0638082610

FA2 Pneumatic Feed Crimp Applicator for MX150 18 Grip Receptacle Terminals Order Number 63808-2610 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. Fine adjustment of the bend is achieved using the bend adjust dial. 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 is configured with a pneumatic feed, which requires a 4-way pneumatic valve for operation. Crimped terminal checking aid (63868-2008) can be ordered separately. SCOPE Products: MX150 18 Grip Receptacle for 20 AWG and 0.75mm2 wire. Terminal Series No. 33001 33012 34750 Terminal Order No. Wire Wire Type Insulation Diameter Wire Size GXL 20 AWG 33001-3004 33001-5002 HIFLON 20 AWG 33012-3002 TXL 20 AWG 34750-1002 EXRAD BLOCKED 0.75 mm² 33012-3022 PSA FTP 00949_10_00768 0.75 mm² 33012-5022 FLR91X-A-XLPO 33001-3022 M1l-126A1 0.75 mm² 33001-5022 EXRAD UNBLOCKED Strip Length mm In. mm In. 1.60-2.54 .063-.100 4.70-5.60 .185-.220 1.60-2.54 .063-.100 4.70-5.60 .185-.220 1.60-2.54 .063-.100 4.70-5.60 .185-.220 1.60-2.54 .063-.100 4.70-5.60 .185-.220 1.60-2.54 .063-.100 4.70-5.60 .185-.220 1.60-2.54 .063-.100 4.70-5.60 .185-.220 CAUTION: This applicator was designed for use in a wire processor only. CAUTION: To operate the pneumatic feed, a 4-way pneumatic valve is required. Doc. No: 638082610 Revision: C Release Date: 09-21-18 Revision Date: 11-28-23 UNCONTROLLED COPY Page 1 of 7 FA2 Pneumatic Feed Crimp Applicator for MX150 18 Grip Receptacle Terminals DEFINITION OF TERMS CRIMP/TRANSITION 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. Bend Up 3° Max 2. Bend Down 3° Max 3. Twist 3° Max 4. Roll 3° Max 5. Bell Mouth Rear 0.30-0.70mm (.012-.028”) 6. Bell Mouth Front Not Applicable 7. Conductor Brush 0.40mm (.016”) Not to extend above conductor crimp/transition height 0.50mm (.020”) Max No Burr 8. Cut-Off Tab Conductor Crimp Insulation Crimp Doc. No: 638082610 Revision: C Wire Type Wire Size GXL 20 AWG 1.10-1.20mm .043-.047 in. 2.05-2.25mm .081-.089 in. HIFLON 20 AWG 1.10-1.20mm .043-.047 in. 2.05-2.25mm .081-.089 in. 20 AWG 1.10-1.20mm .043-.047 in. 2.05-2.25mm .081-.089 in. TXL 9. Crimp Height 10. Crimp Width EXRAD BLOCKED 0.75 mm² 1.10-1.20mm .043-.047 in. 2.05-2.25mm .081-.089 in. PSA FTP 00949_10_00768 FLR91X-A-XLPO M1l-126A1 EXRAD UNBLOCKED 0.75 mm² 1.25-1.35mm .049-.053 in. 2.05-2.25mm .081-.089 in. 0.75 mm² 1.20-1.30mm .047-.051 in. 2.05-2.25mm .081-.089 in. Wire Type Wire Size 11. Crimp Height 12. Crimp Width GXL 20 AWG 1.90-2.10mm .075-.083 in. 2.20-2.40mm .087-.094 in. HIFLON 20 AWG 1.80-2.35mm .071-.093 in. 2.00-2.20mm .079-.087 in. TXL 20 AWG 1.80-2.00mm .071-.079 in. 2.00-2.20mm .079-.087 in. EXRAD BLOCKED 0.75 mm² 2.25-2.35mm .089-.093 in. 2.00-2.20mm .079-.087 in. PSA FTP 00949_10_00768 FLR91X-A-XLPO M1l-126A1 EXRAD UNBLOCKED 0.75 mm² 2.25-2.35mm .089-.093 in. 2.00-2.20mm .079-.087 in. 0.75 mm² .089-.093mm .089-.093 in. 2.00-2.20mm .079-.087 in. Release Date: 09-21-18 Revision Date: 11-28-23 UNCONTROLLED COPY Page 2 of 7 FA2 Pneumatic Feed Crimp Applicator for MX150 18 Grip Receptacle Terminals Pull Force Wire Type Wire Size GXL 20 AWG 75 N 16.9 lb. HIFLON 20 AWG 75 N 16.9 lb. TXL 20 AWG 75 N 16.9 lb. EXRAD BLOCKED 0.75 mm² 90 N 20.3 lb. 0.75 mm² 90 N 20.3 lb. 0.75 mm² 90 N 20.3 lb. PSA FTP 00949_10_00768 FLR91X-A-XLPO M1l-126A1 EXRAD UNBLOCKED 13. Conductor Anvil Flash 0.22mm (.009”) Max Minimum Force 14. Insulation Grip Step 0.20-0.40mm (.008-.016”) 15. Crimp Bulge 2.65mm (.104”) Max within 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 standard 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 wire-processing 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: 638082610 Revision: C Release Date: 09-21-18 Revision Date: 11-28-23 UNCONTROLLED COPY Page 3 of 7 FA2 Pneumatic Feed Crimp Applicator for MX150 18 Grip Receptacle Terminals PARTS LIST Item Order No. 1 2 3 4 5 63808-2670 63454-0171 63457-0117 63456-2002 63455-0145 63443-0034 6 7 8 9 10 11 12 13 14 15 16 17 63443-0128 11-24-1067 63443-0117 63443-7502 63443-0090 63443-3601 63443-3702 63600-5776 63600-5775 63443-4714 63808-0220 63808-0229 18 19 20 63808-0200 63808-0190 63808-0196 21 22 23 24 25 26 27 28 29 30 31 32 — — — — — — — — — — — — FA2 Applicator 63808-2610 Engineering No. Description Quantity Perishable Tooling 63808-2670 Tool Kit (All "Y" Items) Ref 63454-0171 Insulation Punch 1Y 63457-0117 Conductor Punch 1Y 63456-2002 Insulation Anvil 1Y 63455-0145 Conductor Anvil 1Y 63443-0034 Front Plunger 1Y Non-Perishable Components 63443-0128 Front Plunger Retainer 1 4996-4 Cut-Off Plunger Spring 1 63443-0117 Front Scrap Shute 1 63443-7502 Anvil Mount 1 63443-0090 Wire Stop 1 63443-3601 Front Plunger Striker 1 63443-3702 Wire Hold Down Plunger 1 63600-5776 Nose Hold Down 1 63600-5775 Nose Hold Down Shank 1 63443-4714 Terminal Guide 1 63808-0220 Hold Down Block 1 63808-0229 Bend Adjust Dial 1 Frame 63808-0200 Applicator Core 1 63808-0190 Track Assembly 1 63808-0196 Pneumatic Feed Assembly 1 Hardware — M2.5 by 4 Long SHCS 1* — M3 Flat Washer Hard 1* — M3 Inner Tooth Lock Washer 1* — M3 Hex Nut 1* — M3 by 3 Long SSS 2* — M3 by 6 long BHCS 2* — M3 by 12 Long SHCS 4* — M4 by 6 Long SHCS 1* — M4 by 6 Long SSS 1* — M4 by 50 Long SHCS 2* — M5 by 12 Long SHCS 1* — #10-32UNF by .25" Long BHCS 1* *Fastener parts can be purchased through most industrial suppliers by using the description in the table above. Doc. No: 638082610 Revision: C Release Date: 09-21-18 Revision Date: 11-28-23 UNCONTROLLED COPY Page 4 of 7 FA2 Pneumatic Feed Crimp Applicator for MX150 18 Grip Receptacle Terminals ASSEMBLY DRAWING 17 22 32 23 2 1 27 16 11 14 29 24 (2) 25 12 27 (3) 13 20 18 19 31 15 26 (2) 4 5 3 7 10 9 6 21 28 30 (2) Doc. No: 638082610 Revision: C Figure 1 8 Release Date: 09-21-18 Revision Date: 11-28-23 UNCONTROLLED COPY Page 5 of 7 FA2 Pneumatic Feed Crimp Applicator for MX150 18 Grip Receptacle Terminals FACTORY SETTINGS Feed Pawl Assembly The FA2 applicator number 63808-2610 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 Figure 2 M3 x 6 SHCS (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 63.1mm (Ref) BEND ADJUST DIAL 10.6 mm (Ref) NOSE HOLD DOWN SHANK NOSE HOLD DOWN 17 NOSE HOLD DOWN SHANK NOSE HOLD DOWN 14 13 16 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: 638082610 Revision: C Release Date: 09-21-18 Revision Date: 11-28-23 UNCONTROLLED COPY Page 6 of 7 FA2 Pneumatic Feed Crimp Applicator for MX150 18 Grip Receptacle Terminals PNEUMATIC CONNECTION (AIR FEED)   The pneumatic feed applicator uses a double-acting air cylinder that must be actuated by a 4-way pneumatic valve. The air cylinder is equipped with push-in fittings for 6mm diameter vinyl or Nylon tube. Adapters are included for ¼” diameter and 4mm diameter vinyl or Nylon tube. Note: The TM-3000 and TM-4000 presses have pneumatic valves with ¼” diameter tube fittings. Be sure to install the ¼” diameter adapters in the air cylinder fittings and use ¼” diameter vinyl or Nylon tube.   Pneumatic tubes must be connected as shown in Figure 4. Tubes are typically connected so the terminal feed is forward when the applicator ram is up. When using the TM-3000 or TM-4000 presses, connect the tubes to the press pneumatic valve as shown in Figure 5. FEED FORWARD CONNECTION FEED BACK CONNECTION FEED BACK CONNECTION FEED FORWARD CONNECTION PRESS PNEUMATIC VALVE (TM-3000 & TM-4000) Figure 5 Figure 4 Application Tooling Support 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: 638082610 Revision: C Release Date: 09-21-18 Revision Date: 11-28-23 UNCONTROLLED COPY Page 7 of 7