molex PicoBlade 1.25 W/W User guide

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TITLE: PicoBlade 1.25 W/W TYPE
APPLICATION SPECIFICATION
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2018/11/02 S.OBARA
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DESIGN CONTROL
J
STATUS
WRITTEN BY:
SOBARA01
CHECKED BY:
A.IDA
APPROVED BY:
T.KANEKO
DATE:
2018/08/14
DOCUMENT NUMBER
510210001-AS
DOC. TYPE
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DOC. PART
000
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GENERAL
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EN-127(2015-12 )
APPLICATION SPECIFICATION
This application specification is written in English and Japanese.
本取扱説明書は、英文および和文で記載されております。
English 英文: Page 1~28
Japanese 和文: Page 29~57
【1.APPLICATION】
Product Name
Part Number
RECEPTACLE
SIDE
RECEPTACLE HOUSING
51021 series
RECEPTACLE CRIMP TERMINAL
AWG#28~32
50058 series
AWG#26~28
50079 series
APPLICABLE CRIMP DIE MODEL No.
57067-3**0
PLUG SIDE
PLUG HOUSING
51047 series
PLUG CRIMP TERMINAL
AWG#28~32
50133 series
AWG#26~28
50125 series
APPLICABLE CRIMP DIE MODEL No.
57138-3000
APPLICABLE WIRE
AWG#26～32
Tin plated stranded wire
※Please refer to crimp specification for further details.
APPLICATION SPECIFICATION
PicoBlade 1.25 W/W TYPE

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―Before using ―
・Be sure to read the following precautions before using connector.
・Keep this manual for reference at any time.
・The displays and illustrations shown in this manual are for illustrative purposes only and may differ
from the actual product.
・The contents of this manual are subject to change without notice.
・If you find any mistake or there is anything that is not clear, lease contact your sales representative.

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TITLE: PicoBlade 1.25 W/W TYPE
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Contents
1．Application････････････････････････････････････････････････････････････････ P-1
2．Instructions
2-1. Product exterior････････････････････････････････････････････････････････ P-4
2-2. Applicable wire and crimp tooling････････････････････････････････････････ P-4
2-3. About safekeeping before harness process･･･････････････････････････････ P-4
2-4. Harness process instruction.････････････････････････････････････････････ P-5～6
2-5. About use in the machinery.･････････････････････････････････････････････ P-6
2-6. About rating / performance standard.・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ P-6
2-7. Use of the product. ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ P-6
3．The name of each part & explanation
3-1. Receptacle crimp terminal・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ P-7
3-2. Receptacle housing・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ P-8
3-3. Plug crimp terminal・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ P-9
3-4. Plug housing・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ ・P-10
4．The confirmation item for crimping wire
4-1. The appearance before crimping.・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ P-11
4-2. The appearance after crimping.・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ P-11
4-3. Crimping failure・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ P-12～14
5．Wire bundling and package after crimping・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ P-15
6．Harness processing (crimping wire insertion method in housing)
6-1. Insertion crimping wire・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ P-16～19
6-2. Repair of crimp terminal・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ P-20～21
7．Banding of harness・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ P-22～23
8．Packing method of harness・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ P-24～25
9．Mating instruction
9-1．Mating process method ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ P-26
9-2．Un-mating process method ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ P-27
9-3．Wiring after mating ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ P-27～28

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TITLE: PicoBlade 1.25 W/W TYPE
APPLICATION SPECIFICATION
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【2.Instructions】
2-1. Product exterior
1. There is no influence on the product performance if black spots, bubbles might be on the plastic part of this
product, or different color tone including discoloration by secular change.
2. Slide marks may sometimes appear on plating part of the product, but there is no impact on the function of this
product.
2-2. Applicable wire and crimp tooling
1. Guarantee is void when product is used with wire out of application range specified in the product
specifications.
2. Guarantee is void when product is used with non Molex authorized tooling.
3. Recommended electric wire is tin plated stranded copper wire.
2-3. About safekeeping before harness process
1. Please keep product as it is delivered and packaged. Also, please keep it under normal temperature and
humidity away from direct sunlight.
2. Please do not allow external force on product and package during the storage.
3. During handling, avoid shock or dropping products as it may cause damage.
4. First-in, first-out of the stock is recommended.
5. Keep product in original packaging until using.
6. This product should be inspected its appearance and solder performance before using after storage expiration
date.

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2-4. Harness process instruction.
1. Please confirm if the products and crimp machine, crimp condition, an applicable wire are equal to product
drawing, crimp specifications before use.
2. Beware of dust, debris, or foreign objects on the product, or deformation of the product before using. It may
result in insufficient of the insertion performance to the housing and electric performance.
3. Please do not touch the terminal by bare hand.
4. When a terminal is twisted or tangled, please do not handle it by too much force. The terminal may become
damaged.
5. Do not apply force to the product during work in process or in finishing goods. Product may be damaged and
may not function properly as a connector.
6. Please do not expose a product including a harness half-finished goods to the following condition.
・Dust
・Corrosive material
・Corrosive gas
・High temperature and high humidity
・Direct sunlight
The above conditions may cause poor contact, corrosion of the terminal and the insulation performance
deterioration of the housing. Please keep in boxes.
7. Please do not add loads to connector, harness and half-finished goods during production, packaging,
transportation, or storage. It may cause damage and result in poor performance.
8. Do not apply excessive force or tension to avoid damage to the contact part, crimp part, or lance part when
pulling a wire of a harness or a half-finished goods.
9. Do not damage housing and crimp terminal intentionally. Product performance can be affected by this
condition.
10. Please use product within the day of its package is opened. Moisture absorption or drying may cause the
deterioration of materials by neighboring atmospheres. When you cannot use it up, please seal the bag again
and keep it in a box.
11. Please be careful not to be injured with the edges part such as metal parts when handling a connector.
12. To avoid injury, please be careful when handling the paper between terminals and metal carrier on reels.
13. Do not pull wires of mated connector with so much force to prevent connector from damage.

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2-5. About use in the machinery.
1. Vibration of an electric wire or contact area due to machinery vibration or rotation must be avoided to prevent
damage to connector at contact area. Contact failure due to abrasion may be caused. Therefore, please fix
electric wires and connector in the machinery and take measures to hold resonances.
2. Please insert and withdraw connector along fixed axis. The diagonal insertion and withdrawal cause damage
to the connector.
3. After mating, do not intentionally apply force to span or rotate a connector. Such force may cause damage to
connector or solder cracking.
4. If electric wire is pulled after mating a connector, it may damage contact or crimping areas or the lock area
and result in contact failure. When performing the guidance wiring of the electric wire. Please keep the wire
loose to avoid applying excessive force and tension to connector.
5. Mold lances may be damaged after removing crimp terminals. Therefore, please use a new housing when
repairing a connector.
2-6. About rating / performance standard.
1. Please use the product within the rating / the standard of product specifications.
2. This product is not designed for usage in “hot-swap”applications where power is on.
3. Before using, please confirm that this product satisfies the equipment specifications.
4. In order to avoid short circuits, please do not allow connectors to contact with metal objects.
5. Please avoid to use current higher than the rated current.
2-7. Use of the product.
1. This product is not designed and produced for the machine to be used under the condition involving human
lives or for the use of system. If you use this product for special use such as medical, aerospace and nuclear
power etc., please confirm us before using.
2. Please contact us without fail before using if you plan to use the product for automobile and ship etc. (We will
consider if the product can be applied to such specification condition.)
3. Please avoid using the product outdoors or under similar environment.

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【3. The name of each part & explanation】
※Please refer to sales drawing for product form and its dimensions.
3-1．Receptacle crimp terminal：50058, 50079 series.
Pilot hole
Part for positioning in crimping process
Carrier (not included in loose version)
Part for connecting each termina
Insulation barrel
Crimping area for wire insulation
Wire barrel
Crimping area for wire conductor.
Terminal lance
Part to prevent terminal from
coming out of housing
Fig. 3-1 Receptacle crimp terminal
Terminal
Contact
Electrical mating part.

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3-2．Receptacle housing：51021 series
Electric wire
Receptacle housing
(51021 series)
Friction Lock
Lock structure not to come off accidentally
after mating
Mold lance
Part to prevent terminal from coming out of housing
Fig. 3-2 Receptacle housing

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3-3．Plug terminal: 50133, 50125 series.
Pilot hole
Part for positioning in crimping process
Carrier (not included in loose version)
Part for connecting each terminal
Insulation barrel
Crimping area for wire insulation
Wire barrel
Crimping area for wire conductor
Contact
Electrical mating part.
Terminal
Terminal lance
Part to prevent terminal from
coming out of housing
Fig. 3-3 Plug terminal

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3-4. Plug housing：51047 series
Locking window
Lock structure not to come off accidentally after
mating
Mold lance
Part to prevent terminal from coming out of housing
Fig. 3-4 Plug housing
Plug housing
(51047 series)
Electric wire

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1. No visible damage or deformation on contact area.
2. All stranded wires do not protrude to the outside of the terminal.
3. The insulator part of wire is located in the intermediate position of wire barrel
and insulation barrel.
4. No damage on terminal lance.
5. No damage on appearance.（Dirt / foreign objects）
【4. Confirmation items for crimping wire】
4-1．The appearance before crimping.
Please make sure that there is no deformation of the crimp terminal. If you find that the terminals are tangled,
please do not remove them forcibly.Please refer to sales drawing for product form and its dimensions.
4-2．The appearance after crimping.
Confirmation items and crimping failure after crimping are shown as follows. Please refer to crimp specifications
for crimp height, and applicable wire specifications, and so on.
Fig. 4-1
1
4
3
2
4
2
3
1

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4-3．Crimping failure.
Please be careful of the crimping failure as shown below. It may affect the insertion to housing and affect a
product function. (Although the case of the receptacle terminal is shown below as example, please be careful
about the plug terminal as well.)
1. Bend up
It may deteriorate insertion to housing and terminal retention force or cause contact failure.
2. Bend down
It may deteriorate insertion to housing and terminal retention force or cause contact failure.
3. Twist
It may deteriorate insertion to housing and terminal retention force or cause contact failure.
○
Good
×
×
No Good
No Good
×
No Good
×
No Good
Fig. 4-2
Fig. 4-3
Fig. 4-4

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4. Rolling
It may deteriorate insertion to housing and terminal retention force or cause contact failure.
5. Crush and deformation of contact area and contact box
It may deteriorate insertion to housing and terminal retention force or cause contact failure.
6. Stranded wires are not inside the conductor barrel
It may deteriorate insertion to housing and cause contact failure.
○
×
×
Good
No Good
No Good
×
No Good
×
No Good
Fig. 4-5
Fig. 4-6
Fig. 4-7
×
No Good

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7. Crimping position: Too front
It maycause breaking of wire, deterioration of wire crimping strength and disconnection by crimping insulator.
8. Crimping position: Too behind
It may cause deterioration of wire crimping strength and disconnection by not having enough crimping margin.
As wire insulation is not crimped completely, wire insulation falls off easily when wire is pulled.
9. Deformation of terminal lance
Locking of the terminal becomes insufficient and causes lowering of the terminal retention force.
×
No Good
×
No Good
Pulling
Fig. 4-8
Fig. 4-9
Fig. 4-10
×
No Good
×
No Good
×
No Good

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【5. Wire bundling and package after crimping】
Please check for damaged terminal and wire insulation, when bundling wires.
(Recommended bundling position is 30mm from crimped portion. Fig. 5-1)
Please check for the quantity per packing-box.
Do not over pack crimped wires in a box as there is risk of damaging terminals
※When bundling wires, please be careful not to apply excessive force to terminals.
※When packing bundled harnesses in package box, please stack product alternately so that no load is
applied to connector for a long time. (Fig.5-2)
※Please lay buffer material on the bottom and top of the package box. (Fig.5-2)
Also, please lay buffer material between bundled wires as necessary, in order to avoid applying force
to connector for a long time by stacking the wires.
Instruction
Fig. 5-1
Fig. 5-2
Buffer material
(Air-packing)
Packing box
Pile up the bundled
wires alternately.
30mm
Recommended
bundling position

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【6. Harness processing (crimping wire insertion method in Receptacle housing)】
Insertion procedure and instructions (※) of the crimping wire are shown as follows:
(Although the case of the receptacle terminal and housing is shown below as example,
please be careful about the plug terminal and housing as well.)
6-1．Insertion of crimping wire
1. Hold receptacle housing by pinching right and left side softly.
※Don’t hold on mold lance when you insert crimping wire to receptacle housing. (Fig.6-1)
It makes difficult to insert, or connector may be deformed or damaged.
2. Please hold the cable at about 10mm away from the crimped portion with fingers lightly.
※If you hold the wire at a position distant from terminal, wires will be easily bent and it may be difficult to insert.
※Optimum distance to hold wire depends on wire gauge, UL, etc. Please confirm with the wire
that you chose before using.
3. Hold wire and have terminal lance part toward receptacle housing, then insert terminal slowly and straightly
till the tip of terminal touches housing (with force of around 2～4N). (Fig.6-2)
Fig. 6-1
No Good
×
○
Good
Fig. 6-2
Terminal lance
Mold lance

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TITLE: PicoBlade 1.25 W/W TYPE
APPLICATION SPECIFICATION
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DOC. PART
000
CUSTOMER
GENERAL
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17 OF 58
EN-127(2015-12)
APPLICATION SPECIFICATION
※If crimping height and width are too large, there is a problem for the terminal insertion.
Please follow the instructed crimping height. (Please refer to crimping specifications for detail）
※Please keep correct insertion direction. (Fig.6-3)
Please be careful that the terminal is not upside down, not having an angle over 5°, or not rotated against
receptacle housing. These may cause terminal deformation or damage to receptacle housing. (Fig.6-4)
※If you feel unusual such as hooking during the insertion, please stop insertion and confirm if there is
no damage of terminal or receptacle housing.
If the damage is found, do not use the terminal and receptacle housing.
Instruction
〇
Terminal lance
Mold lance
Upside down direction
×
Rotated (Beyond 5°)
×
Oblique direction
×
Fig.6-4 Inappropriate insertion direction
Fig.6-3 Correct insertion direction
Good
No Good
No Good
No Good

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TITLE: PicoBlade 1.25 W/W TYPE
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TECHNOLOGIES, LLC AND SHOULD NOT BE USED WITHOUT WRITTEN PERMISSION
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DOCUMENT NUMBER
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DOC. PART
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GENERAL
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18 OF 58
EN-127(2015-12)
APPLICATION SPECIFICATION
4. After inserting the terminal, please confirm if terminals are not pulled out from receptacle housing
by pulling wires lightly (with about 100g force, in order not to damage connector.)
5. After inserting all terminals, please confirm the position of mold lance and terminal lance.
If they are inserted correctly, terminal lance is locked by mold lance. (Fig.6-5, 6-6)
Fig.6-5 Case of correct insertion
〇
Terminal has reached the end
Terminal lance is
locked by mold lance
Terminal has not reached the end
Fig.6-6 Case of incomplete insertion
×
Terminal lance is under mold
lance and not locked.
Good
No Good

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TITLE: PicoBlade 1.25 W/W TYPE
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EN-127(2015-12)
APPLICATION SPECIFICATION
※If terminal is inserted incompletely, terminal lance is not locked with mold lance and terminal is not retained.
※In the case of incomplete insertion (see Fig.6-6), mold lance is deformed. Mold lance kept in such condition
is deformed and not go back to correct position, and retention force may decrease even if terminal is
re-inserted in to housing. In this case, please replace housing to new one.
6. When checking harness after processing, please avoid bending wire excessively or with tension.
That might cause contact failure because force was added to terminal crimping part or receptacle
housing lance part.
7. When having a conduction check, do not attach anything besides applicable mating connector.
That might cause contact failure because of transformation of terminal etc.
Instruction

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TITLE: PicoBlade 1.25 W/W TYPE
APPLICATION SPECIFICATION
A
SEE SHEET 1 OF 58
THIS DOCUMENT CONTAINS INFORMATION THAT IS PROPRIETARY TO MOLEX ELECTRONIC
TECHNOLOGIES, LLC AND SHOULD NOT BE USED WITHOUT WRITTEN PERMISSION
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DOC. TYPE
PS
DOC. PART
000
CUSTOMER
GENERAL
SHEET
20 OF 58
EN-127(2015-12)
APPLICATION SPECIFICATION
6-2．Repair of crimp terminal
For receptacle terminal
When you withdraw the crimp terminal inserted once, please use jig 57072-6000 to raise mold lance.
However, mold lance is deformed by being raised. As strength of the deformed lance decreases extremely,
the terminal might come off easily from housing even if you insert it again.
Therefore, please be sure to change the receptacle housing to a new one when you repair crimp terminal.
Also, please use an appropriate magnifying glass and repair with caution.
※Please avoid pulling off terminal by force.
※When repairing, please be careful not to deform or scratch terminal lance.
※When you use jig 57072-6000, please refer to instruction manual for jig.
Fig.6-7
Step.3
Pull out jig and wires together.
Step.2
Insert a jig and lift up mold
lance.
Step.1
Bend the wire in the downward
direction in the figure.