Molex 63903-8900 Bedienungsanleitung

Fine Adjust Applicator for Poseidon II Terminals

Doc No: ATS-639038900 Release Date: 02-25-16 UNCONTROLLED COPY Page 1 of 6

Revision: A Revision Date: 02-25-16

CONDUCTOR BRUSH

STRIP LENGTH

CONDUCTOR

CRIMP

CUT-OFF

TAB

BELL MOUTH

BEND UP

TWISTING

ROLLING

BEND

DOWN

SEAM

INSULATION

CRIMP

Fine Adjust

Applicator

Application Tooling

Specification Sheet

Order No. 63903-8900

FEATURES

Directly adapts to most automatic wire processing machines

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

SCOPE

Products: Poseidon II Terminals, 16 AWG UL1061, 18 AWG UL1007 and 18 AWG UL1095 wires.

Terminal Series No.

Terminal Order No.

Wire Size

Insulation Diameter

Strip Length

AWG

mm2

In.

173041

173041-0001

16-18

---

1.90-2.05

.075-.081

3.18-3.80

.125-.150

173042

173042-0001

16-18

---

1.90-2.05

.075-.081

3.18-3.80

.125-.150

DEFINITION OF TERMS

The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the scope.

Fine Adjust Applicator for Poseidon II Terminals

Doc No: ATS-639038900 Release Date: 02-25-16 UNCONTROLLED COPY Page 2 of 6

Revision: A Revision Date: 02-25-16

CRIMP SPECIFICATIONS

Terminal Series No.

Bell mouth

Cut-off Tab Max.

Conductor Brush

(Contact side)

(Insulation side)

In.

173041

0.10-0.60

.004-.024

0.13

.005

0.30

.012

0.25-0.50

.010-.020

173042

0.10-0.60

.004-.024

0.13

.005

0.30

.012

0.25-0.50

.010-.020

To achieve the conductor brush specification, special care must be taken, or a light touch

must be maintained while presenting wire against the wire stop.

Terminal Series No.

Bend up Bend down

Twist Roll

Punch Width (Ref)

Conductor

Insulation

Degree (Max)

173041

1.90

.075

2.40

.095

173042

1.90

.075

2.40

.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.

Wire Size

Conductor

Pull Force Minimum

Crimp Height

Crimp Width

AWG

mm2

In.

Lb.

173041

---

1.15-1.25

.045-.049

1.90-2.00

.075-.079

133.5

30.0

---

1.00-1.10

.039-.043

1.90-2.00

.075-.079

89.0

20.0

173042

---

1.15-1.25

.045-.049

1.90-2.00

.075-.079

133.5

30.0

---

1.00-1.10

.039-.043

1.90-2.00

.075-.079

89.0

20.0

Terminal Series No.

Wire Size

Insulation

Crimp Height (Ref)

Crimp Width (Ref)

AWG

mm2

In.

173041

---

2.20

.087

2.50

.098

---

2.20

.087

2.50

.098

173042

---

2.20

.087

2.50

.098

---

2.20

.087

2.50

.098

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.

3. This terminal design will produce an insulation crimp shown in the Figure below:

16AWG INSULATION CRIMP

CONDITION

Fine Adjust Applicator for Poseidon II Terminals

Doc No: ATS-639038900 Release Date: 02-25-16 UNCONTROLLED COPY Page 3 of 6

Revision: A Revision Date: 02-25-16

WIRE STOP

Figure 1

ADJUST THE WIRE STOP AS

CLOSE AS POSSIBLE TO

THIS TERMINAL SURFACE

CONDUCTOR PUNCH

.13mm (.005”)

Maximum

Clearance

ADJUST WIRE STOP

Wire Stop Set-Up Positioning Procedure

In order to maintain the conductor brush within the specifications the following set-up procedure needs to be

followed.

1. Manually cycle the press until the press ram with the punches is in the full down position.

2. Adjust the wire stop blade down towards the terminal as close as possible to the terminal transitional surface.

See Figure 1.

3. Adjust the clearance between the wire stop blade and the conductor punch to.13mm (.005”) maximum.

4. Manually cycle the press until the press ram is in the full up position.

5. Manually cycle the press again, to make sure the terminals are feeding properly.

6. Power up the press and crimp terminals without wire to make sure they are feeding properly

7. Crimp terminals with wire and check for proper feeding.

WARNING

Never install or service this machine while connected to any electrical power source.

Disconnect power by unplugging the press from its power source.

Failure to observe this warning could result In severe injury or death.

Always hand cycle the applicator in the equipment to ensure the tooling is properly aligned.

Failure to observe these precautions may result in injury or property damage.

Fine Adjust Applicator for Poseidon II Terminals

Doc No: ATS-639038900 Release Date: 02-25-16 UNCONTROLLED COPY Page 4 of 6

Revision: A Revision Date: 02-25-16

PARTS LIST

FineAdjust Applicator 63903-8900

Item

Order No.

Engineering No.

Description

Quantity

Perishable Tooling

63903-8970

Tool Kit (All “Y” Items)

REF

63457-0118

Conductor Punch

1 Y

63455-0136

Conductor Anvil

1 Y

63454-2405

Insulation Punch-Full R

1 Y

63456-2402

Insulation Anvil

1 Y

63443-0005

Cut-Off Plunger-Front

1 Y

63443-0003

Cut-Off Plunger-Rear

1 Y

63443-1402

Rear Cut-Off Die Blade

1 Y

63443-0012

Cut-off Plunger Retainer-Front

1 Y

63443-1004

Cut-off Plunger Retainer-Rear

1 Y

Other Components

11-17-0022

1739-21

Hold Down Spring

11-18-4083

60707-8

Feed Guide

11-24-1067

4996-4

Cut-Off Plunger Spring

63443-0009

Scrap Chute-Front

63443-0024

Key

63443-0090

Wire Stop

63443-0093

Shank

63443-1718

Height Spacer (18.80mm)

63443-2201

Spacer (1.0mm)

63443-2203

Spacer (3.0mm)

63443-2313

Spacer (3.65mm)

63443-2803

Front Plunger Striker

63443-2908

Striker Plunger

63443-3060

Rear Plunger Striker

63443-6111

Rear Cover

63903-8911

Terminal Hold Down

63466-0101

Scrap Chute-Rear

63600-1057

Striker Plunger Spring

Frame

63800-4901

Top

63801-3281

Base

63801-4650

Track

Hardware

N/A

M3 by 6 Long SHCS

2**

N/A

M3 by 6 Long FHCS

1**

N/A

M3 by 8 Long SHCS

1**

N/A

M4 by 6 Long SHCS

3**

N/A

M4 by 10 Long BHCS

2**

N/A

M4 by 12 Long BHCS

2**

N/A

M4 by 50 Long SHCS

2**

N/A

M5 by 12 Long SHCS

1**

N/A

#10-32 by 3/8”Long Flat Point SSS

1**

N/A

#10-32 Hex Jam Nut

1**

** Available from an industrial supply company such as MSC (1-800-645-7270).

Fine Adjust Applicator for Poseidon II Terminals

Doc No: ATS-639038900 Release Date: 02-25-16 UNCONTROLLED COPY Page 5 of 6

Revision: A Revision Date: 02-25-16

Figure 1

(3)

(2)

Assembly Drawing

Fine Adjust Applicator for Poseidon II Terminals

Doc No: ATS-639038900 Release Date: 02-25-16 UNCONTROLLED COPY Page 6 of 6

Revision: A Revision Date: 02-25-16

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 Fine Adjust Manual.

CAUTION: This applicator should only be used in a press with a shut height of 135.8mm (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.

Visit our Web site at http://www.molex.com

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