63868-5000 Fine Adjust Applicator 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 AWG mm 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. Terminal Series No. DEFINITION OF TERMS BRUSH BEND UP BELL MOUTH 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 any terminal listed in the scope. Doc No. 63868-5000 Revision: A Release Date: 02-07-06 Revision Date: 03-01-06 UNCONTROLLED COPY Page 1 of 5 63868-5000 Fine Adjust Applicator CRIMP SPECIFICATION Terminal Series No. 35047 Terminal Series No. Bell mouth mm In. 0.20-0.50 .008-.020 Cut-off Tab Max. mm In. 0.30 .012 Bend up Bend down Twist Roll Degree Degree 3 3 35047 3 3 Conductor Brush mm In. 0.00-1.40 .000-.055 Punch Width (Ref) Seam Conductor Insulation Seam shall not be mm In mm In open and no wire allowed 1.40 .055 1.90 .075 out of the crimping area After crimping, the crimp profiles should measure the following: Terminal Series No. AWG 22 24 26 28 35047 35047 35047 35047 Terminal Series No. 35047 35047 35047 35047 Wire Size Wire Size AWG 22 24 26 28 2 mm 0.32 0.20 0.13 0.08 2 mm 0.32 0.20 0.13 0.08 Conductor Crimp Height Crimp Width (Ref) mm In. mm In. 0.82-0.87 .032-.034 1.40 +/- 0.10 .055 +/- .004 0.75-0.80 .029-.031 1.40 +/- 0.10 .055 +/- .004 0.70-0.75 .027-.029 1.40 +/- 0.10 .055 +/- .004 0.66-0.71 .026-.028 1.40 +/- 0.10 .055 +/- .004 Crimp Height (Ref) mm In. 1.60 .063 1.50 .059 1.45 .057 1.40 .055 Insulation Pull Force Min. Crimp Width (Ref) mm In. N Lb. 1.90 +/- 0.10 .075 +/- .004 39.1 8.8 1.90 +/- 0.10 .075 +/- .004 29.3 6.6 1.90 +/- 0.10 .075 +/- .004 19.6 4.4 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. Doc No. 63868-5000 Revision: A Release Date: 02-07-06 Revision Date: 03-01-06 UNCONTROLLED COPY Page 2 of 5 63868-5000 Fine Adjust Applicator 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 1Y 2 63445-1430 63445-1430 Conductor Anvil 1Y 3 63446-1906 63446-1906 Insulation Punch 1Y 4 63445-1906 63445-1906 Insulation Anvil 1Y 5 63443-0002 63443-0002 Cut-Off Plunger Front 1Y 6 63443-0012 63443-0012 Plunger Retainer Front 1Y 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). Doc No. 63868-5000 Revision: A Release Date: 02-07-06 Revision Date: 03-01-06 UNCONTROLLED COPY Page 3 of 5 63868-5000 Fine Adjust Applicator Assembly Drawing 15 23 18 (2) 3 10 1 8 (2) 16 11 5 7 15 6 14 20 17 21 2 19 13 12 9 4 Doc No. 63868-5000 Revision: A Release Date: 02-07-06 Revision Date: 03-01-06 22 Figure 1 UNCONTROLLED COPY Page 4 of 5 63868-5000 Fine Adjust Applicator NOTES 1. 2. 3. 4. 5. Molex recommends an extra perishable tooling kit be maintained at your facility. Verify tooling alignment by manually cycling the press and Applicator before crimping under power. Check that all screws are tight. Slugs, Terminals, Dirt and Oil should be kept clear of work area. Wear safety glasses at all times. 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 Doc No. 63868-5000 Revision: A Release Date: 02-07-06 Revision Date: 03-01-06 UNCONTROLLED COPY Page 5 of 5