0638682008

Fine Adjust Applicator for “MX150” Receptacle FineAdjust Applicator Specification Sheet Part No. 63868-2000 FEATURES Œ Œ Œ Œ Œ Œ 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 Directly adapts to most automatic wire processing machines SCOPE Products: MX150Receptacle Terminals 1.50 metric and 14-16 AWG. Wire Size Insulation Diameter Strip Length AWG mm² mm In. mm In. 33001-3003 33001-3021 14-16 1.30-2.00 2.18-2.69 .087-.106 4.70-5.60 .185-.220 33001 33001-3003 33001-3021 Metric Only 1.50 2.20-2.40 .087-.094 4.70-5.60 .185-.220 33012-3001 33012-3021 14-16 1.30-2.00 2.18-2.69 .086-.106 4.70-5.60 .185-.220 33012 33012-3001 33012-3021 Metric Only 1.50 2.20-2.40 .087-.094 4.70-5.60 .185-.220 Terminal is designed for thin wall insulation per Ford’s specification M1L135-A1, M1L123-A, and M1L126-A1/A2/A3 Terminal Series No. Terminal Order No. DEFINITION OF TERMS BRUSH BEND UP BELL MOUTH CONDUCTOR CRIMP ROLLING SEAM INSULATION CRIMP TWISTING STRIP LENGTH BEND DOWN CUT-OFF TAB CRIMP HEIGHT The above terminal drawing is a generic terminal representation. It is not an image of any terminal listed in the scope. Doc No. 63868-2000 Revision: D Release Date: 03-26-06 Revision Date: 06-26-06 UNCONTROLLED COPY Page 1 of 5 Fine Adjust Applicator for “MX150” Receptacle CRIMP SPECIFICATION Terminal Series No. 33001 33012 Terminal Series No. ÒÒ Bell mouth Cut-off Tab Max. Conductor Brush mm In. mm In. mm In. 0.25-1.25 .010-.049 0.50 .020 0.15-0.40 .006-.016 0.25-1.25 .010-.049 0.50 .020 0.15-0.40 .006-.016 Wire brush to be below top of Conductor Crimp. ÒÒ Bend up Bend down Twist Roll Degree Degree Ò Crimped terminals and up to 5mm of wire past the insulator 33001 33012 cutoff tab must freely fit in the Checking Aid, Part No. 63868-2008 Ò Order Separately Punch Width (Ref) Conductor Insulation mm In mm In 2.39 .094 2.48 .098 2.39 .094 2.48 .098 Seam Seam shall not be open and no wire allowed out of the crimping area After crimping, the crimp profiles should measure the following: 33001 33001 33001 AWG 14 Metric Only 16 mm2 2.00 1.50 1.27 Conductor Insulation Pull Force Min. Crimp Height Crimp Width Crimp Height Crimp Width mm In. mm In. mm In. mm In. N Lb. 1.60-1.70 .063-.067 2.35-2.55 .092-.100 2.60-2.80 .102-.110 2.50-2.70 .098-.106 180.1 40.5 1.35-1.45 .053-.057 2.35-2.55 .092-.100 2.50-2.70 .098-.106 2.50-2.70 .098-.106 151.2 34.0 1.30-1.40 .051-.055 2.35-2.55 .092-.100 2.30-2.50 .090-.098 2.50-2.70 .098-.106 120.1 27.0 33012 33012 33012 14 Metric Only 16 2.00 1.50 1.27 1.60-1.70 .063-.067 2.35-2.55 1.35-1.45 .053-.057 2.35-2.55 1.30-1.40 .051-.055 2.35-2.55 Terminal Series No. Wire Size .092-.100 2.60-2.80 .102-.110 2.50-2.70 .098-.106 180.1 40.5 .092-.100 2.50-2.70 .098-.106 2.50-2.70 .098-.106 151.2 34.0 .092-.100 2.30-2.50 .090-.098 2.50-2.70 .098-.106 120.1 27.0 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. ✴ Adjusting the Wire Bend Angle (See Item17 in parts list and assembly drawing.) Note: If the Wire Bend is present after crimping use the following method to remove the bend. This tooling may not be necessary for all wire gauges. 1. The screw is provided for wire straightening. See Figure 1. 2. Loosen the (2) M3 x 5mm long setscrews; see Figure 1, before turning the screw. 3. Start by adjusting the screw so it just touches the insulation outside diameter of the wire being crimped. If wire Bend Up exists, turn the screw a quarter turn clockwise (CW) to lengthen it. 4. Continue to adjust the length of the screw until the wire appears to be straight after crimping. If wire Bend Down exists, turn the screw a quarter turn counter clockwise (CCW) to shorten it. Continue to adjust the length of the screw until the wire appears to be straight after crimping. 5. Tighten the M3 x 5mm long setscrews, when finished adjusting the screw. Two M3 x 5mm long setscrews are provided; the top setscrew is to lock the screw after adjustments. The M3 x 5mm long setscrew on the side of plunger striker is used when making adjustments. Doc No. 63868-2000 Revision: D Release Date: 03-26-06 Revision Date: 06-26-06 UNCONTROLLED COPY PLUNGER STRIKER M3 X 5mm LG. SETSCREW (2) SCREW Figure 1 Page 2 of 5 Fine Adjust Applicator for “MX150” Receptacle PARTS LIST FineAdjust Applicator 63868-2000 Engineering No. Description Quantity Perishable Tooling 63868-2070 63868-2070 Tool Kit (All “Y” Items) REF 1 63457-0029 63457-0029 Conductor Punch 1Y 2 63455-0033 63455-0033 Conductor Anvil 1Y 3 63454-0047 63454-0047 Insulation Punch 1Y 4 63456-0033 63456-0033 Insulation Anvil 1Y 5 63461-0001 63461-0001 Cut-Off Plunger Front 1Y 6 63443-0036 63443-0036 Plunger Retainer Front 1Y Other Components 7 11-17-0022 1739-21 Compression Spring 1 8 11-18-4094 60709-A111 Front Cover 1 9 11-24-1149 4996-37 Shank 1 10 63443-0009 63443-0009 Scrap Chute Front 1 11 63443-0021 63443-0021 Lower Tooling Key 1 12 11-18-4080 60707-5 Wire Stop 1 13 63443-0069 63443-0069 Terminal Hold Down 1 14 63443-2506 63443-2506 Anvil Mount 1 15 63443-6013 63443-6013 Rear Cover 1 16 63700-0539 63700-0539 Cut-off Plunger Spring 1 17 63443-0082 63443-0082 Plunger Striker Front 1 18 63443-0083 63443-0083 Striker Screw 1 19 63868-2008 63868-2008 Checking Aid REF Frame 20 63801-3100 63801-3100 Wide Track Fine Adjust Frame 1 21 63459-0001 63459-0001 Wide Terminal Track 1 Hardware 22 N/A N/A M3 by 5Lg. SHSS-Brass Tip 2** 23 N/A N/A M3 by 6Lg. SHCS 2** 24 N/A N/A M3 by 8Lg. SHCS 1** 25 N/A N/A M4 by 6Lg. SHCS 1** 26 N/A N/A M4 by 12Lg. BHCS 2** 27 N/A N/A M4 by 50Lg. SHCS 2** 28 N/A N/A M5 by 12Lg. SHCS 1** 29 N/A N/A 3MM by 6Lg. Roll Pin 1** 30 N/A N/A #10-32 by 1/4”Lg. BHCS 1** ** Available from an industrial supply company such as MSC (1-800-645-7270). Item Order No Ò Ò The Checking Aid 63868-2008 to be ordered separately if required. (This item is not included with the Applicator and is shown for Reference purpose only) Doc No. 63868-2000 Revision: D Release Date: 03-26-06 Revision Date: 06-26-06 UNCONTROLLED COPY Page 3 of 5 Fine Adjust Applicator for “MX150” Receptacle Assembly Drawing 20 30 26 3 (2) (2) 7 1 22 9 15 13 17 24 18 (2) 23 8 5 21 20 16 6 10 (2) 27 12 25 28 2 14 19 11 4 Doc No. 63868-2000 Revision: D Release Date: 03-26-06 Revision Date: 06-26-06 29 Figure 2 UNCONTROLLED COPY Page 4 of 5 Fine Adjust Applicator for “MX150” Receptacle NOTES 1. 2. 3. 4. 5. Molex recommends an extra perishable tooling kit be maintained at your facility. Verify tooling alignment by manually cycling the press and Applicator before crimping under power. Check that all screws are tight. Slugs, Terminals, Dirt and Oil should be kept clear of work area. Wear safety glasses at all times. For recommended maintenance refer to the FineAdjust Manual. CAUTION: This applicator should only be used in a press with a shut height of 135.80 mm (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 crimp specifications are valid only when used with Molex terminals, applicators and tooling. Americas Headquarters Far East North Headquarters Far East South Headquarters European Headquarters Corporate Headquarters -JTMF
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 Visit our Web site at http://www.molex.com Doc No. 63868-2000 Revision: D Release Date: 03-26-06 Revision Date: 06-26-06 UNCONTROLLED COPY Page 5 of 5