molex AT-200 Operating And Maintenance Instructions Manual
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molex AT-200 Operating And Maintenance Instructions Manual

Air-powered crimping tool with optional bench adapter and foot switch shown
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AT-200 Air-Powered Crimping Tool

Description
Operation
Maintenance
Doc No: TM-192790001
Revision: G
AT-200 AIR-POWERED CRIMPING TOOL
Operating and Maintenance Instructions with
With Optional Bench Adapter and Foot Switch shown

Order No. 19279-0001

Release Date: 07-01-02
Revision Date: 01-17-14
UNCONTROLLED COPY
Page 1 of 20

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  • Page 1: At-200 Air-Powered Crimping Tool

    AT-200 Air-Powered Crimping Tool AT-200 AIR-POWERED CRIMPING TOOL Operating and Maintenance Instructions with With Optional Bench Adapter and Foot Switch shown Order No. 19279-0001 Description  Operation  Maintenance  UNCONTROLLED COPY Doc No: TM-192790001 Release Date: 07-01-02 Page 1 of 20...

  • Page 2: Safety Warnings And Information

    Keep this manual available when using this tool. Replacement manuals are available for download at no charge at www.molex.com. SAFETY ALERT SYMBOL This symbol is used to call your attention to hazards or unsafe practices which could result in an injury or property damage.
  • Page 3 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.

  • Page 4: Table Of Contents

    AT-200 Air-Powered Crimping Tool Table of Contents Contents AT-200 AIR-POWERED CRIMPING TOOL ........................1 Order No. 19279-0001 ..............................1 Safety Warnings and Information ..........................2 Table of Contents ................................4 Section 1 ..................................5 General Description ..............................5 Description ..............................6 Features ................................

  • Page 5: Section 1

    AT-200 Air-Powered Crimping Tool Section 1 General Description Description Features Technical Specifications Delivery Check Tools Specification Sheets UNCONTROLLED COPY Doc No: TM-192790001 Release Date: 07-01-02 Page 5 of 20 Revision: G Revision Date: 01-17-14...

  • Page 6: Description

    1.1 Description The following tools are recommended for setup and adjustments to this tool. The AT-200 Air-Powered Crimping Tool is a hand held pneumatic tool weighting less than two pounds. Metric standard hex wrench set It is designed to crimp high quality and consistent Inch standard hex wrench set crimped terminals.

  • Page 7: Section 2

    AT-200 Air-Powered Crimp Tool Section 2 Setup Operation UNCONTROLLED COPY Doc No: TM-192790001 Release Date: 07-01-02 Page 7 of 20 Revision: G Revision Date: 01-17-14...

  • Page 8: Set-Up

    1. Connect the air hose to the tool and to the air supply 85 to 95 PSI. Do not exceed 100 PSI. May cause injury or damage to the tool. Air supply must be equipped with a 1/4NPT air filter /regulator which is not supplied by Molex. See Figure 2-1. (Available from any Industrial supply co.) TO AIR TRIGGER SUPPLY...

  • Page 9: Operation

    3. Push on the wire to assure it is fully seated in the terminal. 4. Activate the AT-200 Crimp Tool by sliding the safety on the trigger forward using your thumb and then squeezing the trigger until the crimp jaws are fully closed. See Figure 2-4.

  • Page 10: Section 3

    AT-200 Air-Powered Crimp Tool Section 3 Adjustments 3.1. Changing Crimp Tool Heads 3.2. Insulation Support Crimp Adjustment (Older style fixed jaw air powered crimp tools heads) 3.3. Insulation Support Crimp Adjustment (Newer style insertion air powered crimp tools heads) 3.4.

  • Page 11: Changing Crimp Tool Heads

    AT-200 Air-Powered Crimp Tool CAUTION: Always disconnect air supply before all maintenance. 3.1 Changing Crimp Tool Heads 1. Disconnect the air supply. CRIMPIMG HEAD 2. Remove the (2) #1 /4-20 slotted screws on both sides of JAW ASSY the power unit. Pull the crimp tool head jaw assembly out of the tool.

  • Page 12: Insulation Support Crimp Adjustment

    5. If crimp configuration is too tight, change adjustment setting by removing the air powered crimp tool head from 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.

  • Page 13: Warranty

    Should such a defect occur, we would repair or exchange the tool free of charge. This repair or exchange will not be applicable to altered, misused or damaged tools. If seals are damaged the warranty is invalid. CAUTION: Molex crimp specifications are valid only when used with Molex terminals and tooling. UNCONTROLLED COPY Doc No: TM-192790001...

  • Page 14: Section 4

    AT-200 Air-Powered Crimp Tool Section 4 Parts List and Assemblies 19279-0001 Parts List and Assembly Drawings 19279-0135 Parts List and Assembly Drawings 19078-0307 Parts List and Assembly Drawings (Optional) 64001-4000 Parts List and Assembly Drawings (Optional) 19279-0099 Parts List and Assembly Drawings...

  • Page 15: 19279-0001 Parts List And Assembly Drawings

    4.1 19279-0001 Parts List and Assembly Drawings 19279-0001-Air Power Crimp Tool Assembly Figure 4-1 Item Order No. Engineering No. Description Notes 19279-0080 19279-0080 Cam For AT-200 Air Tool 19279-0135 19279-0135 AT-200 Air Powered Crimping Tool Figure 4-2 19279-0140 19279-0140 Air Hose 1/8 NPT Male FTG 19279-0161...

  • Page 16: 19279-0135 Parts List

    AT-200 Air-Powered Crimp Tool 4.2 19279-0135 Parts List 19279-0135-AT-200 Air Powered Crimping Tool Figure 4-2 Item Order No. Eng. No. Description 1/4 ID by 3/8 OD by 1/16” Cross Section Buna O-Ring 5/32 ID by 9/32 OD by 1/16” Cross Section Buna O-Ring 3/8 ID by 1/2 OD by 1/16”...

  • Page 17: 19279-0135 Assembly Drawings

    AT-200 Air-Powered Crimp Tool 4.2 19279-0135 Assembly Drawings 12 (2) Figure 4-2 UNCONTROLLED COPY Doc No: TM-192790001 Release Date: 07-01-02 Page 17 of 20 Revision: G Revision Date: 01-17-14...

  • Page 18: 19078-0307 (Optional) Parts List And Assembly Drawings

    AT-200 Air-Powered Crimp Tool 4.3 19078-0307 (Optional) Parts List and Assembly Drawings (See ATS-19078-0307 specification sheet for installation) 19078-0307-Optional Bench Adapter Figure 4-3 Item Order No. Engineering No. Description Dual Air Hose (1/8 ID by 8’) Air Foot Switch (3B – 30A2 – S) 1/8”...

  • Page 19: 64001-4000 (Optional) Parts List And Assembly Drawing

    AT-200 Air-Powered Crimp Tool 4.4 64001-4000 (Optional) Parts List and Assembly Drawing (See ATS-640014000 specification sheet for installation) 64001-4000 Optional Full Cycle/ Pressure Electrical Control Box Figure 4-4 Item Order No. Description 64001-4000 Electrical Controls 62500-1265 Power Supply 63800-8394 Footswitch Assembly...

  • Page 20: 19279-0099 Parts List And Assembly Drawings

    3/32 Diameter by 3/4 Long Dowel Pin ** Available from an industrial supply company such as MSC (1-800-645-7270). This assembly is included in the AT-200 Air-Powered Crimp Tool 19279-0001 however for older models of this tool it is recommended to purchase the Trigger Safety Kit 19279-0099.

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