Fine Adjust Applicator for 1.20mm (.047") Pitch Pico-EZmateTM Wire-to-Board Crimp Terminal 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-EZmateTM Wire-to-Board Crimp Terminal, 28-30 AWG. Terminal Series No. Terminal Order No. Wire Size Insulation Diameter IPC/WHMA-A620 (1) Terminal (2) mm In. mm In. Strip Length AWG mm mm In. 78172-0410 78172 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 BELL MOUTH BRUSH BEND UP SEAM INSULATION CRIMP ROLLING TWISTING STRIP LENGTH BEND DOWN CUT-OFF TAB CONDUCTOR COND.CRIMP CRIMP HEIGHT The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the scope. Doc No: ATS-639011300 Revision: C Release Date: 09-05-08 Revision Date: 05-12-11 UNCONTROLLED COPY Page 1 of 5 Fine Adjust Applicator for 1.20mm (.047") Pitch Pico-EZmateTM Wire-to-Board Crimp Terminal CRIMP SPECIFICATION Terminal Series No. 78172 Terminal Series No. Bell mouth mm In. 0.05-0.15 .002-.006 Bend up Bend down Degree (Max) 3 3 78172 Cut-off Tab Maximum mm In. 0.05 .002 Conductor Brush mm In. 0.15-0.70 .006-.028 Punch Width mm (Ref) Seam Conductor Insulation Seam shall not be open Degree (Max) mm In mm In and no wire allowed out of the crimping area 2 3 0.80 .031 0.80 .031 Twist Roll After crimping, the conductor profile should measure the following. Wire Size Terminal Series No. AWG mm2 78172 28 30 Conductor Crimp Pull Force Crimp Height Crimp Width (Ref.) Minimum mm In. mm In. N Lb. 0.08 0.44-0.48 .017-.019 0.85 .033 10.0 2.25 0.05 0.40-0.44 .015-.017 0.85 .033 5.0 1.12 Wire Size Terminal Ordr No. 78172-0410 78172-0411 AWG mm2 28 30 28 30 0.08 0.05 0.08 0.05 Insulation Crimp Height mm 0.73-0.77 0.71-0.75 0.77-0.81 0.75-0.79 In. .028-.030 .027-.029 .030-.032 .029-.031 Crimp Width (Ref.) mm In. 0.85 .033 0.85 .033 0.85 .033 0.85 .033 Pull Force should be measured with no influence from the insulation crimp. The above specifications are guidelines to an optimum crimp. Doc No: ATS-639011300 Revision: C Release Date: 09-05-08 Revision Date: 05-12-11 UNCONTROLLED COPY Page 2 of 5 Fine Adjust Applicator for 1.20mm (.047") Pitch Pico-EZmateTM Wire-to-Board Crimp Terminal 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 1Y 2 63455-0059 63455-0059 Conductor Anvil 1Y 3 63454-0082 63454-0082 Insulation Punch 1Y 4 63456-0054 63456-0054 Insulation Anvil 1Y 5 63443-0005 63443-0005 Cut-Off Plunger 1Y 6 63443-0012 63443-0012 Front Plunger Retainer 1Y 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). Doc No: ATS-639011300 Revision: C Release Date: 09-05-08 Revision Date: 05-12-11 UNCONTROLLED COPY Page 3 of 5 Fine Adjust Applicator for 1.20mm (.047") Pitch Pico-EZmateTM Wire-to-Board Crimp Terminal Assembly Drawing 27 23 28 20 17 3 1 9 24 (2) 16 17 19 (2) 18 21 12 7 26 5 23 2 4 8 14 15 6 12 13 11 Figure 1 22 25 10 (2) Doc No: ATS-639011300 Revision: C 23 Release Date: 09-05-08 Revision Date: 05-12-11 UNCONTROLLED COPY Page 4 of 5 Fine Adjust Applicator for 1.20mm (.047") Pitch Pico-EZmateTM Wire-to-Board Crimp Terminal 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 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. http://www.molex.com Doc No: ATS-639011300 Revision: C Release Date: 09-05-08 Revision Date: 05-12-11 UNCONTROLLED COPY Page 5 of 5