63860-2000 Fine Adjust Applicator
Doc No. 63860-2000 Release Date: 08-04-99 UNCONTROLLED COPY Page 1 of 5
Revision: B Revision Date: 01-26-04
INSULATI
O
N
CRIMP
BRUS
H
STRI
P
LENGTH
BEL
L
MOUTH
CRIMP HEIGH
T
BEN
D
DOWN
BEND U
P
ROLLIN
G
CONDUCTO
R
CRIMP
TWISTIN
G
CU
T
-
OF
F
TAB
SEA
M
FineAdjust Applicator
Specification Sheet
Part No. 63860-2000
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.
70058-00** 24-30 0.20-0.05 1.01-1.52 .040-.060 3.17-3.56 .125-.140
71851-000* 24-30 0.20-0.05 1.01-1.52 .040-.060 3.17-3.56 .125-.140
DEFINITION OF TERMS
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the
scope.
63860-2000 Fine Adjust Applicator
Doc No. 63860-2000 Release Date: 08-04-99 UNCONTROLLED COPY Page 2 of 5
Revision: B Revision Date: 01-26-04
CRIMP SPECIFICATION
Cut-off Tab Max.
Bell mouth Front Rear Conductor Brush
Terminal Series No.
mm In. mm In. mm In. mm In.
70058-00** 0.20-0.50 .008-.020 0.13 .005 .08 .003 0.00-1.00 .000-.039
71851-000* 0.20-0.50 .008-.020 0.13 .005 .08 .003 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
70058-00** 3 3 3 8 1.00 .039 1.60 .063
71851-000* 3 3 3 8 1.00 .039 1.60 .063
Seam
Seam shall not be open
and no wire allowed out
of the crimping area
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.
70058-00** 24 0.20 0.79-0.84 .031-.033 22.2 5.0
70058-00** 26 0.12 0.74-0.79 .029-.031 13.3 3.0
70058-00** 28 0.08 0.71-0.76 .028-.030 8.9 2.0
70058-00** 30 0.05 0.66-0.71 .026-.028 6.7 1.5
71851-000* 24 0.20 0.79-0.84 .031-.033 22.2 5.0
71851-000* 26 0.12 0.74-0.79 .029-.031 13.3 3.0
71851-000* 28 0.08 0.71-0.76 .028-.030 8.9 2.0
71851-000* 30 0.05 0.66-0.71 .026-.028 6.7 1.5
Pull Force should be measured with no influence from the insulation crimp.
The above specifications are guidelines to an optimum crimp.
63860-2000 Fine Adjust Applicator
Doc No. 63860-2000 Release Date: 08-04-99 UNCONTROLLED COPY Page 3 of 5
Revision: B Revision Date: 01-26-04
PARTS LIST
Item Order No Engineering No. Description Quantity
63860-2000 63860-2000 FineAdjust Applicator (Fig. 1) REF
1 63444-1018 63444-1018 Conductor Punch 1 Y
2 63445-1031 63445-1031 Conductor Anvil 1 Y
3 63446-1622 63446-1622 Insulation Punch 1 Y
4 63445-1630 63445-1630 Insulation Anvil 1 Y
5 63443-0003 63443-0003 Cut-Off Plunger 2 Y
6 63443-0012 63443-0012 Front Plunger Retainer 1 Y
7 63443-1402 63443-1402 Cut-off Die Blade 1 Y
8 63443-1002 63443-1002 Rear Plunger Retainer 1 Y
9 11-24-1067 4996-4 Cut-Off Plunger Spring 2
10 11-40-4039 8302-5 Front Plunger Striker 1
11 63443-0021 63443-0021 Lower Tooling Key 1
12 63443-6003 63443-6003 Rear Cover 1
13 11-18-4094 60709A111 Front Cover 1
14 11-18-4020 60704-8 Wire Stop 1
15 63800-4900 63800-4900 FineAdjust Applicator 1
16 63443-3060 63443-3060 Rear Plunger Striker 1
17 63443-2102 63443-2102 Front Spacer 1
18 63443-2103 63443-2103 Rear Spacer 1
19 11-24-1149 4996-37 Shank 1
20 11-40-4274 8331-8 Hold Down Blade 1
21 11-17-0022 1739-21 Hold Down Spring 1
22 63860-2015 63860-2015 *Drag Frame (Modified) 1
23 N/A N/A M3 by 6Lg. SHCS 2**
24 N/A N/A M4 by 10Lg. SHCS 2**
25 N/A N/A M4 by 12Lg. BHCS 2**
26 N/A N/A M4 by 35Lg. SHCS 1**
27 N/A N/A M4 by 50Lg. SHCS 1**
28 N/A N/A M5 by 12Lg. SHCS 1**
29 N/A N/A #5-40 by 3/8”Lg. SHCS 1**
30 N/A N/A 1/8 “ Tubular by 0.24” Lg. Rivet Pin 1**
31 N/A N/A #10-32 by 1/4”Lg. BHCS 1**
63860-2070 63860-2070 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).
63860-2000 Fine Adjust Applicator
Doc No. 63860-2000 Release Date: 08-04-99 UNCONTROLLED COPY Page 4 of 5
Revision: B Revision Date: 01-26-04
Figure 1
31
2
5
1
2
1
5
1
3
1
5
2
3
1
3
2
2
5
6
2
6
2
7
1
7
7
1
8
11
3
0
1
4
2
8
2
4
(2
)
(2
)
1
0
8
2
4
1
6
(2
)
(2
)
(2
)
(Install and
g
rind flat with
ottom of Tooling Key)
21
1
9
2
0
2
9
9
Assembly Drawing
63860-2000 Fine Adjust Applicator
Doc No. 63860-2000 Release Date: 08-04-99 UNCONTROLLED COPY Page 5 of 5
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
