Fine Adjust Applicator for 1.20mm (.047") Pitch Pico-EZmate™ Wire-to-Board Crimp Terminal
Doc No: ATS-639011300 Release Date: 09-05-08 UNCONTROLLED COPY Page 1 of 5
Revision: C Revision Date: 05-12-11
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
BELL MOUTH
COND.CRIMP
HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
CUT-OFF TAB
SEAM
FineAdjust
Applicator
Application Tooling
Specification Sheet Order No. 63901-1300
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 .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
Directly adapts to most automatic wire processing machines
SCOPE
Products: 1.20mm (.047") Pitch Pico-EZmate™ Wire-to-Board Crimp Terminal, 28-30 AWG.
Terminal
Series No.
Terminal
Order No.
Wire Size Insulation Diameter Strip Length
IPC/WHMA-A620 (1)
Terminal (2)
AWG
mm² mm In. mm In. mm In.
78172 78172-0410
28-30
0.08-0.05
0.50-0.70
.020-.028
0.50-0.70
.020-.028
0.90-1.30
.035-.051
78172-0411
Oiler is required for this applicator due to gold plating on terminal.
Oiler order number 63801-7240 (See Part Number 63801-7240 on Molex Web)
(1) To achieve optimum IPC-A620 insulation crimps, use this insulation OD range.
(2) Overall insulation OD specification for terminal.
DEFINITION OF TERMS
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the
scope.
Fine Adjust Applicator for 1.20mm (.047") Pitch Pico-EZmate™ Wire-to-Board Crimp Terminal
Doc No: ATS-639011300 Release Date: 09-05-08 UNCONTROLLED COPY Page 2 of 5
Revision: C Revision Date: 05-12-11
CRIMP SPECIFICATION
Terminal Series No. Bell mouth Cut-off Tab Maximum Conductor Brush
mm In. mm In. mm In.
78172 0.05-0.15 .002-.006 0.05 .002 0.15-0.70 .006-.028
Terminal Series No.
Bend up Bend down
Twist Roll Punch Width mm (Ref) Seam
Seam shall not be open
and no wire allowed out
of the crimping area
Conductor Insulation
Degree (Max) Degree (Max)
mm In mm In
78172 3 3 2 3 0.80
.031 0.80
.031
After crimping, the conductor profile should measure the following.
Terminal
Series No.
Wire Size Conductor Crimp Pull Force
Minimum
AWG
mm2
Crimp Height Crimp Width (Ref.)
mm In. mm In. N Lb.
78172 28 0.08 0.44-0.48
.017-.019
0.85 .033 10.0
2.25
30 0.05 0.40-0.44
.015-.017
0.85 .033 5.0 1.12
Terminal
Ordr No.
Wire Size Insulation
AWG
mm2
Crimp Height Crimp Width
(Ref.)
mm In. mm In.
78172-0410
28 0.08 0.73-0.77 .028-.030 0.85
.033
30 0.05 0.71-0.75 .027-.029 0.85
.033
78172-0411
28 0.08 0.77-0.81 .030-.032 0.85
.033
30 0.05 0.75-0.79 .029-.031 0.85
.033
Pull Force should be measured with no influence from the insulation crimp.
The above specifications are guidelines to an optimum crimp.
Fine Adjust Applicator for 1.20mm (.047") Pitch Pico-EZmate™ Wire-to-Board Crimp Terminal
Doc No: ATS-639011300 Release Date: 09-05-08 UNCONTROLLED COPY Page 3 of 5
Revision: C Revision Date: 05-12-11
PARTS LIST
FineAdjust Applicator 63901-1300
Item Order No Engineering No. Description Quantity
Perishable Tooling
63901-1370 63901-1370 Tool Kit (All “Y” Items) REF
1
63457-0046 63457-0046 Conductor Punch 1 Y
2
63455-0059 63455-0059 Conductor Anvil 1 Y
3
63454-0082 63454-0082 Insulation Punch 1 Y
4
63456-0054 63456-0054 Insulation Anvil 1 Y
5
63443-0005 63443-0005 Cut-Off Plunger 1 Y
6
63443-0012 63443-0012 Front Plunger Retainer 1 Y
Other Components
7
63901-1301 63901-1301 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 Front Scrap Chute 1
11
63443-0025 63443-0025 Key 1
12
63443-0090 63443-0090 Wire Stop 1
13
63890-0058 63890-0058 Height Spacer 1
14
63443-2217 63443-2217 Coarse Spacer (17.00mm) 1
15
63443-2314 63443-2314 Fine Spacer (3.70mm) 1
16
63443-6101 63443-6101 Rear Cover 1
Frame
17
63800-4901 63800-4901 Top 1
18
63801-3281 63801-3281 Base 1
19
63801-4650 63801-4650 Track 1
20
63820-7820 63820-7820 Feed Cam-Special 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 3**
24
N/A N/A M4 by 12 Long BHCS 2**
25
N/A N/A M4 by 50 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 Point 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).
Fine Adjust Applicator for 1.20mm (.047") Pitch Pico-EZmate™ Wire-to-Board Crimp Terminal
Doc No: ATS-639011300 Release Date: 09-05-08 UNCONTROLLED COPY Page 4 of 5
Revision: C Revision Date: 05-12-11
Figure 1
26
23
10
17
1
3
17
28
16
5
20
6
7
8
19
18
25
23
12
24
21
4
(2)
(2)
9
12
(2)
22
14
15
13
11
2
23
27
Assembly Drawing
Fine Adjust Applicator for 1.20mm (.047") Pitch Pico-EZmate™ Wire-to-Board Crimp Terminal
Doc No: ATS-639011300 Release Date: 09-05-08 UNCONTROLLED COPY Page 5 of 5
Revision: C Revision Date: 05-12-11
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.
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