Fine Adjust Applicator for 2.50mm (.098") Pitch Splash Proof Crimp Terminal
Doc No: ATS-639000100 Release Date: 05-22-08 UNCONTROLLED COPY Page 1 of 5
Revision: A Revision Date: 05-22-08
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
BELL
MOUTH
CRIMP HEIGHT
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
CUT
-
OFF
TAB
SEAM
FineAdjust Applicator
Specification Sheet
Order No. 63900-0100
FEATURES
Directly adapts to most automatic wire processing machines
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
SCOPE
Products: 2.50mm (.098") Pitch Splash Proof Crimp Terminal, 20-22 AWG.
Wire Size
Insulation Diameter
Strip Length
Terminal Series No.
Terminal Order No.
AWG
mm² mm In. mm In.
50038 50038-8000 20-22
0.50-0.35
1.50-1.90 .059-075 2.00-2.50
.078-.098
50039 50039-8000 20-22
0.50-0.35
1.50-1.90 .059-075 2.00-2.50
.078-.098
Note:
Insulation OD: 1.50-1.70mm (.059-.067”) will achieve optimum IPC-A620 class 2 insulation crimps.
Insulation OD: 1.70-1.90mm (.067-.075”) will not achieve optimum IPC-A620 class 2 insulation crimps.
DEFINITION OF TERMS
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the
scope.
Fine Adjust Applicator for 2.50mm (.098") Pitch Splash Proof Crimp Terminal
Doc No: ATS-639000100 Release Date: 05-22-08 UNCONTROLLED COPY Page 2 of 5
Revision: A Revision Date: 05-22-08
CRIMP SPECIFICATION
Bell mouth Cut-off Tab Maximum Conductor Brush
Terminal Series No. mm In. mm In. mm In.
50038 0.00-0.30 .000-.012 0.30 .012 0.10-0.90 .004-.035
50039 0.00-0.30 .000-.012 0.30 .012 0.10-0.90 .004-.035
Punch Width mm (Ref)
Bend up Bend down
Twist Roll Conductor
Insulation
Terminal Series No.
Degree (Max) Degree (Max)
mm In mm In
50038 2 0 3 10 1.40
.055
1.80
.070
50039 2 0 3 10 1.40
.055
1.80
.070
Seam
Seam shall not be open
and no wire allowed out
of the crimping area
After crimping, the conductor profile should measure the following.
Wire Size Conductor Crimp Height
Pull Force Minimum
Terminal Series No.
AWG
mm2
mm In. N Lb.
20 0.50 0.96-1.06 .038-.042 53.3 12.0
50038 22 0.35 0.94-0.99 .037-.039 48.9 11.0
20 0.50 0.96-1.06 .038-.042 53.3 12.0
50039 22 0.35 0.94-0.99 .037-.039 48.9 11.0
Pull Force should be measured with no influence from the insulation crimp.
The above specifications are guidelines to an optimum crimp.
Fine Adjust Applicator for 2.50mm (.098") Pitch Splash Proof Crimp Terminal
Doc No: ATS-639000100 Release Date: 05-22-08 UNCONTROLLED COPY Page 3 of 5
Revision: A Revision Date: 05-22-08
PARTS LIST
FineAdjust Applicator 63900-0100
Item Order No Engineering No. Description Quantity
Perishable Tooling
63900-0170 63900-0170 Tool Kit (All “Y” Items) REF
1 63444-1407 63444-1407 Conductor Punch 1 Y
2 63445-1426 63445-1426 Conductor Anvil 1 Y
3 63446-1808 63446-1808 Insulation Punch 1 Y
4 63445-1810 63445-1810 Insulation Anvil 1 Y
5 63443-0002 63443-0002 Cut-Off Plunger 1 Y
6 63443-0012 63443-0012 Front Plunger Retainer 1 Y
Other Components (000150)
7 11-17-0022 1739-21 Hold Down Spring 1
8 11-18-4083 60707-8 Feed Guide 1
9 11-24-1067 4996-4 Cut-off Plunger Spring 1
10 11-24-1149 4996-37 Shank 1
11 11-40-4039 8302-5 Front Plunger Striker 1
12 63443-0009 63443-0009 Scrape Chute 1
13 63443-0025 63443-0025 Lower Tooling Key 1
14 63443-0090 63443-0090 Wire Stop 1
15 63443-1719 63443-1719 18.90mm Height Spacer 1
16 63443-2213 63443-2213 13.00mm Coarse Spacer 1
17 63443-2302 63443-2302 3.10mm Spacer 1
18 63443-2314 63443-2314 3.70mm Fine Spacer 1
19 63443-6111 63443-6111 Rear Cover 1
20 63443-7001 63443-7001 Terminal Hold Down 1
Frame
21 63800-4901 63800-4901 Top 1
22 63801-3281 63801-3281 Base 1
23 63801-4650 63801-4650 Track 1
Hardware
24 N/A N/A M3 by 6 Long SHCS 2**
25 N/A N/A M3 by 6 Long FHCS 1**
26 N/A N/A M4 by 6 Long SHCS 2**
27 N/A N/A M4 by 12 Long BHCS 2**
28 N/A N/A M5 by 12 Long SHCS 1**
29 N/A N/A M4 by 50 Long SHCS 2**
30 N/A N/A #5-40 by 3/8 Long SHCS 1**
31 N/A N/A #10-32 by 3/8”Long Flat Point SSS 1**
32 N/A N/A #10-32 Hex Jam Nut 1**
** Available from an industrial supply company such as MSC (1-800-645-7270).
Fine Adjust Applicator for 2.50mm (.098") Pitch Splash Proof Crimp Terminal
Doc No: ATS-639000100 Release Date: 05-22-08 UNCONTROLLED COPY Page 4 of 5
Revision: A Revision Date: 05-22-08
Figure 1
31
19
28
21
1
3
7
27
24
29
5
6
16
17
14
11
26
23
30
18
9
2
4
(2)
(2)
10
12
8
20
21
22
25
15
13
(2)
14
26
3
2
Assembly Drawing
Fine Adjust Applicator for 2.50mm (.098") Pitch Splash Proof Crimp Terminal
Doc No: ATS-639000100 Release Date: 05-22-08 UNCONTROLLED COPY Page 5 of 5
Revision: A Revision Date: 05-22-08
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 135.8mm (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.
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