0639028400

Fine Adjust Applicator for “MX150™ Male Shorting Bar Terminal FineAdjust Applicator Application Tooling Specification Sheet Order No. 63902-8400 FEATURES 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™ Male Shorting Bar Terminal, 18-20 AWG. Wire Size Insulation Diameter Strip Length AWG mm² mm In. mm In. 18 0.80 1.91-2.06 .075-.081 4.70-5.60 .185-.220 31296-0004 Male (Gold) 31296 31296-0008 Male (Gold) 20 0.50 1.70-1.85 .067-.073 4.70-5.60 .185-2.20 Terminals were validated per USCAR-21 using the following wire specifications: M1L-123A (TXL), M1L-135A1 (UTX), and M1L-126A1(metric-TXL) Customers are required to complete validation testing if tooling purchased outside Molex Inc. and/or wire specifications are different than above. Terminal Series No. Terminal Order No. DEFINITION OF TERMS BRUSH WIRE BEND BEND UP WIRE BRUSH MUST BE FLUSH OR BELOW TOP OF CONDUCTOR CRIMP 0.30 ROLLING CUT-OFF TAB BELL MOUTH STRIP LENGTH TWISTING INSULATION CRIMP BEND DOWN SEAM THIS AREA TERMINAL WIDTH NOT TO EXCEED 2.65mm AFTER CRIMP Doc No: ATS-639028400 Revision: A WIRE BEND Release Date: 01-02-13 Revision Date: 01-02-13 CRIMP HEIGHT CONDUCTOR CRIMP UNCONTROLLED COPY Page 1 of 6 Fine Adjust Applicator for “MX150™ Male Shorting Bar Terminal CRIMP SPECIFICATION Terminal Series No. 31296 Bell mouth Cut-off Tab Maximum Conductor Brush mm In. mm In. mm In. 0.30-0.70 .012-.028 0.50 .020 0.15-0.40 .006-.016 Wire brush must be flush or below top of Conductor Crimp. Bend up Bend down Terminal Series No. 31296 Twist Degree 3 Roll Degree 3 1.5 1.5 Punch Width mm (Ref) Conductor Insulation mm In mm In 2.10 .082 2.41 .095 Seam Seam shall not be open and no wire allowed out of the crimping area After crimping, the conductor profile should measure the following. Terminal Series No. 31296 Conductor Insulation Pull Force Minimum Crimp Height Crimp Width Crimp Height Crimp Width AWG mm2 mm In. mm In. mm In. mm In. N Lb. 18 0.80 1.20-1.30 .047-.051 2.05-2.25 .081-.089 .190-2.10 .075-.083 2.35-2.55 .093-1.00 90 20.2 20 0.50 1.10-1.20 .043-.047 2.05-2.25 .081-.089 2.30-2.50 .091-.098 2.35-2.55 .093-1.00 58 13.0 Wire Size 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. Doc No: ATS-639028400 Revision: A Release Date: 01-02-13 Revision Date: 01-02-13 UNCONTROLLED COPY Page 2 of 6 Fine Adjust Applicator for “MX150™ Male Shorting Bar Terminal Adjusting the Wire Bend Angle (See Item No. 11 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. PLUNGER STRIKER M3 X 5mm LONG SETSCREW (2) SCREW Figure 1 Adjusting the Wire Brush Length (See Item No. 13 in parts list and assembly drawing.) 1. If the wire brush is too long or extends above the top of the conductor crimp, adjust the Wire Stop, Item 13, closer to the conductor punch. 2. If the wire brush is too short, adjust the Wire Stop further away from the conductor punch. Doc No: ATS-639028400 Revision: A Release Date: 01-02-13 Revision Date: 01-02-13 UNCONTROLLED COPY Page 3 of 6 Fine Adjust Applicator for “MX150™ Male Shorting Bar Terminal PARTS LIST FineAdjust Applicator 63902-8400 Engineering No. Description Quantity Perishable Tooling 63902-8470 63902-8470 Tool Kit (All “Y” Items) REF 1 63444-2137 63444-2137 Conductor Punch 1Y 2 63445-2168 63445-2168 Conductor Anvil 1Y 3 63454-2401 63454-2401 Insulation Punch 1Y 4 63456-2401 63456-2401 Insulation Anvil 1Y 5 63443-0037 63443-0037 Cut-Off Plunger 1Y 6 63443-0038 63443-0038 Front Plunger Retainer 1Y Other Components 7 11-17-0022 1739-21 Hold Down Spring 1 8 11-18-4094 60709A111 Feed Guide 1 9 63443-0009 63443-0009 Scrap Chute 1 10 63443-0024 63443-0024 Key 1 11 63443-0082 63443-0082 Front Plunger Striker 1 12 63443-0083 63443-0083 Striker Screw 1 13 63443-0090 63443-0090 Wire Stop 1 14 63443-0093 63443-0093 Shank 1 15 63443-1719 63443-1719 Height Spacer (18.90mm) 1 16 63443-2205 63443-2205 Coarse Spacer (5.00mm) 1 17 63443-2209 63443-2209 Coarse Spacer (9.00mm) 1 18 63443-2306 63443-2306 Fine Spacer (3.30mm) 1 19 63443-6122 63443-6122 Rear Cover 1 20 63443-7102 63443-7102 Terminal Hold Down 1 21 63700-0539 63700-0539 Cut-off Plunger Spring 1 Frame 22 63800-4901 63800-4901 Top 1 23 63801-3281 63801-3281 Base 1 24 63801-4650 63801-4650 Track 1 24A 63459-0001 63459-0001 Terminal Track 1 Hardware 25 N/A N/A M3 by 5Lg. SHSS-Brass Tip 2** 26 N/A N/A M3 by 6 Long SHCS 2** 27 N/A N/A M3 by 6 Long FHCS 1** 28 N/A N/A M3 by 8 Long SHCS 1** 29 N/A N/A M4 by 6 Long SHCS 2** 30 N/A N/A M4 by 12 Long BHCS 2** 31 N/A N/A M4 by 50 Long SHCS 2** 32 N/A N/A M5 by 12 Long SHCS 1** 33 N/A N/A #10-32 by 3/8”Long Flat Point SSS 1** 34 N/A N/A #10-32 Hex Jam Nut 1** ** Available from an industrial supply company such as MSC (1-800-645-7270). Item Order No Doc No: ATS-639028400 Revision: A Release Date: 01-02-13 Revision Date: 01-02-13 UNCONTROLLED COPY Page 4 of 6 Fine Adjust Applicator for “MX150™ Male Shorting Bar Terminal Assembly Drawing 22 33 34 7 1 3 25 (2) 30 (2) 19 14 11 28 20 12 (2) 26 8 5 22 24 21 6 23 9 13 32 29 18 29 16 (2) 31 2 17 13 15 10 4 Doc No: ATS-639028400 Revision: A Release Date: 01-02-13 Revision Date: 01-02-13 Figure 4 27 UNCONTROLLED COPY Page 5 of 6 Fine Adjust Applicator for “MX150™ Male Shorting Bar Terminal NOTES 1. Molex recommends an extra perishable tooling kit be maintained at your facility. 2. Verify tooling alignment by manually 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 work area. 4. Wear safety glasses at all times. 5. 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 wireprocessing 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. Visit our Web site at http://www.molex.com Doc No: ATS-639028400 Revision: A Release Date: 01-02-13 Revision Date: 01-02-13 UNCONTROLLED COPY Page 6 of 6