Molex AT-200 Manuel

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: 630-969-4550

Fax: 630-505-0049

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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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

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

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