0639044600 Appl Tooling Spec Datasheet by Molex

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Products:
FineAdjust Applicator for 3.96mm (.156”) Pitch SPOX Crimp Terminal
Doc No: ATS-639044600 Release Date: 04-11-17
UNCONTROLLED COPY
Page 1 of 5
Revision: A Revision Date: 04-11-17
FineAdjust
Applicator
Application Tooling
Specification Sheet
Order No. 63904-4600
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: 3.96mm (.156”) Pitch SPOX Crimp Terminal, 18-24 AWG, UL1007 wires.
Terminal
Series No.
Terminal Order No. Wire Size
Insulation Diameter
Strip Length
IPC/WHMA
-
A620 (1)
Terminal (2)
mm
2
mm
In.
mm
In.
mm
In.
5194
08
-
70
-
1031
39
-
00
-
0416
18-24 N/A 1.70-2.10
.067-.083 1.30-3.00
.051-.118
3.00-3.50
.118-.138
3
9
-
00
-
0409
39
-
00
-
0021
(1)
To achieve optimum IPC
-
A620 insulations crimps, use this insulation OD range.
(2) Overall insulation OD specification for terminal.
(3) Other applicators may be available for insulation diameters outside the optimum range (1) described above. Enter the
Terminal Order Number on the Molex website for the latest applicator information.
DEFINITION OF TERMS
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the scope.
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
BELL MOUTH
COND
UCTOR
CRIMP
HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
CUT
-
OFF TAB
SEAM
Tool Qualification Notes:
FineAdjust Applicator for 3.96mm (.156”) Pitch SPOX Crimp Terminal
Doc No: ATS-639044600 Release Date: 04-11-17 UNCONTROLLED COPY Page 2 of 5
Revision: A Revision Date: 04-11-17
CRIMP SPECIFICATION
Terminal
Series No.
Bell Mouth
Cut
-
O
ff Tab Maximum
Conductor Brush
mm
In.
mm
In.
mm
In.
5194
0.20
-
0.70
.008
-
.028
0.40
.016
0.00
-
1.00
.000
-
.039
Terminal Series No.
Bend Up
Bend
D
own
Twist
Roll
Punch Width mm (Ref)
Seam
Degree Degree
Conductor
Insulation
mm
In
mm
In
5194 6 0 3 8 1.60 .063 2.50 .098
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 Crimp
Pull Force
Minimum
Height
Width (Ref.)
mm
2
mm
In.
mm
In.
N
Lb.
5194
18
N
/
A
1.10
-
1.20
.043
-
.047
1.60
.063
88.1
19.80
20
N
/
A
1.07
-
1.17
.042
-
.046
1.60
.063
58.7
13.20
22
N
/
A
0.96
-
1.06
.038
-
.042
1.60
.063
39.1
8.80
24
N
/
A
0.90
-
1.00
.035
-
.039
1.60
.063
29.4
6.60
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. Insulation crimp heights (Ref.) can be adjusted accordingly based on the actual wire OD used to achieve
optimum IPC-A620 insulation crimps.
Insulation Crimp Note:
Due to the terminal’s insulation grip design and/or insulation
diameter range, this applicator uses “overlap” form geometry
in the insulation punch. This produces an overlap insulation
crimp (A620-compliant). While the insulation punch profile
may appear “lopsided,” this is a normal condition. See figure
to the right.
PUNCH
OVERLAP FORM
GEOMETRY
ANVIL
WIRE
OVERLAP
INSULATION CRIMP
FineAdjust Applicator for 3.96mm (.156”) Pitch SPOX Crimp Terminal
Doc No: ATS-639044600 Release Date: 04-11-17 UNCONTROLLED COPY Page 3 of 5
Revision: A Revision Date: 04-11-17
PARTS LIST
FineAdjust Applicator
63904
-
46
00
Item Order No. Engineering No. Description Quantity
Perishable Tooling
63904
-
4670
63904
-
4670
Tool Kit (All “Y” Items)
REF
1
63444
-
1605
63444
-
1605
Conductor Punch
1 Y
2
63445
-
1641
63445
-
1641
Conductor Anvil
1 Y
3
63454
-
2507
63454
-
2507
Insulation Punch
1 Y
4
63456
-
2503
63456
-
2503
Insulation Anvil
1 Y
5
63443
-
0005
63443
-
0005
Front Cut
-
Off Plunger
1 Y
6
63443
-
0012
63443
-
0012
Front Plunger Retainer
1 Y
Other Components
7
11
-
18
-
4083
60707
-
8
Feed Guide
1
8
11
-
24
-
1067
4996
-
4
Cut
-
Off Plunger Spring
1
9
11
-
40
-
4039
8302
-
5
Plunger Striker
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
-
171
9
63443
-
171
9
18.
9
0mm Height Spacer
1
14
63443
-
2216
63443
-
2216
16.00mm Coarse Spacer
1
15
63443
-
2302
63443
-
2302
3.10mm Fine Spacer
1
16
63443
-
6111
63443
-
6111
Rear Cover
1
Frame
17
63800
-
4901
63800
-
4901
Top
1
18
63801
-
3281
63801
-
3281
Base
1
19
63801
-
4650
63801
-
4650
Track
1
Hardware
20
N/A
N/A
M3 by 6 Long SHCS
2**
21
N/A
N/A
M3 by 6 Long FHCS
1**
22
N/A
N/A
M4 by 6 Long SHCS
2**
23
N/A
N/A
M4 by 12 Long BHCS
2**
24
N/A
N/A
M4 by 50 Long SHCS
2**
25
N/A
N/A
M5 by 12 Long SHCS
1**
26
N/A
N/A
#10
-
32 by 3/8”Long Flat Point SSS
1**
27
N/A
N/A
#10
-
32 Hex Jam Nut
1**
** Available from an industrial supply company such as MSC (1
-
800
-
645
-
7270).
FineAdjust Applicator for 3.96mm (.156”) Pitch SPOX Crimp Terminal
Doc No: ATS-639044600 Release Date: 04-11-17 UNCONTROLLED COPY Page 4 of 5
Revision: A Revision Date: 04-11-17
Figure 1
26
23
10
17
1
3
17
27
16
5
20
6
7
8
19
18
25
22
12
24
21
4
(2)
(2)
9
12
(2)
22
14
15
13
11
2
Assembly Drawing
FineAdjust Applicator for 3.96mm (.156”) Pitch SPOX Crimp Terminal
Doc No: ATS-639044600 Release Date: 04-11-17 UNCONTROLLED COPY Page 5 of 5
Revision: A Revision Date: 04-11-17
NOTES
1. Molex recommends that 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 the 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 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.
Application Tooling Support
Phone: +1-402-458-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.

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