0634431402

Fine Adjust Applicator for Poseidon II Terminals Fine Adjust Applicator Application Tooling Specification Sheet Order No. 63903-8900 FEATURES       Directly adapts to most automatic wire processing machines Quick punch removal with the push of a button for fast and easy tooling change Applicator designed to industry standard mounting and shut height 135.80mm (5.346") Quick set-up time; plus the crimp height, track and feed adjustments can be set without removing the applicator from the press Fine adjustment allows users to achieve target with little effort by adjusting in increments of .015mm (.0006") for conductor crimp height and .063mm (.0025") for insulation height Independent adjustment rings allow users to quickly adjust the conductor or insulation crimp height without affecting each other SCOPE Products: Poseidon II Terminals, 16 AWG UL1061, 18 AWG UL1007 and 18 AWG UL1095 wires. Terminal Series No. Terminal Order No. 173041 173042 173041-0001 173042-0001 Wire Size Insulation Diameter Strip Length AWG mm2 mm In. mm In. 16-18 --- 1.90-2.05 .075-.081 3.18-3.80 .125-.150 16-18 --- 1.90-2.05 .075-.081 3.18-3.80 .125-.150 DEFINITION OF TERMS BEND UP STRIP LENGTH CONDUCTOR BRUSH BELL MOUTH SEAM CUT-OFF TAB ROLLING CONDUCTOR CRIMP INSULATION CRIMP TWISTING BEND DOWN The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the scope. Doc No: ATS-639038900 Revision: A Release Date: 02-25-16 Revision Date: 02-25-16 UNCONTROLLED COPY Page 1 of 6 Fine Adjust Applicator for Poseidon II Terminals CRIMP SPECIFICATIONS Cut-off Tab Max. Cut-off Tab Max. Conductor Brush (Contact side) (Insulation side) mm In. mm In. mm In. mm In. 173041 0.10-0.60 .004-.024 0.13 .005 0.30 .012 0.25-0.50 .010-.020 173042 0.10-0.60 .004-.024 0.13 .005 0.30 .012 0.25-0.50 .010-.020  To achieve the conductor brush specification, special care must be taken, or a light touch must be maintained while presenting wire against the wire stop. Bell mouth Terminal Series No. Terminal Series No. Bend up Bend down Degree (Max) 3 3 3 3 173041 173042 Punch Width (Ref) Conductor Insulation Degree (Max) mm In mm In 5 10 1.90 .075 2.40 .095 5 10 1.90 .075 2.40 .095 Twist Roll Seam Seam shall not be open and no wire allowed out of the crimping area. After crimping, the conductor profile should measure the following. Terminal Series No. 173041 173042 Conductor Pull Force Minimum Crimp Height Crimp Width AWG mm2 mm In. mm In. N Lb. 16 --- 1.15-1.25 .045-.049 1.90-2.00 .075-.079 133.5 30.0 18 --- 1.00-1.10 .039-.043 1.90-2.00 .075-.079 89.0 20.0 16 --- 1.15-1.25 .045-.049 1.90-2.00 .075-.079 133.5 30.0 18 --- 1.00-1.10 .039-.043 1.90-2.00 .075-.079 89.0 20.0 Wire Size Terminal Series No. 173041 173042 Wire Size AWG 16 18 16 18 mm2 --------- Insulation Crimp Height (Ref) Crimp Width (Ref) mm In. mm In. 2.20 .087 2.50 .098 2.20 .087 2.50 .098 2.20 .087 2.50 .098 2.20 .087 2.50 .098 Tool Qualification Notes: 1. Pull Force should be measured with no influence from the insulation crimp. 2. The above specifications are guidelines to an optimum crimp. 3. This terminal design will produce an insulation crimp shown in the Figure below: 16AWG INSULATION CRIMP CONDITION Doc No: ATS-639038900 Revision: A Release Date: 02-25-16 Revision Date: 02-25-16 UNCONTROLLED COPY Page 2 of 6 Fine Adjust Applicator for Poseidon II Terminals Wire Stop Set-Up Positioning Procedure In order to maintain the conductor brush within the specifications the following set-up procedure needs to be followed. 1. Manually cycle the press until the press ram with the punches is in the full down position. 2. Adjust the wire stop blade down towards the terminal as close as possible to the terminal transitional surface. See Figure 1. 3. Adjust the clearance between the wire stop blade and the conductor punch to.13mm (.005”) maximum. CONDUCTOR PUNCH .13mm (.005”) Maximum Clearance ADJUST WIRE STOP ADJUST THE WIRE STOP AS CLOSE AS POSSIBLE TO THIS TERMINAL SURFACE 4. 5. 6. 7. WIRE STOP Figure 1 Manually cycle the press until the press ram is in the full up position. Manually cycle the press again, to make sure the terminals are feeding properly. Power up the press and crimp terminals without wire to make sure they are feeding properly Crimp terminals with wire and check for proper feeding. WARNING 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. Always hand cycle the applicator in the equipment to ensure the tooling is properly aligned. Failure to observe these precautions may result in injury or property damage. Doc No: ATS-639038900 Revision: A Release Date: 02-25-16 Revision Date: 02-25-16 UNCONTROLLED COPY Page 3 of 6 Fine Adjust Applicator for Poseidon II Terminals PARTS LIST Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Doc No: ATS-639038900 Revision: A FineAdjust Applicator 63903-8900 Engineering No. Description Quantity Perishable Tooling 63903-8970 63903-8970 Tool Kit (All “Y” Items) REF 63457-0118 63457-0118 Conductor Punch 1Y 63455-0136 63455-0136 Conductor Anvil 1Y 63454-2405 63454-2405 Insulation Punch-Full R 1Y 63456-2402 63456-2402 Insulation Anvil 1Y 63443-0005 63443-0005 Cut-Off Plunger-Front 1Y 63443-0003 63443-0003 Cut-Off Plunger-Rear 1Y 63443-1402 63443-1402 Rear Cut-Off Die Blade 1Y 63443-0012 63443-0012 Cut-off Plunger Retainer-Front 1Y 63443-1004 63443-1004 Cut-off Plunger Retainer-Rear 1Y Other Components 11-17-0022 1739-21 Hold Down Spring 1 11-18-4083 60707-8 Feed Guide 1 11-24-1067 4996-4 Cut-Off Plunger Spring 2 63443-0009 63443-0009 Scrap Chute-Front 1 63443-0024 63443-0024 Key 1 63443-0090 63443-0090 Wire Stop 1 63443-0093 63443-0093 Shank 1 63443-1718 63443-1718 Height Spacer (18.80mm) 1 63443-2201 63443-2201 Spacer (1.0mm) 1 63443-2203 63443-2203 Spacer (3.0mm) 1 63443-2313 63443-2313 Spacer (3.65mm) 1 63443-2803 63443-2803 Front Plunger Striker 1 63443-2908 63443-2908 Striker Plunger 1 63443-3060 63443-3060 Rear Plunger Striker 1 63443-6111 63443-6111 Rear Cover 1 63903-8911 63903-8911 Terminal Hold Down 1 63466-0101 63466-0101 Scrap Chute-Rear 1 63600-1057 63600-1057 Striker Plunger Spring 1 Frame 63800-4901 63800-4901 Top 1 63801-3281 63801-3281 Base 1 63801-4650 63801-4650 Track 1 Hardware N/A N/A M3 by 6 Long SHCS 2** N/A N/A M3 by 6 Long FHCS 1** N/A N/A M3 by 8 Long SHCS 1** N/A N/A M4 by 6 Long SHCS 3** N/A N/A M4 by 10 Long BHCS 2** N/A N/A M4 by 12 Long BHCS 2** N/A N/A M4 by 50 Long SHCS 2** N/A N/A M5 by 12 Long SHCS 1** N/A N/A #10-32 by 3/8”Long Flat Point SSS 1** N/A N/A #10-32 Hex Jam Nut 1** ** Available from an industrial supply company such as MSC (1-800-645-7270). Order No. Release Date: 02-25-16 Revision Date: 02-25-16 UNCONTROLLED COPY Page 4 of 6 Fine Adjust Applicator for Poseidon II Terminals Assembly Drawing 28 40 39 10 1 23 3 16 27 21 35 (2) 36 (2) 33 22 25 24 28 30 31 (2) 29 15 11 38 6 34 7 18 17 5 2 20 4 (2) 9 12 19 8 15 26 14 32 (2) 37 Doc No: ATS-639038900 Revision: A 13 Figure 1 34 (3) Release Date: 02-25-16 Revision Date: 02-25-16 UNCONTROLLED COPY Page 5 of 6 Fine Adjust Applicator for Poseidon II Terminals NOTES 1. Molex recommends an extra perishable tooling kit be maintained at your facility. 2. Verify tooling alignment by manually cycling the press and Applicator before crimping under power. Check that all screws are tight. 3. Slugs, Terminals, Dirt and Oil should be kept clear of work area. 4. Wear safety glasses at all times. 5. For recommended maintenance refer to the Fine Adjust Manual. CAUTION: This applicator should only be used in a press with a shut height of 135.8mm (5.346”). Tooling damage could result at a lower setting. CAUTION: To prevent injury never operate this Applicator without the guards supplied with the press or wireprocessing machine in place. Reference the press or wire processing manufacturer’s instruction manual. CAUTION: Molex crimp specifications are valid only when used with Molex terminals, applicators and tooling. Visit our Web site at http://www.molex.com Doc No: ATS-639038900 Revision: A Release Date: 02-25-16 Revision Date: 02-25-16 UNCONTROLLED COPY Page 6 of 6