63861-1000 Fine Adjust Applicator
FineAdjust Applicator
Specification Sheet
Part No. 63861-1000
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 0.15mm (.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
Terminal Series No.
50535-9001
Wire Size
AWG
mm²
16-18 0.80-1.30
Insulation Diameter
mm
In.
2.00-2.45 .079-.096
Strip Length
mm
In.
3.70-4.20 .146-.165
DEFINITION OF TERMS
BELL
MOUTH
INSULATION
CRIMP
SEAM
BEND UP
ROLLING
BRUSH
CONDUCTOR
CRIMP
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. 63861-1000 Release Date: 04-28-00
Revision: B
Revision Date: 02-17-04
UNCONTROLLED COPY
Page 1 of 5
63861-1000 Fine Adjust Applicator
CRIMP SPECIFICATION
Terminal Series No.
50535-9001
Bell mouth
Cut-off Tab Max.
Conductor Brush
mm
In.
mm
In.
mm
In.
0.20-0.70 .008-.028 0.20
.008 0.00-1.00 .000-.039
Terminal
Series No.
50535-9001
Bend up Bend down Twist
Degree
3
2
3
Degree
Roll
5
Punch Width (Ref)
Seam
Seam shall not be open
Conductor
Insulation
mm
In
mm
In and no wire allowed out
of the crimping area
2.20 .086 2.80 .110
After crimping, the conductor profile should measure the following.
Terminal Series No.
50535-9001
50535-9001
Wire Size
Crimp Height
Pull Force Min.
2
mm
In.
N
Lb.
AWG mm
16 1.30 1.51-1.61 .059-.063 127.4 28.7
18 0.80 1.33-1.43 .052-.056 88.2 19.8
Pull Force should be measured with no influence from the insulation crimp.
The above specifications are guidelines to an optimum crimp.
Doc No. 63861-1000 Release Date: 04-28-00
Revision: B
Revision Date: 02-17-04
UNCONTROLLED COPY
Page 2 of 5
63861-1000 Fine Adjust Applicator
PARTS LIST
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Order No
Engineering No.
Description
Quantity
63861-1000 63861-1000 FineAdjust Applicator (Fig. 1)
REF
63444-2215 63444-2215
Conductor Punch
1Y
63445-2247 63445-2247
Conductor Anvil
1Y
63446-2811 63446-2811
Insulation Punch
1Y
63445-2816 63445-2816
Insulation Anvil
1Y
63443-0002 63443-0002
Cut-Off Plunger
1Y
63443-0012 63443-0012
Front Plunger Retainer
1Y
11-24-1067
4996-4
Cut-off Plunger Spring
1
11-40-4039
8302-5
Front Plunger Striker
1
63443-0021 63443-0021
Lower Tooling Key
1
63443-6011 63443-6011
Rear Cover
1
11-18-4083
60707-8
Front Cover
1
63443-2415 63443-2415
Anvil Mount
1
63443-4005 63443-4005
Wire Stop
1
63443-0009 63443-0009
Scrape Chute
1
63800-4900 63800-4900 Fine Adjust Applicator Frame
1
N/A
N/A
M3 by 6Lg. SHCS
2**
N/A
N/A
M4 by 6Lg. SHCS
1**
N/A
N/A
M4 by 12Lg. BHCS
2**
N/A
N/A
M4 by 16Lg SHCS
1**
N/A
N/A
M4 by 20Lg. SHCS
1**
N/A
N/A
M4 by 50Lg. SHCS
1**
N/A
N/A
3MM by 6Lg. Roll Pin
1**
N/A
N/A
#10-32 by 1/4”Lg. BHCS
1**
63861-1070 63861-1070
Tool Kit (All Y Items)
REF
** The following purchased parts are available from an Industrial supply company such as MSC (1-800-645-
7270).
Doc No. 63861-1000 Release Date: 04-28-00
Revision: B
Revision Date: 02-17-04
UNCONTROLLED COPY
Page 3 of 5
63861-1000 Fine Adjust Applicator
Assembly Drawing
23
18
10
8
(2)
15
1
(2)
11
5
7
6
16
3
15
14
20
17
21
19
2
4
9
22
Figure 1
12
13
Doc No. 63861-1000 Release Date: 04-28-00
Revision: B
Revision Date: 02-17-04
UNCONTROLLED COPY
Page 4 of 5
63861-1000 Fine Adjust Applicator
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 135.8 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
1150 E. Diehl Road
Naperville, IL 60563
Tel: (630) 969-4550
Fax: (630) 505-0049
Visit our Web site at http://www.molex.com
Doc No. 63861-1000 Release Date: 04-28-00
Revision: B
Revision Date: 02-17-04
UNCONTROLLED COPY
Page 5 of 5
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