63860-9000 Fine Adjust Applicator
Doc No. 63860-9000 Release Date: 10-05-00 UNCONTROLLED COPY Page 1 of 6
Revision: B Revision Date: 01-26-04
INSULATIO
N
CRIM
P
BRUS
H
STRI
P
LENGTH
BEL
L
MOUTH
CRIMP HEIGH
T
BEN
D
DOWN
BEND U
P
ROLLIN
CONDUCTO
R
CRIMP
TWISTIN
G
CU
T
-
OF
F
TAB
SEA
M
FineAdjust Applicator
Specification Sheet
Part No. 63860-9000
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
Wire Size Insulation Diameter Strip Length
Terminal Series No. AWG mm² mm In. mm In.
35069-*00* 18 0.80 3.60 Max .142 Max 3.00-3.50 .118-.138
DEFINITION OF TERMS
63860-9000 Fine Adjust Applicator
Doc No. 63860-9000 Release Date: 10-05-00 UNCONTROLLED COPY Page 2 of 6
Revision: B Revision Date: 01-26-04
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the
scope.
63860-9000 Fine Adjust Applicator
Doc No. 63860-9000 Release Date: 10-05-00 UNCONTROLLED COPY Page 3 of 6
Revision: B Revision Date: 01-26-04
CRIMP SPECIFICATION
Bell mouth Cut-off Tab Max. Conductor Brush
Terminal Series No. mm In. mm In. mm In.
35069-*00* 0.20-0.70 .008-.028 0.30 .012 0.00-1.00 .000-.039
Bend up Bend down Twist Roll Punch Width mm (Ref)
Conductor Insulation
Terminal
Series No. Degree Degree
mm In mm In
35069-*00* 4 2 3 8 1.80 .070 3.60 .144
Seam
Seam shall not be open
and no wire allowed out
of the crimping area
The above specifications are guidelines to an optimum crimp.
CONDITIONS
After crimping, the conductor profile should measure the following.
Wire Size Crimp Height Pull Force Min.
Terminal Series No. AWG mm2 mm In. N Lb.
35069-*00* 18 0.80 1.08-1.18 .042-.046 88.0 19.8
Pull Force should be measured with no influence from the insulation crimp.
63860-9000 Fine Adjust Applicator
Doc No. 63860-9000 Release Date: 10-05-00 UNCONTROLLED COPY Page 4 of 6
Revision: B Revision Date: 01-26-04
PARTS LIST
Item Order No Engineering No. Description Quantity
63860-9000 63860-9000 FineAdjust Applicator (Fig. 1) REF
1 63444-1816 63444-1816 Conductor Punch 1 Y
2 63445-1831 63445-1831 Conductor Anvil 1 Y
3 63446-3619 63446-3619 Insulation Punch 1 Y
4 63445-3604 63445-3604 Insulation Anvil 1 Y
5 63443-0002 63443-0002 Cut-Off Plunger 1 Y
6 63443-0012 63443-0012 Front Plunger Retainer 1 Y
7 11-24-1067 4996-4 Cut-Off Plunger Spring 1
8 11-40-4039 8302-5 Front Plunger Striker 1
9 63443-0021 63443-0021 Lower Tooling Key 1
10 63443-6003 63443-6003 Rear Cover 1
11 11-18-4094 60709A111 Front Cover 1
12 63443-2409 63443-2409 Anvil Mount 1
13 63443-4005 63443-4005 Wire Stop 1
14 63443-0009 63443-0009 Scrap Chute 1
15 63800-4900 63800-4900 FineAdjust Applicator 1
16 63860-2015 63860-2015 * Drag Frame (Modified) 1
17 N/A N/A M3 by 6Lg. SHCS 2**
18 N/A N/A M4 by 6Lg. SHCS 1**
19 N/A N/A M4 by 12Lg. BHCS 2**
20 N/A N/A M4 by 16Lg SHCS 1**
21 N/A N/A M4 by 20Lg. SHCS 1**
22 N/A N/A M4 by 50Lg. SHCS 1**
23 N/A N/A 3MM by 6Lg. Roll Pin 1**
24 N/A N/A #10-32 by 1/4”Lg. BHCS 1**
63860-9070 63860-9070 Tool Kit (All Y Items) REF
* Frame part - To be modified.
** The following purchased parts are available from an Industrial supply company such as MSC (1-800-645-
7270).
63860-9000 Fine Adjust Applicator
Doc No. 63860-9000 Release Date: 10-05-00 UNCONTROLLED COPY Page 5 of 6
Revision: B Revision Date: 01-26-04
2
4
1
9
1
0
1
5
1
3
1
5
1
7
11
5
7
6
21
2
2
1
4
1
8
2
0
1
3
1
2
9
2
3
2
4
(2
)
(2
)
8
1
6
Assembly Drawing
Figure 1
63860-9000 Fine Adjust Applicator
Doc No. 63860-9000 Release Date: 10-05-00 UNCONTROLLED COPY Page 6 of 6
Revision: B Revision Date: 01-26-04
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