molex AT-200, Operating And Maintenance Instructions Manual

Page 1: ...e Date 07 01 02 UNCONTROLLED COPY Page 1 of 20 Revision G Revision Date 01 17 14 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 ...

Page 2: ...ay 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...

Page 3: ... 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 a...

Page 4: ...s 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...

Page 5: ...TM 192790001 Release Date 07 01 02 UNCONTROLLED COPY Page 5 of 20 Revision G Revision Date 01 17 14 Section 1 General Description 1 1 Description 1 2 Features 1 3 Technical Specifications 1 4 Delivery Check 1 5 Tools 1 6 Specification Sheets ...

Page 6: ... 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...

Page 7: ...AT 200 Air Powered Crimp Tool Doc No TM 192790001 Release Date 07 01 02 UNCONTROLLED COPY Page 7 of 20 Revision G Revision Date 01 17 14 Section 2 2 1 Setup 2 2 Operation ...

Page 8: ... SUPPLY TRIGGER Figure 2 1 Read the following instructions before attempting to operate this tool 2 1 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 If changing...

Page 9: ...nal into the crimp nest Insert the properly stripped wire into the terminal barrel For the Bench Mount Application 1 Slide the Air Powered Crimp Tool into the base The safety will bump against the base top and the trigger on the crimp tool will unlock See Figure 2 3 CAUTION Air Powered Crimp Tool will not operate if the safety in trigger is locked 1 Push on the wire to assure it is fully seated in...

Page 10: ...evision G Revision Date 01 17 14 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 Terminal Crimping 3 5 Maintenance ...

Page 11: ...ion of the cam with a long nose plier and rotate the cam clockwise CW until the center line of the wedge line up with 2 1 4 20 holes in power unit See Figure 3 2 for the correct alignment c Replace the head before cycling the tool Be sure both screws are in place and tightened 4 To replace the crimp tool head hold power unit in left hand as shown in Figure 3 3 5 Grasp the crimp tool head with the ...

Page 12: ...AT 200 and crimp and inspect the insulation support sleeve 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 3 3 Insulation Support Crimp Adjustment Newer style jaw air powe...

Page 13: ...nthly will significantly enhance the tool life and ensure a stable calibration 4 When tool is not in use store the tool in a clean dry area 3 6 Warranty This tool is for electrical terminal crimping purposes only This tool is made of the best quality materials All vital components are long life tested All tools are warranted to be free of manufacturing defects for a period of 30 days Should such a...

Page 14: ...Revision Date 01 17 14 Section 4 Parts List and Assemblies 4 1 19279 0001 Parts List and Assembly Drawings 4 2 19279 0135 Parts List and Assembly Drawings 4 3 19078 0307 Parts List and Assembly Drawings Optional 4 4 64001 4000 Parts List and Assembly Drawings Optional 4 5 19279 0099 Parts List and Assembly Drawings ...

Page 15: ... Tool Assembly Figure 4 1 Item Order No Engineering No Description Qty Notes 1 19279 0080 19279 0080 Cam For AT 200 Air Tool 1 2 19279 0135 19279 0135 AT 200 Air Powered Crimping Tool 1 Figure 4 2 3 19279 0140 19279 0140 Air Hose 1 8 NPT Male FTG 1 4 19279 0161 19279 0161 Screw Silver Slotted 2 5 N A N A 1 4 1 8 Hex Bushing 1 6 N A N A 1 4 28 by 3 4 Cup Point SSS 1 Available from an industrial sup...

Page 16: ... A 1 0 ID by 1 13 16 OD by 3 32 Cross Section Buna O Ring 4 6 N A N A 1 5 8 ID by 1 3 4OD by 1 16 Cross Section Buna O Ring 3 7 N A N A 180 OD by 017 WD Torsion Spring 1 8 N A N A 455 OD by 038 WD by 625 FL Compression Spring 1 9 N A N A Retaining Ring 2 012 OD by 062 Thick 5 10 N A N A 4 40 by 50 Long SHCS 1 11 N A N A 6 32 by 25 Long Flat Head Phillips 1 12 N A N A 6 32 by 88 Long Flat Head Phil...

Page 17: ...Tool Doc No TM 192790001 Release Date 07 01 02 UNCONTROLLED COPY Page 17 of 20 Revision G Revision Date 01 17 14 4 2 19279 0135 Assembly Drawings 11 12 2 Figure 4 2 8 4 4 5 5 6 9 9 3 5 6 3 2 2 13 10 7 15 14 16 5 9 2 9 9 1 6 17 ...

Page 18: ...sheet for installation 19078 0307 Optional Bench Adapter Figure 4 3 Item Order No Engineering No Description Qty 1 N A N A Dual Air Hose 1 8 ID by 8 1 2 N A N A Air Foot Switch 3B 30A2 S 1 3 N A N A 1 8 NPT M Fitting by 1 8 Barb 3 4 N A N A 1 8 Close Nipple M M 1 5 N A N A Clippard Thread on Hose Clamp 2 6 N A N A 1 8 Fitting Brass Pipe Tee M F F 1 7 N A N A 1 8 Brass Coupling 1 8 F F 1 Available ...

Page 19: ...ing See ATS 640014000 specification sheet for installation 64001 4000 Optional Full Cycle Pressure Electrical Control Box Figure 4 4 Item Order No Description Qty 1 64001 4000 Electrical Controls Ref 2 62500 1265 Power Supply 1 3 63800 8394 Footswitch Assembly 1 4 69018 6237 Power Cord 1 5 N A 1 4 OD Tubing 6 N A 1 8 NPT by 1 4 Tube Fitting 7 19078 0307 Bench Adapter Ref 8 19279 0001 Air Power Cri...

Page 20: ... No Engineering No Description Qty 1 19279 0203 19279 0203 Pivot Block 1 2 19279 0204 19279 0204 Safety Latch 1 3 63600 0052 63600 0052 Torsion Spring 1 4 N A N A 4 40 by 50 Long SHCS 1 5 N A N A 3 32 Diameter by 3 4 Long Dowel Pin 1 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 mod...