0639029400

Fine Adjust Applicator for 6.0 W/W Plug Terminals FineAdjust Applicator Application Tooling Specification Sheet Order No. 63902-9400 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: 6.0 W/W Plug Terminals, 18-20 AWG (UL1007) wires. Wire Size and Type ♦Insulation Diameter Strip Length AWG mm² Type mm In. mm In. 35040 35040-9802 18-20 0.82-0.52 UL1007 1.60-2.10 .063-.083 4.20-5.00 .165-.197 ♦ For 18-20 AWG (UL1015) with Insulation Diameter 2.20-2.90mm (.087”-.114”) Use Applicator 63902-9300 Terminal Series No. Terminal Order No. DEFINITION OF TERMS BEND UP STRIP LENGTH TWISTING BRUSH BELL MOUTH ROLLING SEAM BEND DOWN CUT-OFF TAB CONDUCTOR CRIMP HEIGHT WIRE Doc No: ATS-639029400 Revision: A Release Date: 11-05-13 Revision Date: 11-05-13 INSULATION CRIMP HEIGHT UNCONTROLLED COPY Page 1 of 5 Fine Adjust Applicator for 6.0 W/W Plug Terminals CRIMP SPECIFICATION Terminal Series No. 35040 Terminal Series No. 35040 Bell mouth mm In. 0.20-0.50 .008-.020 Cut-off Tab Maximum mm In. 0.20 .008 Conductor Brush mm In. 0.00-1.00 .000-.039 Degree (Max) Degree (Max) Punch Width (Ref) Conductor Insulation mm In mm In 3 3 2.40 Bend up Bend down 3 Twist Roll 5 .095 2.50 .098 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. 35040 Wire Size AWG mm2 18 0.82 20 0.52 Terminal Series No. 35040 Conductor Crimp Height mm In. 1.33-1.40 .052-.055 1.25-1.32 .049-.052 Wire Size AWG mm2 18 0.82 20 0.52 Conductor Crimp Width (Max) mm In. 2.50 .098 2.50 .098 Insulation Crimp Height (Max) mm In. 3.00 .118 2.80 .110 Pull Force Minimum N Lb. 107.8 24.3 58.8 13.2 Insulation Crimp Width (Max) mm In. 2.60 .102 2.60 .102 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-639029400 Revision: A Release Date: 11-05-13 Revision Date: 11-05-13 UNCONTROLLED COPY Page 2 of 5 Fine Adjust Applicator for 6.0 W/W Plug Terminals PARTS LIST FineAdjust Applicator 63902-9400 Item Order No Engineering No. Description Quantity Perishable Tooling 63902-9470 63902-9470 Tool Kit (All “Y” Items) REF 1 63444-2425 63444-2425 Conductor Punch 1Y 2 63445-2443 63445-2443 Conductor Anvil 1Y 3 63446-2519 63446-2519 Insulation Punch 1Y 4 63445-2533 63445-2533 Insulation Anvil 1Y 5 63443-0005 63443-0005 Front Cut-Off Plunger 1Y 6 63443-0012 63443-0012 Front Plunger Retainer 1Y Other Components 7 11-17-0022 1739-21 Hold Down Spring 1 8 11-18-4083 60707-8 Feed Guide 1 9 11-24-1067 4996-4 Cut-Off Plunger Spring 1 10 63443-0009 63443-0009 Front Scrap Chute 1 11 63443-0024 63443-0024 Key 1 12 63443-0090 63443-0090 Wire Stop 1 13 63443-0093 63443-0093 Shank 1 14 63443-1717 63443-1717 18.70mm Height Spacer 1 15 63443-2214 63443-2214 14.00mm Spacer 1 16 63443-2317 63443-2317 3.85mm Spacer 1 17 63443-2802 63443-2802 Front Plunger Striker 1 18 63443-2915 63443-2915 Striker Plunger 1 19 63443-6119 63443-6119 Rear Cover 1 20 63443-7120 63443-7120 Terminal Hold Down 1 21 63600-0021 63600-0021 Striker 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 Hardware 25 N/A N/A M3 by 6 Long SHCS 2** 26 N/A N/A M3 by 6 Long FHCS 1** 27 N/A N/A M3 by 8 Long SHCS 1** 28 N/A N/A M4 by 6 Long SHCS 2** 29 N/A N/A M4 by 12 Long BHCS 2** 30 N/A N/A M4 by 50 Long SHCS 2** 31 N/A N/A M5 by 12 Lg SHCS 1** 32 N/A N/A #10-32 by 3/8”Long Flat Point SSS 1** 33 N/A N/A #10-32 Hex Jam Nut 1** ** Available from an industrial supply company such as MSC (1-800-645-7270). Doc No: ATS-639029400 Revision: A Release Date: 11-05-13 Revision Date: 11-05-13 UNCONTROLLED COPY Page 3 of 5 Fine Adjust Applicator for 6.0 W/W Plug Terminals Assembly Drawing 22 32 33 7 3 13 21 17 1 27 29 (2) 20 18 19 22 24 (2) 23 25 12 8 31 28 5 2 4 15 9 16 12 14 6 11 Figure 1 26 30 (2) Doc No: ATS-639029400 Revision: A 10 28 Release Date: 11-05-13 Revision Date: 11-05-13 UNCONTROLLED COPY Page 4 of 5 Fine Adjust Applicator for 6.0 W/W Plug Terminals 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 135.8mm (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 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-639029400 Revision: A Release Date: 11-05-13 Revision Date: 11-05-13 UNCONTROLLED COPY Page 5 of 5