Fine Adjust Applicator for 1.25mm (.049”) Pitch Wire-to-Board Terminals
FineAdjust
Applicator
Application Tooling
Specification Sheet
Order No. 63900-6600
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: 1.25mm (.049”) Pitch Wire-to-Board Connector Dual Plug Terminal, 26-28 AWG.
Terminal Series No.
Wire Size
Insulation Diameter
Strip Length
AWG
mm²
mm
In.
mm
In.
501930
501930-0100 501930-1100 26-28 .136-.079 0.80-1.00 .031-.039 1.50-1.70 .060-.067
502381
502381-0000 502381-0010 26-28 .136-.079 0.80-1.00 .031-.039 1.50-1.70 .060-.067
This Applicator will not meet A-620 Class 1, 2, or 3 standards with insulation diameter range of 0.80-1.00mm.
Terminal Order No.
DEFINITION OF TERMS
BRUSH
BELL
MOUTH
CONDUCTOR
CRIMP
SEAM
BEND UP
ROLLING
INSULATION
CRIMP
STRIP
LENGTH
CUT-OFF
TAB
TWISTING
BEND
DOWN
CRIMP
HEIGH
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the scope.
Doc. No: ATS-639006600
Revision: C
Release Date: 02-20-08
Revision Date: 09-06-16
UNCONTROLLED COPY
Page 1 of 5
Fine Adjust Applicator for 1.25mm (.049”) Pitch Wire-to-Board Terminals
CRIMP SPECIFICATION
Terminal Series No.
501930
502381
Bell mouth
Mm
In.
0.10-0.30 .004-.012
0.10-0.30 .004-.012
Cut-off Tab Maximum
mm
In.
0.10
.004
0.10
.004
Roll
Conductor Brush
mm
In.
0.10-0.40 .004-.016
0.10-0.40 .004-.016
Terminal Series No.
501930
502381
Bend up Bend down Twist
Degree
3
3
3
3
Degree
4
6
4
6
Punch Width mm (Ref)
Seam
Conductor Insulation
mm In mm In
Seam shall not be open
0.80 .031 0.80 .031 and no wire allowed out
of the crimping area
0.80 .031 0.80 .031
After crimping, the conductor profile should measure the following.
Terminal Series No.
501930
502381
Wire Size
AWG
26
28
26
28
mm
2
.136
.079
.136
.079
Crimp Height
mm
In.
0.56-0.61 .022-.024
0.53-0.58 .021-.023
0.56-0.61 .022-.024
0.53-0.58 .021-.023
Conductor
Crimp Width (Ref)
mm
In.
Terminal Series No.
501930
502381
Wire Size
AWG
26
28
26
28
mm
2
.136
.079
.136
.079
Insulation (Ref)
Pull Force Minimum
Crimp Height
Crimp Width
mm
In.
mm
In.
N
Lb.
1.18-1.28 .046-.050
9.8
2.20
1.15-1.25 .045-.049
9.8
2.20
1.18-1.28 .046-.050
9.8
2.20
1.15-1.25 .045-.049
9.8
2.20
Tool Qualification Notes:
1. Pull Force should be measured with no influence from the insulation crimp.
2. The above specifications are guidelines to an optimum crimp.
Doc. No: ATS-639006600
Revision: C
Release Date: 02-20-08
Revision Date: 09-06-16
UNCONTROLLED COPY
Page 2 of 5
Fine Adjust Applicator for 1.25mm (.049”) Pitch Wire-to-Board Terminals
PARTS LIST
FineAdjust Applicator 63900-6600
Item Order No Engineering No.
Description
Quantity
Perishable Tooling
63900-6670
63900-6670
Tool Kit (All “Y” Items)
REF
1
63444-0804
63444-0804
Conductor Punch
1Y
2
63445-0821
63445-0821
Anvil
1Y
3
63446-0808
63446-0808
Insulation Punch
1Y
4
63443-0002
63443-0002
Front Cut-Off Plunger
1Y
5
63443-0012
63443-0012
Front Plunger Retainer
1Y
Other Components
6
11-18-4083
60707-8
Feed Guide
1
7
63443-0009
63443-0009
Front Scrap Chute
1
8
63443-0025
63443-0025
Key
1
9
63443-0090
63443-0090
Wire Stop
1
10
63443-1719
63443-1719
Height Spacer (18.90mm)
1
11
63443-2201
63443-2201
Fine Spacer (1.00mm)
1
12
63443-2216
63443-2216
Coarse Spacer (16.00mm)
1
13
63443-2310
63443-2310
Fine Spacer (3.50mm)
1
14
63443-2802
63443-2802
Front Plunger Striker
1
15
63443-2904
63443-2904
Wire Hold Down Plunger
1
16
63443-6109
63443-6109
Rear Cover
1
17
63600-0021
63600-0021
Wire Hold Down Spring
1
18
11-24-1067
4996-4
Cut-Off Plunger Spring
1
Frame
19
63800-4901
63800-4901
Top
1
20
63801-3281
63801-3281
Base
1
21
63801-4650
63801-4650
Track
1
Hardware
22
N/A
N/A
M3 by 6 Long SHCS
2**
23
N/A
N/A
M3 by 6 Long FHCS
1**
24
N/A
N/A
M4 by 6 Long SHCS
2**
25
N/A
N/A
M4 by 12 Long BHCS
2**
26
N/A
N/A
M4 by 50 Long SHCS
2**
27
N/A
N/A
M5 by 12 Lg SHCS
1**
28
N/A
N/A
#10-32 by 3/8”Long Flat Point SSS
1**
29
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-639006600
Revision: C
Release Date: 02-20-08
Revision Date: 09-06-16
UNCONTROLLED COPY
Page 3 of 5
Fine Adjust Applicator for 1.25mm (.049”) Pitch Wire-to-Board Terminals
Assembly Drawing
19
29
28
3
17
14
1
25
16
(2)
15
19
21
(2)
6
22
20
9
27
10
4
2
18
11
12
24
5
13
9
8
23
26
7
24
Figure 1
(2)
Doc. No: ATS-639006600
Revision: C
Release Date: 02-20-08
Revision Date: 09-06-16
UNCONTROLLED COPY
Page 4 of 5
Fine Adjust Applicator for 1.25mm (.049”) Pitch Wire-to-Board Terminals
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.
Application Tooling Support
2200 Wellington Court
Lisle, IL 60532 USA
Phone: +1-402-458-TOOL (8665)
E-mail: applicationtooling@molex.com
Visit our Website at www.molex.com/applicationtooling
Doc. No: ATS-639006600
Revision: C
Release Date: 02-20-08
Revision Date: 09-06-16
UNCONTROLLED COPY
Page 5 of 5
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