Fine Adjust Applicator for Right Angle 2.50mm (.098") Board-in-Terminals
FineAdjust Applicator
Specification Sheet
Part No. 63863-2100
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: Right Angle, 2.50mm (.098") Board-In Terminal for 22-28 AWG.
Terminal
Series No.
35021
Terminal Order No.
Wire Size
AWG
mm²
Insulation Diameter
Max
mm
In.
1.90
.075
Strip Length
mm
In.
35021-1001 35021-1110
35021-1100 35021-1160 22-28 0.32-0.08
35021-1101
1.80-2.20 .071-.087
DEFINITION OF TERMS
BRUSH
BELL
MOUTH
CONDUCTOR
CRIMP
INSULATION
CRIMP
SEAM
BEND UP
ROLLING
STRIP
LENGTH
CUT-OFF
TAB
TWISTING
BEND
DOWN
CRIMP HEIGHT
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the scope.
Doc No. ATS-638632100
Revision: B
Release Date: 04-11-00
Revision Date: 03-16-10
UNCONTROLLED COPY
Page 1 of 5
Fine Adjust Applicator for Right Angle 2.50mm (.098") Board-in-Terminals
CRIMP SPECIFICATION
Bell mouth
Cut-off Tab Maximum Conductor Brush
mm
In.
mm
In.
mm
In.
0.20-0.50 .008-.020
0.30
.012
0.0-1.0 0.0-.039
Terminal Series No.
35021
Terminal Series No.
35021
Bend up Bend down Twist
Degree
3
3
Roll
Degree
3
3
Punch Width mm (Ref)
Seam
Conductor Insulation
mm In mm In
Seam shall not be open
and no wire allowed out
1.20 .047 1.90 .075 of the crimping area
After crimping, the conductor profile should measure the following.
Wire Size
AWG
22
24
26
28
mm
2
0.32
0.20
0.13
0.08
Conductor
Crimp Height
Crimp Width (Ref)
mm
In.
mm
In.
0.71-0.76 .028-.030 1.20
.047
0.66-0.71 .026-.028 1.20
.047
0.61-0.66 .024-.026 1.20
.047
0.56-0.61 .022-.024 1.20
.047
Terminal Series No.
35021
Terminal Series No.
Wire Size
AWG
22
24
26
28
mm
2
0.32
0.20
0.13
0.08
35021
Insulation
Pull Force Minimum
Crimp Height (Ref) Crimp Width (Ref)
mm
In.
mm
In.
N
Lb.
1.55
.061
2.10
.083
39.2
8.80
1.50
.059
2.10
.083
29.4
6.60
1.45
.057
2.10
.083
19.6
4.40
1.40
.055
2.10
.083
9.8
2.20
Pull Force should be measured with no influence from the insulation crimp.
The above specifications are guidelines to an optimum crimp.
Doc No. ATS-638632100
Revision: B
Release Date: 04-11-00
Revision Date: 03-16-10
UNCONTROLLED COPY
Page 2 of 5
Fine Adjust Applicator for Right Angle 2.50mm (.098") Board-in-Terminals
PARTS LIST
FineAdjust Applicator 63863-2100
Item Order No Engineering No.
Description
Quantity
Perishable Tooling
63863-2170
63863-2170
Tool Kit (All “Y” Items)
REF
1
63863-2002
63863-2002
Conductor Punch
1Y
2
63445-1213
63445-1213
Conductor Anvil
1Y
3
63863-2103
63863-2103
Insulation Punch
1Y
4
63445-1906
63445-1906
Insulation Anvil
1Y
5
63443-0003
63443-0003
Cut-Off Plunger
1Y
6
63443-0012
63443-0012
Front Plunger Retainer
1Y
Other Components
7
11-18-4083
60707-8
Front Cover
1
8
11-24-1067
4996-4
Cut-off Plunger Spring
1
9
11-40-4039
8302-5
Front Plunger Striker
1
10
63443-0009
63443-0009
Scrape Chute
1
11
63443-0021
63443-0021
Lower Tooling Key
1
12
63443-2411
63443-2411
Anvil Mount
1
13
63443-4029
63443-4029
Wire Stop
1
14
63443-6001
63443-6001
Rear Cover
1
15
63445-1613
63445-1613
Spacer Anvil
1
Frame
16
63800-4901
63800-4901
Top
1
17
63801-3281
63801-3281
Base
1
18
63801-4650
63801-4650
Track
1
Hardware
19
N/A
N/A
M3 by 6 Long SHCS
2**
20
N/A
N/A
M4 by 6 Long SHCS
1**
21
N/A
N/A
M4 by 12 Long BHCS
2**
22
N/A
N/A
M4 by 16 Long SHCS
1**
23
N/A
N/A
M4 by 20 Long SHCS
1**
24
N/A
N/A
M4 by 50 Long SHCS
1**
25
N/A
N/A
3mm by 6 Long Roll Pin
1**
26
N/A
N/A
#10-32 by 1/4”Long BHCS
1**
** Available from an industrial supply company such as MSC (1-800-645-7270).
Doc No. ATS-638632100
Revision: B
Release Date: 04-11-00
Revision Date: 03-16-10
UNCONTROLLED COPY
Page 3 of 5
Fine Adjust Applicator for Right Angle 2.50mm (.098") Board-in-Terminals
Assembly Drawing
16
26
21 (2)
14
9
3
1
(2)
19
7
5
16
8
6
23
10
20
22
18
13
24
2
17
12
25
15
Figure 1
4
11
Doc No. ATS-638632100
Revision: B
Release Date: 04-11-00
Revision Date: 03-16-10
UNCONTROLLED COPY
Page 4 of 5
Fine Adjust Applicator for Right Angle 2.50mm (.098") Board-in-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.
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Lisle, Illinois 60532 U.S.A.
1-800-78MOLEX
amerinfo@molex.com
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Yamato, Kanagawa, Japan
81-462-65-2324
feninfo@molex.com
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Munich, Germany
49-89-413092-0
eurinfo@molex.com
Corporate Headquarters
2222 Wellington Ct.
Lisle, IL 60532 U.S.A.
630-969-4550
Fax: 630-969-1352
Visit our Web site at http://www.molex.com
Doc No. ATS-638632100
Revision: B
Release Date: 04-11-00
Revision Date: 03-16-10
UNCONTROLLED COPY
Page 5 of 5
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