0639029100

Fine Adjust Applicator for Right Angle 2.50mm (.098") Board-in-Terminals FineAdjust Applicator Application Tooling Specification Sheet Order No. 63902-9100 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. Terminal Order No. Wire Size AWG mm² 35021-1001 35021-1110 35021-1100 35021-1160 22-28 0.32-0.08 35021-1101 35021 Insulation Diameter Maximum mm In. 1.90 .075 Strip Length mm In. 1.80-2.20 .071-.087 DEFINITION OF TERMS SEAM BEND UP STRIP LENGTH TWISTING BRUSH BELL MOUTH ROLLING INSULATION CRIMP HEIGHT BEND DOWN CONDUCTOR CRIMP HEIGHT Doc No. ATS-639029100 Revision: A Release Date: 05-07-13 Revision Date: 05-07-13 CUT-OFF TAB UNCONTROLLED COPY Page 1 of 5 Fine Adjust Applicator for Right Angle 2.50mm (.098") Board-in-Terminals CRIMP SPECIFICATION Terminal Series No. 35021 Terminal Series No. Bell mouth mm In. 0.20-0.50 .008-.020 Bend up Bend down Twist Degree 35021 3 Cut-off Tab Maximum mm In. 0.30 .012 Roll Degree 3 3 3 Conductor Brush mm In. 0.0-1.0 0.0-.039 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 Terminal Series No. 35021 Terminal Series No. 35021 AWG 22 24 26 28 Wire Size AWG 22 24 26 28 mm2 0.32 0.20 0.13 0.08 mm2 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 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 Tool Qualification Notes: 1. Pull Force should be measured with no influence from the insulation crimp. 2. The above specifications are guidelines to an optimum crimp. Doc No. ATS-639029100 Revision: A Release Date: 05-07-13 Revision Date: 05-07-13 UNCONTROLLED COPY Page 2 of 5 Fine Adjust Applicator for Right Angle 2.50mm (.098") Board-in-Terminals PARTS LIST FineAdjust Applicator 63902-9100 Item Order No Engineering No. Description Quantity Perishable Tooling 63902-9170 63902-9170 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 Feed Guide 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 63443-0024 63443-0024 Lower Tooling Key 1 12 63443-1703 63443-1703 17.30mm (Height Spacer) 1 13 63443-2215 63443-2215 15.00mm (Coarse Spacer) 1 14 63443-2312 63443-2312 3.60mm (Fine Spacer) 1 15 63443-0090 63443-0090 Wire Stop 1 16 63443-6109 63443-6109 Rear Cover 1 17 63445-1613 63445-1613 Spacer Anvil 1 Frame 18 63800-4901 63800-4901 Top 1 19 63801-3281 63801-3281 Base 1 20 63801-4650 63801-4650 Track 1 Hardware 21 N/A N/A M3 by 6 Long SHCS 2** 22 N/A N/A M3 by 6 Long FHCS 1** 23 N/A N/A M4 by 6 Long SHCS 2** 24 N/A N/A M4 by 12 Long BHCS 2** 25 N/A N/A M4 by 45 Long SHCS 2** 26 N/A N/A M5 by 12 Long SHCS 1** 27 N/A N/A #10-32 by 3/8”Long Flat SSS 1** 28 N/A N/A #10-32 Hex Jam Nut 1** ** Available from an industrial supply company such as MSC (1-800-645-7270). Doc No. ATS-639029100 Revision: A Release Date: 05-07-13 Revision Date: 05-07-13 UNCONTROLLED COPY Page 3 of 5 Fine Adjust Applicator for Right Angle 2.50mm (.098") Board-in-Terminals Assembly Drawing 18 27 28 3 9 1 (2) 24 16 18 20 21 (2) 19 15 7 26 14 23 5 17 2 4 8 13 15 6 12 11 Figure 1 22 25 (2) Doc No. ATS-639029100 Revision: A 10 23 Release Date: 05-07-13 Revision Date: 05-07-13 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 wireprocessing 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. Visit our Web site at http://www.molex.com Doc No. ATS-639029100 Revision: A Release Date: 05-07-13 Revision Date: 05-07-13 UNCONTROLLED COPY Page 5 of 5