molex 63903-8900 User manual

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
mm
In.
mm
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.
Cut-off Tab Max.
Conductor Brush
(Contact side)
(Insulation side)
mm
In.
mm
In.
mm
In.
mm
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)
Degree (Max)
mm
In
mm
In
173041
3
3
5
10
1.90
.075
2.40
.095
173042
3
3
5
10
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
mm
In.
mm
In.
N
Lb.
173041
16
---
1.15-1.25
.045-.049
1.90-2.00
.075-.079
133.5
30.0
18
---
1.00-1.10
.039-.043
1.90-2.00
.075-.079
89.0
20.0
173042
16
---
1.15-1.25
.045-.049
1.90-2.00
.075-.079
133.5
30.0
18
---
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
mm
In.
mm
In.
173041
16
---
2.20
.087
2.50
.098
18
---
2.20
.087
2.50
.098
173042
16
---
2.20
.087
2.50
.098
18
---
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
63903-8970
Tool Kit (All “Y” Items)
REF
1
63457-0118
63457-0118
Conductor Punch
1 Y
2
63455-0136
63455-0136
Conductor Anvil
1 Y
3
63454-2405
63454-2405
Insulation Punch-Full R
1 Y
4
63456-2402
63456-2402
Insulation Anvil
1 Y
5
63443-0005
63443-0005
Cut-Off Plunger-Front
1 Y
6
63443-0003
63443-0003
Cut-Off Plunger-Rear
1 Y
7
63443-1402
63443-1402
Rear Cut-Off Die Blade
1 Y
8
63443-0012
63443-0012
Cut-off Plunger Retainer-Front
1 Y
9
63443-1004
63443-1004
Cut-off Plunger Retainer-Rear
1 Y
Other Components
10
11-17-0022
1739-21
Hold Down Spring
1
11
11-18-4083
60707-8
Feed Guide
1
12
11-24-1067
4996-4
Cut-Off Plunger Spring
2
13
63443-0009
63443-0009
Scrap Chute-Front
1
14
63443-0024
63443-0024
Key
1
15
63443-0090
63443-0090
Wire Stop
1
16
63443-0093
63443-0093
Shank
1
17
63443-1718
63443-1718
Height Spacer (18.80mm)
1
18
63443-2201
63443-2201
Spacer (1.0mm)
1
19
63443-2203
63443-2203
Spacer (3.0mm)
1
20
63443-2313
63443-2313
Spacer (3.65mm)
1
21
63443-2803
63443-2803
Front Plunger Striker
1
22
63443-2908
63443-2908
Striker Plunger
1
23
63443-3060
63443-3060
Rear Plunger Striker
1
24
63443-6111
63443-6111
Rear Cover
1
25
63903-8911
63903-8911
Terminal Hold Down
1
26
63466-0101
63466-0101
Scrap Chute-Rear
1
27
63600-1057
63600-1057
Striker Plunger Spring
1
Frame
28
63800-4901
63800-4901
Top
1
29
63801-3281
63801-3281
Base
1
30
63801-4650
63801-4650
Track
1
Hardware
31
N/A
N/A
M3 by 6 Long SHCS
2**
32
N/A
N/A
M3 by 6 Long FHCS
1**
33
N/A
N/A
M3 by 8 Long SHCS
1**
34
N/A
N/A
M4 by 6 Long SHCS
3**
35
N/A
N/A
M4 by 10 Long BHCS
2**
36
N/A
N/A
M4 by 12 Long BHCS
2**
37
N/A
N/A
M4 by 50 Long SHCS
2**
38
N/A
N/A
M5 by 12 Long SHCS
1**
39
N/A
N/A
#10-32 by 3/8”Long Flat Point SSS
1**
40
N/A
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
8
2
23
11
14
9
25
7
19
10
29
20
31
1
28
26
(3)
(2)
24
13
34
17
(2)
(2)
(2)
21
12
32
22
5
4
30
27
33
15
16
3
(2)
28
35
18
34
15
36
39
37
38
40
6
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.
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