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
OrderNo.19279-0001 ReleaseDate:07-01-02 UNCONTROLLED COPY Page4of19
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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Revision:B RevisionDate:06-18-03
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

AT-200Air-PoweredCrimpTool
OrderNo.19279-0001 ReleaseDate:07-01-02 UNCONTROLLED COPY Page10of19
Revision:B RevisionDate:06-18-03
Section 3
3.1 PartsLists and Assembly Drawings
3.2 Maintenence