Fine Adjust Applicator PicoLock
1.00mm (.039") Wire to Board Crimp Terminal
FineAdjust
Applicator
Application Tooling
Specification Sheet
Order No. 63903-3400
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: PicoLock 1.00mm (.039") Wire to Board Crimp Terminal, 28-30 AWG.
Terminal Series No.
Terminal Order No.
Wire Size
Insulation Diameter
Terminal (1)
mm
In.
0.50-0.70
.020-.028
Strip Length
mm
0.90-1.30
In.
.035-.051
AWG
28
503765
503765-0098
30
(1) Overall insulation OD specification for terminal.
DEFINITION OF TERMS
STRIP LENGTH
BRUSH
BELL MOUTH
SEAM
TWISTING
BEND UP
ROLLING
CUT-OFF
TAB
BEND
DOWN
CONDUCTOR
CRIMP HEIGHT
WIRE
INSULATION CRIMP
▲SEE
NOTE
The above terminal drawing is a generic terminal representation. It is not an image of any terminal listed in the
scope.
Doc No: ATS-639033400
Revision: A
Release Date: 10-09-15
Revision Date: 10-09-15
UNCONTROLLED COPY
Page 1 of 5
Fine Adjust Applicator PicoLock
1.00mm (.039") Wire to Board Crimp Terminal
INSULATION CRIMP FORM
This crimp terminal is designed for miniaturization;
therefore, each dimension of insulation crimp portion
appears small as compared to the terminal material
thickness. In order to avoid insulation piercing the crimp
forms by the insulation barrel, coining is provided inside of the insulation barrel. For this reason, various crimp
forms will occur at the tip of the insulation crimp barrel shown in the figure below.
These crimp forms maybe changed completely by a small change in the wire, insulation punch, or terminal.
These crimp forms are satisfactory for original function of the insulation crimp portion and it is confirmed that all of
these forms below are acceptable insulation crimps.
CRIMP SPECIFICATION
Terminal Series No.
503765
Bell mouth
mm
In.
0.05-0.15 .002-.006
Cut-off Tab Maximum
mm
In.
0.05
.002
Conductor Brush
mm
In.
0.10-0.40 .004-.016
Seam
Seam shall not be open
and no wire allowed out of
the crimping area
Terminal Series No.
503765
Bend up Bend down
Degree
3
2
Twist Roll
Degree
2
3
Punch Width mm (Ref)
Conductor Insulation
mm
In
mm
In
0.70
.028
0.70
.028
After crimping, the conductor profile should measure the following.
Terminal Series No.
503765
Wire Size
AWG
28
30
Conductor Crimp Height
mm
In.
0.42-0.46
.017-.018
0.38-0.42
.015-.017
Pull Force Minimum
N
Lb.
9.8
2.20
4.9
1.10
Wire Size
Terminal Series No.
503765
AWG
28
30
Insulation
Crimp Height (Max.) Crimp Width (Ref.)
mm
In.
mm
In.
0.90
.035
0.70
.028
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-639033400
Revision: A
Release Date: 10-09-15
Revision Date: 10-09-15
UNCONTROLLED COPY
Page 2 of 5
Fine Adjust Applicator PicoLock
1.00mm (.039") Wire to Board Crimp Terminal
PARTS LIST
FineAdjust Applicator 63903-3400
Item Order No Engineering No.
Description
Quantity
Perishable Tooling
63903-3470
63903-3470
Tool Kit (All “Y” Items)
REF
1
63457-0701
63457-0701
Conductor Punch
1Y
2
63456-0020
63456-0020
Combination Anvil
1Y
3
63454-0702
63454-0702
Insulation Punch
1Y
4
63443-0005
63443-0005
Cut-Off Plunger
1Y
5
63443-0012
63443-0012
Front Plunger Retainer
1Y
Other Components
6
11-17-0022
1739-21
Terminal Hold Down Spring
1
7
11-18-4083
60707-8
Feed Guide
1
8
63443-0009
63443-0009
Front Scrap Chute
1
9
63443-0024
63443-0024
Key
1
10 63443-0093
63443-0093
Terminal Hold Down Shank
1
11 63443-2205
63443-2205
Coarse Spacer (5.00mm)
1
12 63443-2318
63443-2318
Fine Spacer (3.90mm)
1
13 63443-2805
63443-2805
Front Plunger Striker
1
14 63443-2904
63443-2904
Wire Hold Down Plunger
1
15 63443-6109
63443-6109
Rear Cover
1
16 63443-7315
63443-7315
Terminal Hold Down Plunger
1
17 63443-7316
63443-7316
Terminal Hold Down Retainer
1
18 63443-7317
63443-7317
Terminal Hold Down Retainer Plate
1
19 63443-7318
63443-7318
Terminal Hold Down
1
20 63600-0021
63600-0021
Striker Compression Spring
1
21 63700-0539
63700-0539
Cut-Off Plunger Spring
1
22 63700-0992
63700-0992
Terminal Hold Down Plunger Spring
1
Frame
23 63800-4901
63800-4901
Top
1
24 63801-3281
63801-3281
Base
1
25 63801-4650
63801-4650
Track
1
26 63820-7820
63820-7820
Feed Cam
1
Hardware
27
N/A
N/A
M3 by 6 Long SHCS
2**
28
N/A
N/A
M3 by 8 Long SHCS
1**
29
N/A
N/A
M3 by 6 Long FHCS
1**
30
N/A
N/A
M4 by 6 Long SHCS
1**
31
N/A
N/A
M4 by 12 Long BHCS
2**
32
N/A
N/A
M4 by 45 Long SHCS
2**
33
N/A
N/A
#10-32 by 3/8”Long Flat Point SSS
1**
34
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-639033400
Revision: A
Release Date: 10-09-15
Revision Date: 10-09-15
UNCONTROLLED COPY
Page 3 of 5
Fine Adjust Applicator PicoLock
1.00mm (.039") Wire to Board Crimp Terminal
Assembly Drawing
23
33
34
26
3
31
(2)
20
15
13
1
6
14
10
(2) 27
23
25
7
17
16
4
2
21
5
22
9
32 (2)
8
29
30
19
28
18
12
11
24
Figure 1
Doc No: ATS-639033400
Revision: A
Release Date: 10-09-15
Revision Date: 10-09-15
UNCONTROLLED COPY
Page 4 of 5
Fine Adjust Applicator PicoLock
1.00mm (.039") 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 135.80 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.
Visit our Web site at http://www.molex.com
Doc No: ATS-639033400
Revision: A
Release Date: 10-09-15
Revision Date: 10-09-15
UNCONTROLLED COPY
Page 5 of 5
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