Exact source leads
Red BU-0061-M-39-2 and black BU-0061-M-39-0 are 39-inch, 18 AWG shrouded-banana leads. Their tin-dipped tips are sacrificial.
Still not permission to build or connect
Exact tooling candidates remove purchase ambiguity; they do not replace received calibration, sample-fit checks, coupon results, qualified review or a signed connection procedure.
Point-to-point assembly drawing
Measured crimp and pull
342-271-30 measures the 1.00-1.10 mm crimp. WT-205M + CERT applies the axial pull at 25 +/-6 mm/min; the coupon must exceed 88.0 N.
Controlled wire preparation
95 11 165 removes the entire dipped segment. 12 12 14 strips the fresh silicone lead; every 3.00-3.30 mm result and every strand still requires inspection.
J1 is explicit
Cavity 1 is BLACK/GND. Cavity 2 is RED/VDD. The PHB barrel and screw inputs stay empty.
Assembly traveler
| Step | Operation | Acceptance | Stop rule |
|---|---|---|---|
| A01 | Verify exact Mueller and Molex parts | Record identity, lots, photos and received lengths | Stop on mismatch |
| A02 | Remove tin-dipped free-end segments | No fused/dipped segment in either crimp zone | Stop if boundary is ambiguous |
| A03 | Inspect and prepare Mini-Fit ends | OD <=3.1 mm; 3.00-3.30 mm strip; zero damaged strands | Stop on incompatibility |
| A04 | Destructive process coupon | 1.00-1.10 mm; 25 +/-6 mm/min; >88.0 N | Stop until calibrated tools, suitable grips and the process pass |
| A05-A06 | Crimp and insert | black J1-1; red J1-2; both locked | Reject nonconformance |
| A07 | Inspect manufacturer source ends | Correct, undamaged shrouds/plugs/strain reliefs | Quarantine damage or mismatch |
| A08-A10 | Label, inspect, sign | continuity/polarity/short and as-built complete | No connection without authority |
complete traveler · as-built record · cut and crimp register · contact map · tooling · primary sources · open holds