63868-5000 Fine Adjust Applicator
Doc No. 63868-5000 Release Date: 02-07-06 UNCONTROLLED COPY Page 1 of 5
Revision: A Revision Date: 03-01-06
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
BELL
MOUTH
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
CUT-OFF
TAB
SEAM
FineAdjust Applicator
Specification Sheet
Part No. 63868-5000
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: 2.50mm (.098") Pitch Board-In Terminal 22-28 AWG
Wire Size Insulation Diameter Strip Length
Terminal Series No. AWG mm² mm In. mm In.
35047 22-28 0.08-0.32 1.15-1.90 .045-.075 3.00-3.50 .118-.138
Note: Terminal will accommodate UL1007 and UL1569 Wires
Terminals must be wound for a left to right feed applicator. Terminals 35047-9802 are
wound in the opposite direction so they must be rewound to run through this applicator.
DEFINITION OF TERMS
The above terminal drawing is a generic terminal representation. It is not an image of any terminal listed in the scope.
63868-5000 Fine Adjust Applicator
Doc No. 63868-5000 Release Date: 02-07-06 UNCONTROLLED COPY Page 2 of 5
Revision: A Revision Date: 03-01-06
CRIMP SPECIFICATION
Bell mouth Cut-off Tab Max. Conductor Brush
Terminal Series No. mm In. mm In. mm In.
35047 0.20-0.50 .008-.020 0.30 .012 0.00-1.40 .000-.055
Punch Width (Ref)
Bend up Bend down Twist Roll Conductor Insulation
Terminal Series No.
Degree Degree mm In mm In
35047 3 3 3 3 1.40 .055 1.90 .075
Seam
Seam shall not be
open and no wire allowed
out of the crimping area
After crimping, the crimp profiles should measure the following:
Conductor
Wire Size Crimp Height Crimp Width (Ref)
Terminal Series No.
AWG mm2 mm In. mm In.
35047 22 0.32 0.82-0.87 .032-.034 1.40 +/- 0.10 .055 +/- .004
35047 24 0.20 0.75-0.80 .029-.031 1.40 +/- 0.10 .055 +/- .004
35047 26 0.13 0.70-0.75 .027-.029 1.40 +/- 0.10 .055 +/- .004
35047 28 0.08 0.66-0.71 .026-.028 1.40 +/- 0.10 .055 +/- .004
Insulation
Wire Size Crimp Height (Ref) Crimp Width (Ref) Pull Force Min.
Terminal Series No.
AWG mm2 mm In. mm In. N Lb.
35047 22 0.32 1.60 .063 1.90 +/- 0.10 .075 +/- .004 39.1 8.8
35047 24 0.20 1.50 .059 1.90 +/- 0.10 .075 +/- .004 29.3 6.6
35047 26 0.13 1.45 .057 1.90 +/- 0.10 .075 +/- .004 19.6 4.4
35047 28 0.08 1.40 .055 1.90 +/- 0.10 .075 +/- .004 9.8 2.2
✴ Tool Qualification Notes:
1. This Applicator was qualified to the above specifications with UL1007 wire.
2. Pull Force should be measured with no influence from the insulation crimp.
3. The above specifications are guidelines to an optimum crimp.
63868-5000 Fine Adjust Applicator
Doc No. 63868-5000 Release Date: 02-07-06 UNCONTROLLED COPY Page 3 of 5
Revision: A Revision Date: 03-01-06
PARTS LIST
FineAdjust Applicator 63868-5000
Item Order No Engineering No. Description Quantity
Perishable Tooling
63868-5070 63868-5070 Tool Kit (All “Y” Items) REF
1 63444-1407 63444-1407 Conductor Punch 1 Y
2 63445-1430 63445-1430 Conductor Anvil 1 Y
3 63446-1906 63446-1906 Insulation Punch 1 Y
4 63445-1906 63445-1906 Insulation Anvil 1 Y
5 63443-0002 63443-0002 Cut-Off Plunger Front 1 Y
6 63443-0012 63443-0012 Plunger Retainer Front 1 Y
Other Components
7 11-24-1067 4996-4 Cut-off Plunger Spring 1
8 11-40-4039 8302-5 Plunger Striker Front 1
9 63443-0021 63443-0021 Lower Tooling Key 1
10 63443-6003 63443-6003 Rear Cover 1
11 11-18-4083 60707-8 Front Cover 1
12 63443-2430 63443-2430 Anvil Mount 1
13 63443-4005 63443-4005 Wire Stop 1
14 63443-0009 63443-0009 Scrap Chute Front 1
Frame
15 63800-4900 63800-4900 Fine Adjust Applicator Frame 1
Hardware
16 N/A N/A M3 by 6Lg. SHCS 2**
17 N/A N/A M4 by 6Lg. SHCS 1**
18 N/A N/A M4 by 12Lg. BHCS 2**
19 N/A N/A M4 by 16Lg SHCS 1**
20 N/A N/A M4 by 20Lg. SHCS 1**
21 N/A N/A M4 by 50Lg. SHCS 1**
22 N/A N/A 3MM by 6Lg. Roll Pin 1**
23 N/A N/A #10-32 by 1/4”Lg. BHCS 1**
** Available from an industrial supply company such as MSC (1-800-645-7270).
63868-5000 Fine Adjust Applicator
Doc No. 63868-5000 Release Date: 02-07-06 UNCONTROLLED COPY Page 4 of 5
Revision: A Revision Date: 03-01-06
Figure 1
23
18
10
15
1
3
15
16
11
5
7
6
20
21
14
17
19
13
12
9
22
2
4
(2)
(2)
8
Assembly Drawing
63868-5000 Fine Adjust Applicator
Doc No. 63868-5000 Release Date: 02-07-06 UNCONTROLLED COPY Page 5 of 5
Revision: A Revision Date: 03-01-06
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 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.
Molex Application Tooling Group
2200 Wellington Court
Lisle, IL 60532
Tel: (630) 969-4550
Fax: (630) 505-0049
Visit our Web site at http://www.molex.com
