH

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Revision:B RevisionDate:06-18-03
Section 3
3.1 PartsLists and Assembly Drawings
3.2 Maintenence

AT-200Air-PoweredCrimpTool
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3.1. Parts List and Assembly Drawings
Item Order No. Engineering No. Description Qty Notes
19279-0001 19279-0001 Air Power Crimp Tool Assembly REF
(Fig. 9)
119279-0080 19279-0080 CamForAT-200AirTool 1
219279-0135 19279-0135 AT-200AirPoweredCrimpingTool 1(Fig.10)
319279-0140 19279-0140 AirHose1/8NPTMaleFTG 1
419279-0161 19279-0161 ScrewSilverSlotted 2
5N/A N/A 1/4–1/8HexBushing 1**
6N/A N/A 1/4–28by3/4CupPointSoc.SetScrew 1**
** Thefollowingpurchased partsareavailable fromanIndustrialsupplycompanysuchas MSC1-800-645-7270.
2
6
3
1
4
5
(2)
Figure 9

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Revision:B RevisionDate:06-18-03
3.1 Parts List and Assembly Drawings
Item
Order No. Engineering No. Description Qty Notes
19279-0135 19279-0135 AT-200 Air Powered Crimping Tool REF (Fig 10)
1 N/A N/A 1/4IDby3/8ODby1/16CROSSSECTIONBUNAO-RING 4**
2 N/A N/A 5/32IDby9/32ODby1/16CROSSSECTIONBUNAO-RING 2**
3 N/A N/A 3/8IDby1/2ODby1/16CROSSSECTIONBUNAO-RING 2**
4 N/A N/A 1/2IDby11/16ODby3/32CROSSSECTIONBUNAO-RING 1**
5 N/A N/A 1.IDby1-13/16ODby3/32CROSSSECTIONBUNAO-RING 4**
6 N/A N/A 1-5/8IDby1-3/4ODby1/16CROSSSECTIONBUNAO-RING 3**
7 N/A N/A .180ODby.016WDby.25FLCOMPRESSIONSPRING 1**
8 N/A N/A .455ODby.038WDby.625FLCOMPRESSIONSPRING 1**
9 N/A N/A RETAININGRING2.012ODby.062THICK 5**
10 N/A N/A #4-40by.50LGSHCS 1**
11 N/A N/A #6-32by.25LGFLATHEADPHILLIPS 1**
12 N/A N/A #6-32by.88LGFLATHEADPHILLIPS 2**
13 N/A N/A #8-32by.375LGROUNDHEADPHILLIPS 2**
14 N/A N/A 1/16by.187LG.DOWELPIN 1**
15 N/A N/A 1/16by.25LG.DOWELPIN 1**
16 N/A N/A 1/8DIA.by.75LGSPRINGPIN 1**
** Thefollowingpurchased partsareavailablefroman Industrialsupply companysuch asMSC1-800-645-7270.

AT-200Air-PoweredCrimpTool
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Revision:B RevisionDate:06-18-03
3.1 Parts List and Assembly Drawings
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)
Figure 10

AT-200Air-PoweredCrimpTool
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Revision:B RevisionDate:06-18-03
3.1 Parts List and Assembly Drawings
Item Order No. Engineering No. Description Qty
Notes
19078-0307 19078-0307 Optional Bench Adapter REF
(Fig 11)
1 N/A N/A DualAirHose (1/8 IDx8’) 1**
2 N/A N/A AirFoot Switch(3B–30A2–S) 1**
3 N/A N/A Fitting,1/8NPT–Mby1/8Barb 3**
4 N/A N/A CloseNipple1/8(M/M) 1**
5 N/A N/A ClippardThreadonHoseClamp 2**
6 N/A N/A Fitting1/8BrassPipeTeeM/F/F 1**
7 N/A N/A BrassCoupling 1/8-1/8(F/F) 1**
** Thefollowingpurchasedpartsare availablefroman Industrialsupplycompanysuchas MSC 1-800-645-7270.
3
6
7
4
2
3
5
1
(2)
(2)
Figure 11

AT-200Air-PoweredCrimpTool
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Revision:B RevisionDate:06-18-03
3.3 Maintenance
Crimpingnestshouldbekeptfreeofall foreignparticles.
Crimptoolheadassembliesshouldbelubricatedmonthlybyplacingafewdropsoflightmachineoilonthepivotpinsandcamfollower
rollers.

AT-200Air-PoweredCrimpTool
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Revision:B RevisionDate:06-18-03
Appendix A
Options
1. Accessories
64001-4000Full Cycle/Pressure Electrical Control Box Instruction Sheet

AT-200Air-PoweredCrimpTool
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Revision:B RevisionDate:06-18-03
Accessory
64001-4000
Full Cycle/Pressure
Electrical Control Box
Instruction Sheet
DESCRIPTION
§The64001-400FullCycleElectricalControl Boxis anoption foruse onAirPowerCrimpTool (AT200)part no.19279-0001
equippedwithBenchAdapterpartno.19078-0307.
§Thiscontrolboxwillassurethattheairtoolcompletesafullcrimpcycle.Applyingtheairpressureforalongenoughcycleto
assurea successfullycompleted crimp.
§Preventsactuationifsufficientpneumatic pressureisnotavailabletoproducegoodcrimps.
§Eliminatesoperatorjudgmentandlowlinepressureassourcesofvariabilityforcriticalapplications.
OPERATION
1. Toinstallthe controlboxremove the
pneumaticfootswitchandallofthetubing.
2. Replacewiththe components,fittingsand
tubing,(SeeFigures1and3).
3. Makesuretheyarecorrectlyconnectedin
therightpositions, whichareclearly marked
on theeachside ofthe CycleBox inFigure
1.
4. Thepowerisonifthe“Green“indicator
lightison.
5. Ifthe“Yellow“indicatorlight turnson,theairpressureislow(90PSI–Min.). Checkthepressuregaugeand
resetifnecessary.
6. Tochangethecycletime,thetimerhas to bereadjusted. This is
donebytaking outthefour screwsonthetopcover. Placethe
coverasideandlocatethetimer,(SeeFigure2). Usingaphillips
screwdriverinsertitintheslotontopofthetimer. Turnthe
timer clockwise (CW)to increase timeor counterclockwise(CCW)
todecreasetime. Thedialcanbeturnedbyhandifascrewdriver
isnotavailable. Besuretoreplaceandsecurethecover.
7. Pushthefootswitchtostartthecrimpcycle.
8. Whenthecrimp cycleiscompletethecircuit willreleaseand the
jawsoftheairtoolwillopen.
9. Tostopcyclebeforecomplete,pushtheemergencystopbutton.
Toreset,rotatethebutton clockwise(CW)asindicatedby the
arrowsonthebutton.
Figure 1
POWER SUPPLY
FILTER
REGULATOR
AIR CRIMP
TOOL
BENCH ADAPTER
ACTUATOR
FOOTSWITCH
ASSEMBLY
TIMER
Figure 2
SLOT

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Revision:B RevisionDate:06-18-03
Parts List
** Thefollowingpurchased partsareavailable fromanIndustrialsupplycompanysuchas MSC1-800-645-7270
Item Order No. Description Qty
164001-4000 ElectricalControls(TimedCycle) Fig3
262500-1265 PowerSupply 1
363800-8394 FootswitchAssembly 1
469018-6237 PowerCord 1
5N/A 1/4“.ODTubing **
6N/A 1/8NPTby1/4TubeFitting **
719078-0307 BenchAdapter REF
819279-0001 AirPowerCrimp Tool REF
3
6
4
7
1
2
1
1
5
5
Figure 3
REF
EMERGENCY
STOP TO AIR
SUPPLY
TO
120 VAC
NOT SUPPLIED
1/4 NPT by 1/4 TUBE
FITTING (REF)
8

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Revision:B RevisionDate:06-18-03
Application Tooling Group
1150E.DiehlRoad
Naperville,IL,60563
Tel:[phone]
Fax:[phone]
Far East North Headquarters
Yamato,Kanagawa,Japan
Tel:[phone]
Fax:[phone]
Far East South Headquarters
Jurong,Singapore
Tel:[phone]
Fax:[phone]
European Headquarters
Munich,Germany
Tel:[phone]
Fax:[phone]
Corporate Headquarters
2222WellingtonCourt
Lisle,IL,60532,U.S.A
Tel:1-800-78MOLEX
Fax:[phone]
VisitourWebsiteathttp://www.molex.com