Molex AT-200 Handbuch

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: 630-969-4550

Fax: 630-505-0049

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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Revision: D Revision Date:11-10-09

SAFETY

(UNLOCKED)

SAFETY

(LOCKED)

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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Revision: D Revision Date:11-10-09

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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Revision: D Revision Date:11-10-09

LOOSEN THE

M4 SCREW

LUBRICATION POINTS

(BOTH SIDES)

LIGHT OIL (EVERY MONTH

OR 5,000 CRIMPS)

Fig re 8

3/32” HE

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.

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