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.
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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
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