2130691510

FA2 Pneumatic Feed Crimp Applicator for Pico-Lock 2.0 Crimp Terminals Order Number 213069-1510 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 0.015mm (.0006”) for conductor crimp height and 0.025mm (.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 This tool is IPC/WHMA-A-620 Class 2 compliant, as indicated below This applicator is configured with a pneumatic feed, which requires a 4-way pneumatic valve for operation SCOPE Products: Pico-Lock 2.0 Crimp Terminals, 24-26 AWG Wire. Terminal Series No. Terminal Order No. 205342 205342-5128 Wire Wire Type Wire Size Insulation Diameter IPC/WHMA-A-620 (1) Strip Length Terminal (2) mm In. mm In. mm In. UL1061 24 AWG 1.00-1.25 .039-.049 0.85-1.30 .033-.051 2.20-2.60 .087-.102 UL1061 26 AWG 1.00-1.25 .039-.049 0.85-1.30 .033-.051 2.20-2.60 .087-.102 (1) To achieve optimum IPC/WHMA-A-620 insulation crimps, use this insulation OD range. (2) Overall insulation OD specification for terminal. CAUTION: To operate the air feed, a 4-way air valve is required. Doc. No: 2130691510 Revision: B Release Date: 09-22-21 Revision Date: 12-21-21 UNCONTROLLED COPY Page 1 of 8 FA2 Pneumatic Feed Crimp Applicator for Pico-Lock 2.0 Crimp Terminals DEFINITION OF TERMS CRIMP/TRANSITION K L K L SECTION K-K SECTION L-L CRIMP SPECIFICATIONS Feature Requirement 1. Bend Up 2° Max 2. Bend Down 2° Max 3. Twist 2° Max 4. Roll 4° Max 5. Bell Mouth Rear 0.20-0.45mm (.008-.018”) 6. Bell Mouth Front Not Applicable 7. Conductor Brush 0.10-0.70mm (.004-.028”) 8. Cut-Off Tab 0.10mm (.004”) Max Conductor Crimp Insulation Crimp Pull Force Wire Type Wire Size UL1061 24 AWG 0.68-0.73mm 9. Crimp Height .027-.029 in. 1.11-1.15mm .044-.045 in. 0.62-0.67mm .024-.026 in. 1.11-1.15mm .044-.045 in. UL1061 26 AWG Wire Type Wire Size UL1061 24 AWG 1.46-1.50mm .057-.059 in. 1.44-1.48mm .057-.058 in. UL1061 26 AWG 1.40-1.44mm .055-.057 in. 1.44-1.48mm .057-.058 in. Wire Type Wire Size UL1061 24 AWG 29.4 N 6.6 lb. 0.05mm .002 in. UL1061 26 AWG 19.6 N 4.4 lb. 0.08mm .003 in. 11. Crimp Height 0.10mm (.004”) Max 14. Insulation Grip Step 0.22-0.28mm (.009-.011”) 15. Crimp Bulge 1.48mm (.058”) Max within crimp/transition area Release Date: 09-22-21 Revision Date: 12-21-21 12. Crimp Width Minimum Force 13. Conductor Anvil Flash Doc. No: 2130691510 Revision: B 10. Crimp Width 13. Anvil Flash UNCONTROLLED COPY Page 2 of 8 FA2 Pneumatic Feed Crimp Applicator for Pico-Lock 2.0 Crimp Terminals NOTES 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 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 wireprocessing 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: 2130691510 Revision: B Release Date: 09-22-21 Revision Date: 12-21-21 UNCONTROLLED COPY Page 3 of 8 FA2 Pneumatic Feed Crimp Applicator for Pico-Lock 2.0 Crimp Terminals PARTS LIST Item Order No. 1 2 3 4 5 6 213069-1570 63454-1503 63457-0171 63456-0150 63455-0205 63443-0136 63443-0119 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 63443-0118 11-24-1067 63443-0117 63443-2208 63443-2806 63890-0140 63600-4389 63600-5775 63443-4722 63443-7403 63808-0229 63443-7315 63700-0992 63443-7316 63443-7317 63443-7322 23 24 25 63808-0200 63808-0196 63808-0191 26 27 28 29 30 31 32 33 34 35 36 37 38 — — — — — — — — — — — — — Applicator 213069-1510 Engineering No. Description Perishable Tooling 213069-1570 Tool Kit (All "Y" Items) 63454-1503 Insulation Punch 63457-0171 Conductor Punch 63456-0150 Insulation Anvil 63455-0205 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 63443-2208 Spacer 63443-2806 Front Plunger Striker 63890-0140 Wire Hold Down Plunger 63600-4389 Wire Hold Down Spring 63600-5775 Nose Hold Down Shank 63443-4722 Terminal Guide 63443-7403 Hold Down Block 63808-0229 Bend Adjust Dial 63443-7315 Terminal Hold Down Plunger 63700-0992 Terminal Hold Down Plunger Spring 63443-7316 Terminal Hold Down Retainer 63443-7317 Terminal Hold Down Retainer Plate 63443-7322 Terminal Hold Down Frame 63808-0200 Applicator Core 63808-0196 Pneumatic Feed Assembly 63808-0191 Track Assembly Hardware — M2.5 x 4 SHCS — M3 Flat Washer Hard — M3 Hex Nut — M3 Inner Tooth Lock Washer — M3 x 6 BHCS — M3 x 8 SHCS — M3 x 10 SHCS — M3 x 12 SHCS — M4 x 5 SSS — M4 x 6 SHCS — M4 x 50 SHCS — M5 x 10 Long Cup Point SSS — M5 Hex Jam Nut Quantity Ref 1Y 1Y 1Y 1Y 1Y 1Y 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2* 1* 2* 1* 2* 1* 1* 4* 1* 1* 2* 1* 1* *Fastener parts can be purchased through most industrial suppliers by using the description in the table above. Doc. No: 2130691510 Revision: B Release Date: 09-22-21 Revision Date: 12-21-21 UNCONTROLLED COPY Page 4 of 8 FA2 Pneumatic Feed Crimp Applicator for Pico-Lock 2.0 Crimp Terminals ASSEMBLY DRAWING 17 37 27 38 29 2 1 16 13 33 11 14 34 12 28 32 24 33 23 (3) 25 15 26 21 5 18 30 (2) 4 10 3 8 20 6 22 7 31 19 26 Figure 1 9 36 35 (2) Doc. No: 2130691510 Revision: B Release Date: 09-22-21 Revision Date: 12-21-21 UNCONTROLLED COPY Page 5 of 8 FA2 Pneumatic Feed Crimp Applicator for Pico-Lock 2.0 Crimp Terminals FACTORY SETTINGS Feed Pawl Assembly The FA2 applicator number 213069-1510 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 2 3 1 FEED PAWL AB GUIDE BLOCK C 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 60.20mm (Ref) BEND ADJUST DIAL 7.70mm (Ref) NOSE HOLD DOWN SHANK NOSE HOLD DOWN 33 17 NOSE HOLD DOWN SHANK NOSE HOLD DOWN 14 16 14 33 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: 2130691510 Revision: B Release Date: 09-22-21 Revision Date: 12-21-21 UNCONTROLLED COPY Page 6 of 8 FA2 Pneumatic Feed Crimp Applicator for Pico-Lock 2.0 Crimp Terminals CAUTION: A tooling crash may occur if any of the following conditions exist:  The M3 x 10 SHCS extends more than 7.70mm from the nose hold down shank  The bend adjust dial is adjusted too far down  The press shut height is less than 135.80mm (5.346”) 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 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 5. 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 6. FEED FORWARD CONNECTION FEED BACK CONNECTION FEED BACK CONNECTION FEED FORWARD CONNECTION PRESS PNEUMATIC VALVE (TM-3000 & TM-4000) Figure 6 Figure 5 Doc. No: 2130691510 Revision: B Release Date: 09-22-21 Revision Date: 12-21-21 UNCONTROLLED COPY Page 7 of 8 FA2 Pneumatic Feed Crimp Applicator for Pico-Lock 2.0 Crimp Terminals 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: 2130691510 Revision: B Release Date: 09-22-21 Revision Date: 12-21-21 UNCONTROLLED COPY Page 8 of 8