63866-9000 Fine Adjust Applicator for Wedge Terminals
FineAdjust Applicator
Specification Sheet
Part No. 63866-9000
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
Wire Size
Insulation Diameter
Strip Length
Series No.
AWG mm²
mm
In.
mm
In.
35477-9002
0.50 2.00- 2.10 .079-.083 5.00-5.50 .197-.217
35477-9002
20
0.56
2.00-2.10
.079-.083 5.00-5.50 .197-.217
Terminal will accommodate the following wire specification:
AVS 0.50 mm
2
or equivalent wires: 20 AWG GXL wire –7 strands.
DEFINITION OF TERMS
SEAM
BEND UP
BELL MOUTH
TWISTING
EXTRUDED
WIRE LENGTH
BEND
DOWN
CONDUCTOR
CRIMP HEIGHT
INSULATION
CRIMP HEIGHT
ROLLING
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the scope.
Doc No. 63866-9000
Revision: A
Release Date: 09-23-04
Revision Date: 09-23-04
UNCONTROLLED COPY
Page 1 of 5
63866-9000 Fine Adjust Applicator for Wedge Terminals
CRIMP SPECIFICATION
Terminal
Series No.
35477-9002
Bell mouth
mm
0.30-0.60
In.
.012-.024
Cut-off Tab Max.
mm
In.
0.40
.016
Conductor Brush
mm
In.
0.30-0.80
.012-.031
Terminal
Series No.
35477-9002
Bend up Bend down
Degree
3
3
Twist
Degree
3
Roll
5
Punch Width mm (Ref)
Conductor
Insulation
mm
In
mm
In
2.05 .081 4.55 .179
Seam
Seam shall not be
open and no wire allowed
out of the crimping area
After crimping, the conductor profile should measure the following.
Terminal
Part No.
35477-9002
35477-9002
20
Wire Size
AWG
mm
0.50
2
Conductor Crimp
Height
mm
1.25-1.35
1.25-1.35
In.
.049-.053
.049-.053
mm
2.00-2.20
2.00-2.20
Width
In.
.079-.087
.079-.087
0.56
Terminal
Part No.
35477-9002
35477-9002
Wire Size
AWG
mm
2
0.50
0.56
Insulation Crimp
Height
mm
4.20 Max.
4.20 Max.
In.
.165 Max.
.165 Max.
Width
mm
4.40-4.60
4.40-4.60
In.
.173-.181
.173-.181
Pull Force Min.
N
88.2
88.2
Lb.
19.84
19.84
20
Pull Force should be measured with no influence from the insulation crimp.
The above specifications are guidelines to an optimum crimp.
Doc No. 63866-9000
Revision: A
Release Date: 09-23-04
Revision Date: 09-23-04
UNCONTROLLED COPY
Page 2 of 5
63866-9000 Fine Adjust Applicator for Wedge Terminals
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
63866-9000
63457-0022
63455-0022
63454-0035
63456-0030
63443-0035
63443-0049
63700-0539
63866-9008
63443-0021
63830-0113
11-18-4083
63866-9012
63443-4033
63443-0009
63801-3100
63821-0024
N/A
N/A
N/A
N/A
N/A
N/A
N/A
63866-9070
Engineering No.
63866-9000
63457-0022
63455-0022
63454-0035
63456-0030
63443-0035
63443-0049
63700-0539
63866-9008
63443-0021
63830-0113
60707-8
63866-9012
63443-4033
63443-0009
63801-3100
63821-0024
N/A
N/A
N/A
N/A
N/A
N/A
N/A
63866-9070
Description
FineAdjust Applicator (Fig. 1)
Conductor Punch
Conductor Anvil
Insulation Punch
Insulation Anvil
Cut-Off Plunger
Front Plunger Retainer
Cut-off Plunger Spring
Front Plunger Striker
Lower Tooling Key
Rear Cover
Front Cover
Anvil Mount
Wire Stop
Scrape Chute
Fine Adjust Applicator Frame
“L” Feed Finger
M3 by 6Lg. SHCS
M4 by 6Lg. SHCS
M4 by 12Lg. BHCS
M4 by 16Lg SHCS
M4 by 50Lg. SHCS
3MM by 6Lg. Roll Pin
#10-32 by 1/4”Lg. BHCS
Tool Kit (All Y Items)
Quantity
REF
1Y
1Y
1Y
1Y
1Y
1Y
1
1
1
1
1
1
1
1
1
1
2**
1**
2**
1**
2**
1**
1**
REF
** The following purchased parts are available from an Industrial supply company such as MSC (1-800-645-7270).
Doc No. 63866-9000
Revision: A
Release Date: 09-23-04
Revision Date: 09-23-04
UNCONTROLLED COPY
Page 3 of 5
63866-9000 Fine Adjust Applicator for Wedge Terminals
Assembly Drawing
23
15
19
10
8
1
(2)
(2)
11
5
7
6
17
3
15
14
21
(2)
18
16
20
2
4
9
22
Figure 1
13
12
Doc No. 63866-9000
Revision: A
Release Date: 09-23-04
Revision Date: 09-23-04
UNCONTROLLED COPY
Page 4 of 5
63866-9000 Fine Adjust Applicator for Wedge Terminals
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 135.8 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. 63866-9000
Revision: A
Release Date: 09-23-04
Revision Date: 09-23-04
UNCONTROLLED COPY
Page 5 of 5
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