0634562003

FineAdjust Applicator for Mini-Fit Crimp Terminals Order Number 63904-8000 Application Tooling Specification 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 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 .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: Mini-Fit Jr., Mini-Fit HCS and Mini-Fit Plus HCS Crimp Terminals, 18-24 AWG with smaller insulation ODs. Terminal Series No. 5556 5558 30490 44476 44478 44485 45750 46012 46018 46083 Terminal Order No. Wire Size AWG 39-00-0038 39-00-0059 39-00-0108 39-00-0153 39-00-0169 39-00-0181 39-00-0200 39-00-0213 39-00-0407 39-00-0419 39-00-0428 39-00-0440 39-00-0040 39-00-0061 39-00-0120 39-00-0126 39-00-0411 39-00-0426 39-00-0430 40-01-0853 98-00-0174 30490-0002 30490-2002 44476-1111 44478-1111 44485-1211 44485-1411 45750-1111 46012-1111 46012-1211 46018-1541 46083-1111 46083-1211 Doc. No: 639048000 Revision: B 39-00-0055 39-00-0073 39-00-0114 39-00-0163 39-00-0175 39-00-0194 39-00-0207 39-00-0405 39-00-0410 39-00-0425 39-00-0436 40-13-0851 39-00-0053 39-00-0075 39-00-0121 39-00-0219 39-00-0420 39-00-0427 39-00-0437 40-13-0853 mm² Insulation Diameter IPC/WHMA-A-620 Terminal (2) (1) mm In. mm In. Strip Length mm In. 18-24 0.80-0.20 1.65-2.05 .065-.085 1.30-3.10 .051-.122 3.00-3.50 .118-.138 18-24 0.80-0.20 1.65-2.05 .065-.085 1.30-3.10 .051-.122 3.00-3.50 .118-.138 18-24 0.80-0.20 1.65-2.05 .065-.085 1.30-3.10 .051-.122 3.00-3.50 .118-.138 44476-1211 18-20 44478-1211 18-20 44485-1311 18-24 0.80-0.50 1.65-2.05 .065-.085 0.80-0.50 1.65-2.05 .065-.085 1.30-3.10 1.30-3.10 .051-.122 .051-.122 3.00-3.50 3.00-3.50 .118-.138 .118-.138 0.80-0.20 1.65-2.05 .065-.085 1.30-3.10 .051-.122 3.00-3.50 .118-.138 45750-1211 18-20 46012-1141 18-20 46012-1241 18-20 46083-1121 18-20 46083-1221 0.80-0.50 1.65-2.05 .065-.085 1.65-2.95 .065-.116 3.00-3.50 .118-.138 0.80-0.50 1.65-2.05 .065-.085 1.65-2.95 .065-.116 3.00-3.50 .118-.138 0.80-0.50 1.65-2.05 .065-.085 1.65-2.95 .065-.116 3.00-3.50 .118-.138 0.80-0.50 1.65-2.05 .065-.085 1.65-2.95 .065-.116 3.00-3.50 .118-.138 30490-1002 Release Date: 05-16-19 Revision Date: 07-30-19 UNCONTROLLED COPY Page 1 of 6 FineAdjust Applicator for Mini-Fit Crimp Terminals Terminal Series No. 46098 46134 Terminal Order No. Insulation Diameter IPC/WHMA-A-620 Terminal (2) (1) 2 mm mm In. mm In. 0.80-0.50 1.65-2.05 .065-.085 1.65-2.95 .065-.116 mm In. 3.00-3.50 .118-.138 0.80-0.50 1.65-2.05 3.00-3.50 .118-.138 Wire Size AWG 46098-1541 18-20 46134-1111 46134-1121 18-20 46134-1211 46134-1221 .065-.085 1.65-2.95 .065-.116 Strip Length (1) To achieve optimum IPC/WHMA-A-620 insulation crimps, use this insulation OD range (example UL1007). (2) Overall insulation OD specification for terminal. Applicator 63904-7800 should be used for insulation OD 2.50-2.95mm (example UL1015). Applicator 63901-5600 should be used for insulation OD 1.90-2.30mm. Applicator 63902-3900 should be used for insulation OD 1.40-1.70mm. Applicator 63902-4900 should be used for insulation OD 2.30-2.60mm. DEFINITION OF TERMS BEND UP BELL MOUTH BRUSH CONDUCTOR CRIMP ROLL SEAM INSULATION CRIMP TWIST STRIP LENGTH BEND DOWN CUT-OFF TAB CRIMP HEIGHT The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the scope. CRIMP SPECIFICATION Terminal Series No. 5556 5558 30490 44476 44478 44485 45750 46012 46018 46083 46098 46134 Doc. No: 639048000 Revision: B Bell Mouth Cut-Off Tab Maximum mm In. mm In. 0.20-0.50 .008-.020 0.30 0.20-0.50 .008-.020 0.20-0.50 Conductor Brush mm In. .012 0.00-1.00 .000-.039 0.30 .012 0.00-1.00 .000-.039 .008-.020 0.30 .012 0.00-1.00 .000-.039 0.20-0.50 .008-.020 0.30 .012 0.00-1.00 .000-.039 0.20-0.50 .008-.020 0.30 .012 0.00-1.00 .000-.039 0.20-0.50 .008-.020 0.30 .012 0.00-1.00 .000-.039 0.20-0.50 .008-.020 0.30 .012 0.00-1.00 .000-.039 Release Date: 05-16-19 Revision Date: 07-30-19 UNCONTROLLED COPY Page 2 of 6 FineAdjust Applicator for Mini-Fit Crimp Terminals Degree Punch Width (Ref) Conductor Insulation mm In. mm In. Bend Up Bend Down Twist Terminal Series No. Degree 5556 5558 30490 44476 44478 44485 45750 46012 46018 46083 46098 46134 Roll 5 2 5 15 1.60 .063 2.00 .079 5 2 5 15 1.60 .063 2.00 .079 5 2 5 15 1.60 .063 2.00 .079 5 2 5 15 1.60 .063 2.00 .079 5 2 5 15 1.60 .063 2.00 .079 5 2 5 15 1.60 .063 2.00 .079 5 2 5 15 1.60 .063 2.00 .079 Seam Seam shall not be open and no wire allowed out of the crimping area After crimping, the crimp profiles should measure the following: Terminal Series No. Wire Size AWG 18 20 22 24 18 20 22 24 18 20 22 24 18 20 18 20 18 20 22 24 18 20 18 20 18 20 18 20 18 20 18 20 5556 5558 30490 44476 44478 44485 45750 46012 46018 46083 46098 46134 mm2 0.80 0.50 0.35 0.20 0.80 0.50 0.35 0.20 0.80 0.50 0.35 0.20 0.80 0.50 0.80 0.50 0.80 0.50 0.35 0.20 0.80 0.50 0.80 0.50 0.80 0.50 0.80 0.50 0.80 0.50 0.80 0.50 Conductor Crimp Height Crimp Width (Ref) mm In. mm In. 0.97-1.07 .038-.042 1.68 .066 0.95-1.04 .037-.041 1.66 .065 0.85-0.94 .033-.037 1.65 .065 0.79-0.87 .031-.034 1.63 .064 0.97-1.07 .038-.042 1.68 .066 0.95-1.04 .037-.041 1.66 .065 0.85-0.94 .033-.037 1.65 .065 0.79-0.87 .031-.034 1.63 .064 0.97-1.07 .038-.042 1.68 .066 0.95-1.04 .037-.041 1.66 .065 0.85-0.94 .033-.037 1.65 .065 0.79-0.87 .031-.034 1.63 .064 0.97-1.07 .038-.042 1.68 .066 0.95-1.04 .037-.041 1.66 .065 0.97-1.07 .038-.042 1.68 .066 0.95-1.04 .037-.041 1.66 .065 0.97-1.07 .038-.042 1.68 .066 0.95-1.04 .037-.041 1.66 .065 0.85-0.94 .033-.037 1.65 .065 0.79-0.87 .031-.034 1.63 .064 0.97-1.07 .038-.042 1.68 .066 0.84-0.94 .033-.037 1.66 .065 0.97-1.07 .038-.042 1.68 .066 0.84-0.94 .033-.037 1.66 .065 0.97-1.07 .038-.042 1.68 .066 0.84-0.94 .033-.037 1.66 .065 0.97-1.07 .038-.042 1.68 .066 0.84-0.94 .033-.037 1.66 .065 0.97-1.07 .038-.042 1.68 .066 0.84-0.94 .033-.037 1.66 .065 0.97-1.07 .038-.042 1.68 .066 0.84-0.94 .033-.037 1.66 .065 Pull Force Minimum N Lb. 88.0 19.8 58.7 13.2 39.1 8.8 29.3 6.6 88.0 19.8 58.7 13.2 39.1 8.8 29.3 6.6 88.0 19.8 58.7 13.2 39.1 8.8 29.3 6.6 68.4 15.4 58.7 13.2 68.4 15.4 58.7 13.2 88.0 19.8 58.7 13.2 39.1 8.8 29.3 6.6 68.4 15.4 58.7 13.2 68.4 15.4 58.7 13.2 68.4 15.4 58.7 13.2 68.4 15.4 58.7 13.2 68.4 15.4 58.7 13.2 68.4 15.4 58.7 13.2 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: 639048000 Revision: B Release Date: 05-16-19 Revision Date: 07-30-19 UNCONTROLLED COPY Page 3 of 6 FineAdjust Applicator for Mini-Fit Crimp Terminals PARTS LIST Item Order No. 1 2 3 4 5 6 63904-8070 63444-1609 63455-1607 63446-2001 63456-2003 63443-0002 63443-0012 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 11-17-0022 11-18-4083 11-24-1067 63443-0009 63443-0024 63443-0090 63443-0093 63443-1717 63443-2215 63443-2314 63443-2802 63443-2907 63443-6111 63443-7143 63600-1057 22 23 24 63800-4901 63801-3281 63801-4650 25 26 27 28 29 30 31 32 33 — — — — — — — — — Doc. No: 639048000 Revision: B FineAdjust Applicator 63904-8000 Engineering No. Description Perishable Tooling 63904-8070 Tool Kit (All “Y” Items) 63444-1609 Conductor Punch 63455-1607 Conductor Anvil 63446-2001 Insulation Punch 63456-2003 Insulation Anvil 63443-0002 Front Cut-Off Plunger 63443-0012 Front Plunger Retainer Other Components 1739-21 Hold Down Spring 60707-8 Feed Guide 4996-4 Cut-Off Plunger Spring 63443-0009 Front Scrap Chute 63443-0024 Key 63443-0090 Wire Stop 63443-0093 Hold Down Shank 63443-1717 Height Spacer 63443-2215 Coarse Spacer (15.00mm) 63443-2314 Fine Spacer (3.70mm) 63443-2802 Plunger Striker 63443-2907 Wire Hold Down Plunger 63443-6111 Rear Cover 63443-7143 Terminal Hold Down 63600-1057 Compression Spring Frame 63800-4901 Top 63801-3281 Base 63801-4650 Track Hardware — M3 by 6 Long SHCS — M3 by 6 Long FHCS — M3 by 8 Long SHCS — M4 by 6 Long SHCS — M4 by 12 Long BHCS — M4 by 50 Long SHCS — M5 by 12 Long SHCS — #10-32 by 3/8”Long Flat Point SSS — #10-32 Hex Jam Nut * Available from an industrial supply company. Release Date: 05-16-19 Revision Date: 07-30-19 UNCONTROLLED COPY 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 2* 1* 1* 2* 2* 2* 1* 1* 1* Page 4 of 6 FineAdjust Applicator for Mini-Fit Crimp Terminals ASSEMBLY DRAWING 22 32 33 1 7 3 13 21 17 27 20 18 29 (2) 22 24 19 25 (2) 23 12 8 31 16 28 14 5 2 4 15 9 12 6 11 26 Figure 1 28 30 (2) Doc. No: 639048000 Revision: B 10 Release Date: 05-16-19 Revision Date: 07-30-19 UNCONTROLLED COPY Page 5 of 6 FineAdjust Applicator for Mini-Fit Crimp Terminals 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 FineAdjust manual. 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 wire-processing 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. 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: 639048000 Revision: B Release Date: 05-16-19 Revision Date: 07-30-19 UNCONTROLLED COPY Page 6 of 6