0638082300

FA2 Crimp Applicator for MX150 Mat Seal/Unsealed Receptacle Terminals Order Number 63808-2300 Application Tooling Specification FEATURES        Applicator designed to industry-standard mounting and 135.80mm (5.346") shut height Quick setup 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 .025mm (.001") for insulation height Independent adjustment rings allow users to quickly adjust the conductor or insulation crimp height without affecting each other Directly adapts to most automatic wire processing machines This applicator was designed for use in a wire processor only Fine adjustment of the bend is achieved using the bend adjust dial SCOPE Products: MX150 Mat Seal/Unsealed Receptacle Terminals: 14 AWG, 16 AWG, 1.25mm2 and 1.50mm2 specific type wires below: Terminal Series No. Terminal Order No. 33001-3003 Wire Type and Size Insulation Diameter Strip Length (Ref.) Type Wire Size M1L-135A1 (UTX) 14 AWG M1L-123A4 (TXL) 16 AWG JASO D611 (AVSS) 1.25mm2 M1L-126A1 FLR91X-A-XLPO EXRAD BLOCKED EXRAD UNBLOCKED PSA FTP 00949_10_00770 1.50mm2 mm In. mm In. 33001-3021 33001 33012 34750 33001-5001 33001-5021 33012-3001 33012-3021 33012-5021 34750-1001 2.10-2.70 .083-.106 4.70-5.60 .185-.220 CAUTION: This applicator was designed for use in a wire processor only. Doc. No: 638082300 Revision: C2 Release Date: 02-02-18 Revision Date: 03-12-21 UNCONTROLLED COPY Page 1 of 7 FA2 Crimp Applicator for MX150 Mat Seal/Unsealed Receptacle Terminals DEFINITION OF TERMS CRIMP/TRANSITION J K L K L SECTION K-K SECTION L-L CRIMP SPECIFICATIONS The following crimp specifications are based on document AS-33012-002 Rev. E: Feature Requirement 1. 2. 3. 4. 5. 6. 3° Max 3° Max 3° Max 3° Max 0.30-0.70mm (.012-.028”) Not Applicable Bend Up Bend Down Twist Roll Rear Bell Mouth Front Bell Mouth 7. Cut-Off Tab 0.50mm (.020”) Max No Burr 8. Conductor Brush 0.40mm (.016”) Max Not to extend above conductor crimp/transition height Wire Type Conductor Crimp Insulation Crimp Doc. No: 638082300 Revision: C2 M1L-135A1 (UTX) M1L-123A4 (TXL) JASO D611 (AVSS) MIL-126A1 FLR91X-A-XLPO EXRAD BLOCKED EXRAD UNBLOCKED PSA FTP 00949_10_00770 Wire Type M1L-135A1 (UTX) M1L-123A4 (TXL) JASO D611 (AVSS) MIL-126A1 FLR91X-A-XLPO EXRAD BLOCKED EXRAD UNBLOCKED PSA FTP 00949_10_00770 Wire Size 9. Crimp Height 10. Crimp Width 14 AWG 1.60-1.70mm .063-.067 in. 16 AWG 1.30-1.40mm .051-.054 in. 1.25mm2 1.30-1.40mm .051-.054 in. 2.35-2.55mm 1.50mm2 .093-.100 in. 1.35-1.45mm .053-.057 in. 1.40-1.50mm .054-.059 in. Wire Size 11. Crimp Height 12. Crimp Width 14 AWG 2.60-2.80mm .102-.110 in. 2.50-2.70mm .098-.106 in. 16 AWG 2.30-2.50mm .091-.098 in. 1.25mm2 2.41-2.61mm .095-.103 in. 2.53-2.73mm .100-.107 in. 1.50mm2 Release Date: 02-02-18 Revision Date: 03-12-21 2.63-2.73mm .104-.107 in. 2.63-2.73mm .104-.107 in. 2.45-2.55mm .096-.100 in. UNCONTROLLED COPY Page 2 of 7 FA2 Crimp Applicator for MX150 Mat Seal/Unsealed Receptacle Terminals Wire Type Wire Size Minimum Force M1L-135A1 (UTX) 14 AWG 180 N 40.5 lb. M1L-123A4 (TXL) 16 AWG 120 N 27.0 lb. JASO D611 (AVSS) 1.25mm2 176.5 N 39.7 lb. Pull Force MIL-126A1 FLR91X-A-XLPO 150 N 33.7 lb. EXRAD BLOCKED 1.50mm2 EXRAD UNBLOCKED PSA FTP 00949_10_00770 155 N 34.8 lb. 13. Conductor Anvil Flash 0.1mm (.004”) Max 14. Insulation Grip Step 0.20-0.40mm (.008-.016”) from Datum J 15. Conductor Grip Step 0.00±0.10mm (.000±.004”) from Datum J 16. Crimp Bulge 2.55mm (.100”) Max within the crimp/transition area To be measured with no influence from the insulation crimp. NOTES CUTTING INSERT Applicator Notes    This applicator is for automatic wire processor use only. This applicator does not include a cutting insert. Installing a cutting insert will cause jamming in this applicator. Specification Notes   It is very important that the brush length is consistently within specification for this sealed connector system to work properly. This applicator should only be run in a properly set up wire processor to consistently achieve the brush length. General Notes 1. Molex recommends that an extra perishable tooling kit be maintained at your facility. 2. Verify tooling alignment by hand 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 the work area. 4. Wear safety glasses at all times. 5. For recommended maintenance, refer to the FA2 manual (TM-638080200). 6. Molex recommends crimping stranded copper wire only. 7. Lubrication must be used when crimping gold and select gold terminals to prevent terminals from sticking in the conductor punch. Use 63801-7240 oiler or equivalent. WARNINGS CAUTION: This applicator must be installed in a press with a standard shut height of 135.80mm (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 tooling crimp specifications are valid only when used with Molex terminals and tooling manufactured by Molex and sold by Molex or authorized distributors (“Molex Tooling”). When using tooling other than Molex Tooling with Molex-specific connector systems listed in our ATS documents, the Molex Tooling qualification does not apply, and the responsibility for full qualification of the connector system is that of the customer. Molex accepts no liability for connector performance or tooling support where tooling other than Molex Tooling is used or where Molex Tooling is modified. Doc. No: 638082300 Revision: C2 Release Date: 02-02-18 Revision Date: 03-12-21 UNCONTROLLED COPY Page 3 of 7 FA2 Crimp Applicator for MX150 Mat Seal/Unsealed Receptacle Terminals PARTS LIST Applicator 63808-2300 Engineering No. Description Quantity Perishable Tooling 63808-2370 63808-2370 Tool Kit (All “Y” Items) REF 1 63454-0165 63454-0165 Insulation Punch 1Y 2 63457-0116 63457-0116 Conductor Punch 1Y 3 63456-0113 63456-0113 Insulation Anvil 1Y 4 63455-0143 63455-0143 Conductor Anvil 1Y 5 63443-0034 63443-0034 Cut-Off Plunger 1Y Other Components 6 63443-0128 63443-0128 Front Plunger Retainer 1 7 11-24-1067 4996-4 Cut-Off Plunger Spring 1 8 63443-0117 63443-0117 Front Scrap Chute 1 9 63443-7505 63443-7505 Anvil Mount 1 10 63443-0090 63443-0090 Wire Stop 1 11 63443-3601 63443-3601 Front Plunger Striker 1 12 63443-3702 63443-3702 Front Plunger Striker Screw 1 13 63600-5776 63600-5776 Nose Hold Down 1 14 63600-5775 63600-5775 Nose Hold Down Shank 1 15 63443-4711 63443-4711 Terminal Guide 1 16 63808-0229 63808-0229 Bend Adjust Dial 1 17 63808-0220 63808-0220 Hold Down Block 1 18 63808-0297 63808-0297 Feed Cam 1 19 63868-2008 63868-2008 Checking Aid † 0 Frame 20 63808-0200 63808-0200 Applicator Core 1 21 63808-0190 63808-0190 Track Assembly 1 22 63808-0197 63808-0197 Mechanical Feed Assembly 1 Hardware 23 — — M3 Inner Tooth Lock Washer 1* 24 — — M3 by 12 Long SHCS 1* 25 — — M4 by 6 Long SHCS 1* 26 — — M4 by 8 Long SHCS 2* 27 — — M4 by 50 Long SHCS 2* 28 — — M5 by 12 Long SHCS 1* 29 — — M2.5 by 4 Long SHCS 1* 30 — — #10-32UNF by .25” Long SHCS 1* 31 — — M3 by 3 Long Flat Point SSS 2* 32 — — M4 by 6 Long Flat Point SSS 1* 33 — — M3 Flat Washer Hard 1* 34 — — M3 Hex Nut 1* *Fastener parts can be purchased through most industrial suppliers by using the description in the table above. Item Order No. † The Crimped Terminal Checking Aid (63868-2008) can be ordered separately if required. (This item is not included with the Applicator and is shown for reference purposes only.) Doc. No: 638082300 Revision: C2 Release Date: 02-02-18 Revision Date: 03-12-21 UNCONTROLLED COPY Page 4 of 7 FA2 Crimp Applicator for MX150 Mat Seal/Unsealed Receptacle Terminals ASSEMBLY DRAWING 18 26 (2) 16 33 30 23 2 1 17 24 14 11 (2) 32 31 13 34 12 22 20 21 15 5 28 4 3 7 10 9 6 29 19 25 8 27 Doc. No: 638082300 Revision: C2 Figure 1 (2) Release Date: 02-02-18 Revision Date: 03-12-21 UNCONTROLLED COPY Page 5 of 7 FA2 Crimp Applicator for MX150 Mat Seal/Unsealed Receptacle Terminals FACTORY SETTINGS Feed Pawl Assembly The FA2 applicator number 638082300 ships with the following factory settings. See Figure 2:   The feed pawl shaft and M3 screw that holds the feed pawl spring are in position 3. The pin is in position B. FEED PAWL SPRING M3 SCREW FEED PAWL SHAFT 3 2 1 FEED PAWL AB GUIDE BLOCK C PIN M3 x 6 SHCS (2) Figure 2 Note: Each applicator is configured and tested by Molex prior to shipping, and the above settings were used to produce the included sample crimps. Third Dial/Ram Assembly Indicates item number on the Parts List and Assembly Drawing Front HOLD DOWN BLOCK RAM 62.5mm (Ref) BEND ADJUST DIAL 10mm (Ref) NOSE HOLD DOWN SHANK NOSE HOLD DOWN 16 NOSE HOLD DOWN 14 13 NOSE HOLD DOWN SHANK 17 14 13 Figure 3 Note: The above dimensions were measured during setup and are included as a reference only. Additional adjustments may be required before crimping for production. Doc. No: 638082300 Revision: C2 Release Date: 02-02-18 Revision Date: 03-12-21 UNCONTROLLED COPY Page 6 of 7 FA2 Crimp Applicator for MX150 Mat Seal/Unsealed Receptacle Terminals Mounting Datum Location This applicator was assembled and tested by Molex with the mounting datum in the location shown in Figure 4. Do not remove the mounting datum. M4 x 10 SHCS M3 x 10 DOWEL PIN MOUNTING DATUM BASE PLATE Figure 4 Application Tooling Support Phone: (402) 458-TOOL (8665) E-Mail: applicationtooling@molex.com Website: www.molex.com/applicationtooling Molex is a registered trademark of Molex, LLC in the United States of America and may be registered in other countries; all other trademarks listed herein belong to their respective owners. Doc. No: 638082300 Revision: C2 Release Date: 02-02-18 Revision Date: 03-12-21 UNCONTROLLED COPY Page 7 of 7