0638085900

FA2 Crimp Applicator for Mini-Lock Crimp Terminals Order Number 63808-5900 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 Fine adjustment of the bend is achieved using the bend adjust dial SCOPE Products: Mini-Lock Crimp Terminals, 22-20 AWG wire. Wire Terminal Series No. Terminal Order No. Wire Type 50752 50752-8200 UL1569 (1) Insulation Diameter Size 22 AWG 20 AWG mm In. 1.45-1.75 .057-.069 Strip Length mm In. 2.30-2.80 .091-.110 (1) To achieve optimum IPC/WHMA-A-620 insulation crimps, use this insulation OD range. Doc. No: 638085900 Revision: A Release Date: 08-31-18 Revision Date: 08-31-18 UNCONTROLLED COPY Page 1 of 7 FA2 Crimp Applicator for Mini-Lock Crimp Terminals DEFINITION OF TERMS 1 0 K K L 9 SECTION K-K L SECTION L-L CRIMP SPECIFICATIONS Feature Requirement 1. Bend Up 3° Max 2. Bend Down 3° Max 3. Twist 3° Max 4. Roll 6° Max 5. Bell Mouth Rear 0.05-0.40mm (.002-.016”) 6. Bell Mouth Front Not Applicable 7. Conductor Brush 0.80mm (.031”) Max 8. Cut-Off Tab 0.20mm (.008”) Max Conductor Crimp Insulation Crimp Pull Force Doc. No: 638085900 Revision: A Wire Type Wire Size 9. Crimp Height 10. Crimp Width UL1569 22 AWG 0.81-0.86mm .032-.034 in. 1.40-1.46mm .055-.057 in. 0.90-0.98mm .035-.039 in. 1.40-1.46mm .055-.057 in. UL1569 20 AWG Wire Type Wire Size UL1569 22 AWG 1.92-2.00mm .076-.079 in. 1.80-1.95mm .071-.077 in. UL1569 20 AWG 1.95-2.00mm .077-.079 in. 1.80-1.95mm .071-.077 in. Wire Type Wire Size UL1569 22 AWG 39.2 N 8.8 lb. UL1569 20 AWG 49 N 11.0 lb. Release Date: 08-31-18 Revision Date: 08-31-18 11. Crimp Height 12. Crimp Width Minimum Force To be measured with no influence from the insulation crimp. UNCONTROLLED COPY Page 2 of 7 FA2 Crimp Applicator for Mini-Lock Crimp Terminals 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. 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: 638085900 Revision: A Release Date: 08-31-18 Revision Date: 08-31-18 UNCONTROLLED COPY Page 3 of 7 FA2 Crimp Applicator for Mini-Lock Crimp Terminals PARTS LIST Item Order No. 1 2 3 4 5 6 63808-5970 63454-1807 63457-1407 63456-1805 63455-1405 63443-0136 63443-0119 7 8 9 10 11 12 13 14 15 16 17 18 19 20 63443-0118 11-24-1067 63443-0117 63443-7527 63443-0090 63443-2806 63443-2922 63600-0021 63600-5776 63600-5775 63443-4703 63443-7404 63808-0229 63443-4410 21 22 63808-0200 63808-0197 23 24 25 26 27 28 29 30 31 32 33 34 — — — — — — — — — — — — FA2 Applicator 63808-5900 Engineering No. Description Perishable Tooling 63808-5970 Tool Kit (All "Y" Items) 63454-1807 Insulation Punch 63457-1407 Conductor Punch 63456-1805 Insulation Anvil 63455-1405 Conductor Anvil 63443-0136 Cut-Off Plunger 63443-0119 Cutting Insert Non-Perishable Components 63443-0118 Front Plunger Retainer 4996-4 Cut-Off Plunger Spring 63443-0117 Front Scrap Chute 63443-7527 Anvil Mount 63443-0090 Wire Stop Assembly 63443-2806 Front Plunger Striker 63443-2922 Wire Hold Down Plunger 63600-0021 Wire Hold Down Spring 63600-5776 Nose Hold Down 63600-5775 Nose Hold Down Shank 63443-4703 Terminal Guide 63443-7404 Hold Down Block 63808-0229 Bend Adjust Dial 63443-4410 Feed Cam Frame 63808-0200 Applicator Core 63808-0197 Mechanical Feed Assembly Hardware — M2.5 x 3 SHCS — M3 Flat Washer Hard — M3 Hex Nut — M3 Inner Tooth Lock Washer — M3 x 6 BHCS — M3 x 12 SHCS — M4 x 5 SSS — M4 x 6 SHCS — M4 x 8 SHCS — M4 x 45 SHCS — M5 x 12 SHCS — #10-32UNF x .25" SHCS Quantity Ref 1Y 1Y 1Y 1Y 1Y 1Y 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2* 1* 1* 1* 2* 4* 1* 1* 2* 2* 1* 1* *Fastener parts can be purchased through most industrial suppliers by using the description in the table above. Doc. No: 638085900 Revision: A Release Date: 08-31-18 Revision Date: 08-31-18 UNCONTROLLED COPY Page 4 of 7 FA2 Crimp Applicator for Mini-Lock Crimp Terminals ASSEMBLY DRAWING 20 (2) 31 19 24 34 26 2 1 18 28 14 13 16 29 12 25 15 28 22 (3) 21 17 33 23 5 27 (2) 4 8 3 11 6 10 7 23 30 Figure 1 32 Doc. No: 638085900 Revision: A (2) 9 Release Date: 08-31-18 Revision Date: 08-31-18 UNCONTROLLED COPY Page 5 of 7 FA2 Crimp Applicator for Mini-Lock Crimp Terminals FACTORY SETTINGS Feed Pawl Assembly The FA2 applicator number 63808-5900 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 2. The pin is in position C. FEED PAWL SPRING M3 SCREW FEED PAWL SHAFT 1 GUIDE BLOCK 2 3 FEED PAWL C AB 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 10.0mm (Ref) NOSE HOLD DOWN SHANK NOSE HOLD DOWN 15 19 NOSE HOLD DOWN SHANK NOSE HOLD DOWN 16 18 16 15 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: 638085900 Revision: A Release Date: 08-31-18 Revision Date: 08-31-18 UNCONTROLLED COPY Page 6 of 7 FA2 Crimp Applicator for Mini-Lock Crimp 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: 638085900 Revision: A Release Date: 08-31-18 Revision Date: 08-31-18 UNCONTROLLED COPY Page 7 of 7