molex AT-200 Maintance Manual
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
Description
Operation
Maintenance
Order No. 19279-0001
Doc No: TM-192790001 Release Date: 07-01-02 UNCONTROLLED COPY Page 1 of 20
Revision: G Revision Date: 01-17-14
AT-200 Air-Powered Crimping Tool
Read and understand all of the instructions and safety information in this manual before
operating or servicing this tool.
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. The signal word, defined below, indicates the severity of the hazard. The message
after the signal word provides information for preventing or avoiding the hazard.
DANGER
DANGER:
Indicates an imminently hazardous situation which, if not avoided, could result in death or serious injury.
WARNING
WARNING:
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
CAUTION:
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
CAUTION may also be used to alert against unsafe practices associated with events that could lead
to personal injury.
WARNING
WARNING
Always wear proper eye protection when
Operating or servicing this equipment.
Failure to wear eye protection could result
in serious eye injury from flying debris.
Heavy Object
To avoid muscle strain or back injury, use lifting
aids and proper lifting techniques when removing
or replacing.
Failure to observe these precautions may result in
injury or property damage.
WARNING
WARNING
Never wear clothing or jewelery that is loose or
That could potentially hang into the equipement
and get caught.
Failure to observe this warning could result in
Severe Injury or death.
Never install or service this machine while
connected to any electrical power source.
Disconnect power by unplugging the press
from its power source.
Failure to observe this warning could result
In severe injury or death.
WARNING
WARNING
Never operate, service, install, or adjust this
machine without proper instruction and without
first reading and understanding the instructions
in this manual and all applicable press and/or
wire processing machine.
manuals.
Never Install or service this machine while
connected to the compressed air source.
Failure to observe this warning could result
In severe injury or death.
Safety Warnings and Information
Doc No: TM-192790001 Release Date: 07-01-02 UNCONTROLLED COPY Page 2 of 20
Revision: G Revision Date: 01-17-14
AT-200 Air-Powered Crimping Tool
WARNING
WARNING
Never use this machine without guards or safety
devices that are intended
to prevent hands from remaining in the die space.
Failure to observe this warning could result in
Severe injury or death.
Do not use compressed air to clean
this equipment.
The forces created by compressed
air can force debris into the tool.
Failure to observe these precautions may
result in injury or property damage.
WARNING
Always wear proper ear protection when Operating or servicing this equipment.
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.
CAUTION
Never perform any service or maintenance other than as described in this manual.
Never modify, alter or misuse this tool
Molex crimp specifications are valid only when used with Molex terminals, applicators and tooling.
Failure to observe this precaution may result in injury and property damage.
Tooling Technical Assistance
Molex offers tooling technical assistance for customers who may need some guidance for tooling adjustments. This
support can be obtained by calling either of the two numbers listed below and asking for the Molex Tooling Group.
Call Toll Free 1-800-786-6539 (US) 1-630-969-4550 (Global).
This assistance is limited to the operation and set-up of a customer’s tool. Questions with regard to Molex connector
products or how to identify the proper tooling and/ or tooling documentation should be directed to your local Molex
personnel or Customer Service Representative.
When calling for service on the press a copy of the Operation Manual and Specific Applicator Tooling Specification
Sheet should be present and a person that is familiar with the applicator should be present. Be sure the following
information is supplied:
1. Customer name
2. Customer address
3. Person to contact such as (name, title, e-mail, and telephone number
4. Applicator order number (Lease number also if applicable)
5. Serial number (Lease number also if applicable)
6. Molex Connector product order number
7. Urgency of request
8. Nature of problem
Molex Application Tooling Group
2200 Wellington Court
Lisle, IL 60532, USA
Tel: +1 (630) 969-4550
Fax:+1 (630) 505-0049
Doc No: TM-192790001 Release Date: 07-01-02 UNCONTROLLED COPY Page 3 of 20
Revision: G Revision Date: 01-17-14
Visit our Web site at http://www.molex.com
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
1.1 Description .................................................................................................................................................... 6
1.2 Features ........................................................................................................................................................ 6
1.3 Technical Specification .................................................................................................................................. 6
1.4 Delivery Check .............................................................................................................................................. 6
1.5 Tools .............................................................................................................................................................. 6
1.6 Specification Sheets ...................................................................................................................................... 6
Section 2 ....................................................................................................................................................................... 7
2.1 Set-Up ........................................................................................................................................................... 8
2.2 Operation ....................................................................................................................................................... 9
Section 3 ..................................................................................................................................................................... 10
Adjustments ............................................................................................................................................................. 10
3.1 Changing Crimp Tool Heads ....................................................................................................................... 11
3.2 Insulation Support Crimp Adjustment .......................................................................................................... 12
3.3 Insulation Support Crimp Adjustment .......................................................................................................... 12
3.4 Terminal Crimping ....................................................................................................................................... 12
3.5 Maintenance ................................................................................................................................................ 12
3.6 Warranty ...................................................................................................................................................... 13
Section 4 ..................................................................................................................................................................... 14
Parts List and Assemblies ....................................................................................................................................... 14
4.1 19279-0001 Parts List and Assembly Drawings .......................................................................................... 15
4.2 19279-0135 Parts List ................................................................................................................................. 16
4.2 19279-0135 Assembly Drawings ................................................................................................................. 17
4.3 19078-0307 (Optional) Parts List and Assembly Drawings.......................................................................... 18
4.4 64001-4000 (Optional) Parts List and Assembly Drawing ........................................................................... 19
4.5 19279-0099 Parts List and Assembly Drawings .......................................................................................... 20
Doc No: TM-192790001 Release Date: 07-01-02 UNCONTROLLED COPY Page 4 of 20
Revision: G Revision Date: 01-17-14
AT-200 Air-Powered Crimping Tool
General Description
1.1 Description
1.2 Features
1.3 Technical Specifications
1.4 Delivery Check
1.5 Tools
1.6 Specification Sheets
Section 1
Doc No: TM-192790001 Release Date: 07-01-02 UNCONTROLLED COPY Page 5 of 20
Revision: G Revision Date: 01-17-14
AT-200 Air-Powered Crimping Tool
General Description
1.1 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 from
26 to 8AWG.
1.2 Features
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 fatigue.
1.3 Technical Specification
Pneumatic:
Supply Pressure: 100 PSI (6.9 Bars) max
Cycle Time:
15 seconds
Weight
0.9kg (2lbs)
1.4 Delivery Check
Carefully remove the AT-200 Air-Powered
Crimping Tool from its shipping container and
determine that the following items are included in
the package.
19279-0001 Air-Powered Crimping Tool
19279-0140 Air Hose 1/8 NPT Male
TM-192790001 Instruction Manual
1.5 Tools
The following tools are recommended for 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
1.6 Specification Sheets
Molex ships specification 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 specification
sheet contains the following:
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).
Doc No: TM-192790001 Release Date: 07-01-02 UNCONTROLLED COPY Page 6 of 20
Revision: G Revision Date: 01-17-14
Loading...