Fine Adjust Applicator for KK® Crimp Terminal
FineAdjust Applicator
Specification Sheet
Order No. 63900-7300
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: KK®, 3.96mm (.156") Pitch Crimp Terminal, 18-24 AWG.
Note:
Special cut-off tab width for 2478 Series terminals using the
7241 Series IDT housing
only.
2478 Series terminals are not rated for USCAR21 compliancy.
Terminal
Series No.
Terminal Order No.
Wire Size
AWG
mm²
Insulation Diameter
mm
In.
Strip Length
mm
In.
2478
08-50-0001 08-52-0114 39-00-0103
08-50-0015 08-52-0811 39-00-0133
08-50-0063 08-53-0811 39-00-0286
08-50-0073 08-55-0103 39-00-0343
08-50-0105 08-55-0133 39-00-0345
2.79
.110
2.54-3.18
08-50-0119 08-56-0105 39-00-0347 18 - 24 0.80-0.20
08-50-0146 08-56-0153 39-00-0349
08-50-0271 08-58-0103 40-01-1118
08-50-0281 08-58-0114 50-29-1689
08-52-0071 08-58-0121 50-29-1768
08-52-0073 08-65-0114
Insulation below 1.65mm (.065 inch) diameter may produce loose insulation crimps.
.100-.125
Doc No: ATS-639007300
Revision: B
Release Date: 04-20-10
Revision Date: 04-27-10
UNCONTROLLED COPY
Page 1 of 5
Fine Adjust Applicator for KK® Crimp Terminal
DEFINITION OF TERMS
CONDUCTOR CRIMP
LOCKING TANG
HEIGHT
INSULATION CRIMP
CUT-OFF TAB
TERMINAL
LOCATION
BEND UP
C/L
BRUSH
BELL
MOUTH
SEAM
ROLLING
TWISTING
STRIP LENGTH
CUT-OFF
TAB
CRIMP HEIGHT
BEND
DOWN
C/L
Terminal is to be centrally located between the two (2) cut-off edges, within +/- 0.13mm (+/-.005”).
CRIMP SPECIFICATIONS
Terminal Series No.
2478
Terminal
Series No.
2478
Bell mouth
mm
In.
0.20-0.50 .008-.020
Cut-off Tab
mm
In.
3.02±.13 .119±.005
Conductor Brush
mm
In.
0.13-0.64 .005-.025
Locking Tang Height Bend up Bend down Twist Roll
mm
0.64-0.76
In
.025-.030
3
Degree
3
Degree
4
8
Punch Width (Ref)
Seam
Conductor Insulation
Seam shall not be open
mm In mm In
and no wire allowed out
of the crimping area
2.00 .079 2.50 .098
After crimping, the conductor profile should measure the following.
Terminal Series No.
Wire Size
Crimp Height
Pull Force Minimum
2
AWG mm
mm
In.
N
Lb.
2478
18 0.80 1.09-1.14 .043-.045
110
25
08-52-0071
18 0.81 1.07-1.17 .042-.046
110
25
2478
20 0.50 1.02-1.09 .040-.043
66
15
2478
22 0.35 0.97-1.02 .038-.040
44
10
2478
24 0.20 0.91-0.97 .036-.038
35
8
Special for use with 18 AWG UL1015, 16 strand (.010”) diameter wire only.
0.81mm
2
.254mm
Pull Force should be measured with no influence from the insulation crimp.
The above specifications are guidelines to an optimum crimp.
Doc No: ATS-639007300
Revision: B
Release Date: 04-20-10
Revision Date: 04-27-10
UNCONTROLLED COPY
Page 2 of 5
Fine Adjust Applicator for KK® Crimp Terminal
PARTS LIST
FineAdjust Applicator 63900-7300
Item No. Order No. Engineering No.
Description
Quantity
Perishable Tooling
63900-7370
63900-7370
Tool Kit (All “Y” Items)
REF
1
63444-2013
63444-2013
Conductor Punch
1Y
2
63445-2043
63445-2043
Conductor Anvil
1Y
3
63454-0005
63454-0005
Insulation Punch
1Y
4
63445-2566
63445-2566
Insulation Anvil
1Y
5
63443-3314
63443-3314
Cut-Off Die
1Y
6
63443-3418
63443-3418
Cut-Off Punch
1Y
Other Components
7
11-18-4103
60712-3
Cover Plate
1
8
11-18-5015
60805A122
Front Cover
1
9
63443-0025
63443-0025
Key (Dual Carrier)
1
10
63443-1214
63443-1214
Cut-Off Plunger Retainer
1
11
63443-1202
63443-1202
Guide Block
1
12
63443-1203
63443-1203
Rear Cover Retainer
1
13
63443-1204
63443-1204
Wire Stop
1
14
63443-1210
63443-1210
Wire Stop Mounting Bracket
1
15
63443-2310
63443-2310
3.50mm Spacer
1
16
63443-2801
63443-2801
Front Plunger Striker
1
17
63443-2912
63443-2912
Wire Hold-Down Plunger
1
18
63443-3514
63443-3514
Terminal Lifter
1
19
63600-0021
63600-0021
Compression Spring
1
20
63600-2995
63600-2995
Spring Lifter
1
21
63700-0539
63700-0539
Compression Spring
1
22
63820-0012
63820-0012
Terminal Drag Cover
1
Frame
23
63800-4901
63800-4901
Top
1
24
63801-3285
63801-3285
Base
1
25
63801-6550
63801-6550
Track
1
Hardware
26
N/A
N/A
M2.5 by 5 Long SHCS
2**
27
N/A
N/A
M3 by 5 Long SHCS
3**
28
N/A
N/A
M3 by 6 Long FHCS
1**
29
N/A
N/A
M3 by 6 Long SHCS
4**
30
N/A
N/A
M3 by 12 Long SHCS
1**
31
N/A
N/A
M4 by 6 Long SHCS
2**
32
N/A
N/A
M4 by 12 Long BHCS
2**
33
N/A
N/A
M4 by 45 Long SHCS
2**
34
N/A
N/A
#10-32 by 3/8”Long SSS (Flat Point)
1**
35
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-639007300
Revision: B
Release Date: 04-20-10
Revision Date: 04-27-10
UNCONTROLLED COPY
Page 3 of 5
Fine Adjust Applicator for KK® Crimp Terminal
Assembly Drawing
34
35
32
(2)
16
17
1
23
7
3
19
30
11
22
29
(2)
25
23
(2) 27
29
13
(2) 26
14
(2)
24
6
27
31 (2)
18
10
12
8
15
20
5
4
33 (2)
2
21
28
9
Figure 1
Doc No: ATS-639007300
Revision: B
Release Date: 04-20-10
Revision Date: 04-27-10
UNCONTROLLED COPY
Page 4 of 5
Fine Adjust Applicator for KK® Crimp Terminal
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 135.8 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.
Americas Headquarters
Lisle, Illinois 60532 U.S.A.
1-800-78MOLEX
amerinfo@molex.com
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Yamato, Kanagawa, Japan
81-462-65-2324
feninfo@molex.com
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Jurong, Singapore
65-6-268-6868
fesinfo@molex.com
European Headquarters
Munich, Germany
49-89-413092-0
eurinfo@molex.com
Corporate Headquarters
2222 Wellington Ct.
Lisle, IL 60532 U.S.A.
630-969-4550
Fax: 630-969-1352
Visit our Web site at http://www.molex.com
Doc No: ATS-639007300
Revision: B
Release Date: 04-20-10
Revision Date: 04-27-10
UNCONTROLLED COPY
Page 5 of 5
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