63444-1609

FineAdjust for Mini-Fit  Crimp Terminals FineAdjust Applicator Application Tooling Specification Sheet Order No. 63900-2900 FEATURES





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 Directly adapts to most automatic wire processing machines SCOPE Products: Mini-Fit Jr. ™, Mini-Fit HCS™, and Mini-Fit Plus HCS™ Crimp Terminal 18-24 AWG with smaller insulation OD’s. Terminal Series No. 5556 5558 30490 44476 Terminal Order No. 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 Doc No: ATS-639002900 Revision: K Wire Size Insulation Diameter IPC/WHMA-A620 (1) Terminal (2) mm In. mm In. Strip Length AWG mm² mm In. 39-00-0055 39-00-0073 39-00-0114 39-00-0163 39-00-0175 39-00-0194 18-24 0.80-0.20 1.65-2.05 .065-.085 1.30-3.10 .051-.122 3.00-3.50 .118-.138 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 18-24 0.80-0.20 1.65-2.05 .065-.085 1.30-3.10 .051-.122 3.00-3.50 .118-.138 39-00-0427 39-00-0437 40-13-0853 30490-1002 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 0.80-0.50 1.65-2.05 .065-.085 1.30-3.10 .051-.122 3.00-3.50 .118-.138 Release Date: 08-13-07 Revision Date: 10-21-11 UNCONTROLLED COPY Page 1 of 6 FineAdjust for Mini-Fit  Crimp Terminals Insulation Diameter Strip Length IPC/WHMA-A620 (1) Terminal (2) AWG mm² mm In. mm In. mm In. 44478 44478-1111 44478-1211 18-20 0.80-0.50 1.65-2.05 .065-.085 1.30-3.10 .051-.122 3.00-3.50 .118-.138 44485-1211 44485-1311 44485 18-24 0.80-0.20 1.65-2.05 .065-.085 1.30-3.10 .051-.122 3.00-3.50 .118-.138 44485-1411 45750 45750-1111 45750-1211 18-20 0.80-0.50 1.65-2.05 .065-.085 1.65-2.95 .065-.116 3.00-3.50 .118-.138 46012-1111 46012-1141 46012 18-20 0.80-0.50 1.65-2.05 .065-.085 1.65-2.95 .065-.116 3.00-3.50 .118-.138 46012-1211 46012-1241 46018 46018-1541 18-20 0.80-0.50 1.65-2.05 .065-.085 1.65-2.95 .065-.116 3.00-3.50 .118-.138 46083-1111 46083-1121 46083 18-20 0.80-0.50 1.65-2.05 .065-.085 1.65-2.95 .065-.116 3.00-3.50 .118-.138 46083-1211 46083-1221 46098 46098-1541 18-20 0.80-0.50 1.65-2.05 .065-.085 1.65-2.95 .065-.116 3.00-3.50 .118-.138 46134-1111 46134-1121 46134 18-20 0.80-0.50 1.65-2.05 .065-.085 1.65-2.95 .065-.116 3.00-3.50 .118-.138 46134-1211 46134-1221 (1) To achieve optimum IPC-A620 insulation crimps, use this insulation OD range (example UL1007). (2) Overall insulation OD specification for terminal. Applicator 63900-2600 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. Terminal Series No. Terminal Order No. Wire Size BEND UP DEFINITION OF TERMS BELL MOUTH BRUSH CONDUCTOR CRIMP ROLLING SEAM INSULATION CRIMP TWISTING 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 and 5558 30490 44476, 44478 and 44485 45750 46012 and 46018 46083 46098 46134 Doc No: ATS-639002900 Revision: K Bell mouth mm In. 0.20-0.50 .008-.020 0.20-0.50 .008-.020 0.20-0.50 .008-.020 0.20-0.50 .008-.020 0.20-0.50 .008-.020 0.20-0.50 .008-.020 0.20-0.50 .008-.020 0.20-0.50 .008-.020 Release Date: 08-13-07 Revision Date: 10-21-11 Cut-off Tab Maximum mm In. 0.30 .012 0.30 .012 0.30 .012 0.30 .012 0.30 .012 0.30 .012 0.30 .012 0.30 .012 Conductor Brush mm In. 0.00-1.00 .000-.039 0.00-1.00 .000-.039 0.00-1.00 .000-.039 0.00-1.00 .000-.039 0.00-1.00 .000-.039 0.00-1.00 .000-.039 0.00-1.00 .000-.039 0.00-1.00 .000-.039 UNCONTROLLED COPY Page 2 of 6 FineAdjust for Mini-Fit  Crimp Terminals Bend up Terminal Series No. Bend down Twist Degree 5556 and 5558 30490 44476, 44478 and 44485 45750 46012 and 46018 46083 46098 46134 5 5 5 5 5 5 5 5 Roll Degree 5 15 5 15 5 15 5 15 5 15 5 15 5 15 5 15 2 2 2 2 2 2 2 2 Punch Width (Ref) Conductor Insulation mm In. mm In. 1.60 .063 2.00 .079 1.60 .063 2.00 .079 1.60 .063 2.00 .079 1.60 .063 2.00 .079 1.60 .063 2.00 .079 1.60 .063 2.00 .079 1.60 .063 2.00 .079 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. 5556 5558 30490 44476 44478 44485 45750 46012 46018 46083 46098 46134 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 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: ATS-639002900 Revision: K Release Date: 08-13-07 Revision Date: 10-21-11 UNCONTROLLED COPY Page 3 of 6 FineAdjust for Mini-Fit  Crimp Terminals PARTS LIST FineAdjust Applicator 63900-2900 Item Order No Engineering No. Description Quantity Perishable Tooling 63900-2970 63900-2970 Tool Kit (All “Y” Items) REF 1 63444-1609 63444-1609 Conductor Punch 1Y 2 63445-1646 63445-1646 Conductor Anvil 1Y 3 63446-2001 63446-2001 Insulation Punch 1Y 4 63445-2005 63445-2005 Insulation Anvil 1Y 5 63443-0002 63443-0002 Front Cut-Off Plunger 1Y 6 63443-0012 63443-0012 Front Plunger Retainer 1Y Other Components 7 11-18-4083 60707-8 Feed Guide 1 8 11-24-1067 4996-4 Cut-Off Plunger Spring 1 9 63443-0009 63443-0009 Front Scrap Chute 1 10 63443-0024 63443-0024 Key 1 11 63443-0090 63443-0090 Wire Stop 1 12 63443-1717 63443-1717 Height Spacer 1 13 63443-2216 63443-2216 Coarse Spacer (16.00mm) 1 14 63443-2302 63443-2302 Fine Spacer (3.10mm) 1 15 63443-2802 63443-2802 Plunger Striker 1 16 63443-2907 63443-2907 Wire Hold Down Plunger 1 17 63443-6111 63443-6111 Rear Cover 1 18 63600-1057 63600-1057 Compression Spring 1 Frame 19 63800-4901 63800-4901 Top 1 20 63801-3281 63801-3281 Base 1 21 63801-4650 63801-4650 Track 1 Hardware 22 N/A N/A M3 by 6 Long SHCS 2** 23 N/A N/A M3 by 6 Long FHCS 1** 24 N/A N/A M4 by 6 Long SHCS 2** 25 N/A N/A M4 by 12 Long BHCS 2** 26 N/A N/A M4 by 50 Long SHCS 2** 27 N/A N/A M5 by 12 Long SHCS 1** 28 N/A N/A #10-32 by 3/8”Long Flat Point SSS 1** 29 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-639002900 Revision: K Release Date: 08-13-07 Revision Date: 10-21-11 UNCONTROLLED COPY Page 4 of 6 FineAdjust for Mini-Fit  Crimp Terminals Assembly Drawing 19 28 29 3 18 15 1 25 (2) 16 17 19 21 22 (2) 20 11 7 27 5 24 2 8 4 13 14 6 11 12 10 Figure 1 23 26 (2) Doc No: ATS-639002900 Revision: K 9 24 Release Date: 08-13-07 Revision Date: 10-21-11 UNCONTROLLED COPY Page 5 of 6 FineAdjust for Mini-Fit  Crimp 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 135.80 mm (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. http://www.molex.com Doc No: ATS-639002900 Revision: K Release Date: 08-13-07 Revision Date: 10-21-11 UNCONTROLLED COPY Page 6 of 6