0638300120

63830-0000-“Mini-Fit Sr.” Terminals Mini-Mac Applicator Specification Sheet Order No. 63830-0000 FEATURES



Quick set-up time; plus the crimp height, track and feed adjustments can be preset in applicator Conductor and insulation rings allow quick adjustment for conductor and insulation diameter change Applicator designed to industry standard mounting and shut height 135.80mm (5.346") Directly adapts to most automatic wire processing machines. Optimum terminal feed/indexing can be obtained with the optional terminal guide assembly, Order No. 63830-0120. See page 6. SCOPE Mini-Fit Sr.™ Male and Female Crimp Terminals, 8 AWG Terminal Series No. Terminal Order No. 42815-0030 42815-0031 42815-0030 42815-0031 42817-0030 42817-0031 42817-0032 42817-0030 42817-0031 42817-0032 42815 42817 42815-0032 42815-0032 42817-0130 42817-0131 42817-0132 42817-0130 42817-0131 42817-0132 ∗Insulation Diameter mm In. Wire Size AWG mm² Strip Length mm In. 8 8.50 5.00-6.75 .197-.266 9.00-10.00 .354-.394 (2) 12 (2) 3.30 3.50-4.00 .138-.157 11.00-12.00 .433-.472 8 8.50 5.00-6.75 .197-.266 9.00-10.00 .354-.394 (2) 12 (2) 3.30 3.50-4.00 .138-.157 11.00-12.00 .433-.472 ∗On Mini-Fit Sr. 8 AWG terminal, the insulation is stripped in both the conductor and insulation grips. DEFINITION OF TERMS INSULATION GRIP AREA 3.75mm ± 0.20 3.75mm ± 0.20 BELL MOUTH WIRE INSULATION CONTACT GAP 1.00mm ± 0.20 BEND UP SEAM TWISTING ROLLING CONTACT GAP 0.00mm - 0.05mm INSULATION GAP 0.00mm-1.00mm max. BEND DOWN Doc No. ATS-638300000 Revision: G Release Date: 11-16-99 Revision Date: 12-22-06 UNCONTROLLED COPY Page 1 of 7 63830-0000-“Mini-Fit Sr.” Terminals CRIMP SPECIFICATIONS Terminal Series No. 42815 42815 42817 42817 Terminal Series No. 42815 42815 42817 42817 Wire Size AWG mm² 8 8.50-8.42 (2) 12 (2) 3.30 Wire Size Bell mouth mm In. .20-.50 .008-.020 .20-.50 .008-.020 Cut-off Tab Max. mm In. .30-.50 .012-.020 .30-.50 .012-.020 Bend up Bend down Twist Roll AWG mm² 8 8.50-8.42 (2) 12 (2) 3.30 Degree 3 3 3 3 Degree 4 8 4 8 Conductor Brush mm In. 2.10-3.10 .083-.122 2.10-3.10 .083-.122 Seam Seam shall not be open and no wire allowed out of the crimping area. After crimping, the conductor profile should measure the following. Terminal Series No. 42815 42815 42815 Wire Size AWG 8
8 (2) 12 mm2 8.50 8.42 (2) 3.30 Conductor Crimp Height mm In. 3.20-3.30 .126-.130 3.40-3.50 .134-.138 3.20-3.30 .126-.130 Crimp Width mm In. 3.90 .154 3.90 .154 3.90 .154 Pull Force Min. N 400.3 400.3 311.4 Lb. 90.0 90.0 70.0 42817 42817 42817 8 8.50 3.20-3.30 .126-.130 3.90 .154 400.3 90.0
8 8.42 3.40-3.50 .134-.138 3.90 .154 400.3 90.0 (2) 12 (2) 3.30 3.20-3.30 .126-.130 3.90 .154 311.4 70.0
8 AWG Hi-Flex wire (665 strands). This type of wire has very fine strands. Please note: Extra precaution must be maintained during stripping operation to prevent loosing or breaking strands. Lost or broken strands may result in lower pull force strength and broken strands may cause a possible electric shock or shortage. Pull Force should be measured with no influence from the insulation crimp. The above specifications are guidelines to an optimum crimp. Doc No. ATS-638300000 Revision: G Release Date: 11-16-99 Revision Date: 12-22-06 UNCONTROLLED COPY Page 2 of 7 63830-0000-“Mini-Fit Sr.” Terminals Special Note: EXTRUDED WIRE LENGTH (BRUSH) BELL MOUTH (FLARE) 0.50mm REF INSULATION GRIP A 5.00mm REF A WIRE STRANDS CUT-OFF TAB LENGTH SECTION A-A Figure 1 1. Cut-off Tab length below 0.30mm may cause the box dimension to be under recommendation. See Figure 1. 2. Wire insulation should not be crimped and insulation grip area should be formed to contain wire strands only. 3. Changing the insulation height setting may be needed to achieve the dimensions of the insulation grip in Section A-A. See Figure 1. 4. If wire strands are missed from conductor crimps, the operator should place the wires in the terminal, in the correct location, without using the wire stop/ stripper for locating the wire. Doc No. ATS-638300000 Revision: G Release Date: 11-16-99 Revision Date: 12-22-06 UNCONTROLLED COPY Page 3 of 7 63830-0000-“Mini-Fit Sr.” Terminals PARTS LIST Mini-Mac Applicator 63830-0000 Item Order No Engineering No. Description Quantity Perishable Tooling 63830-0070 63830-0070 Tool Kit (All “Y” Items) REF 1 63830-0001 63830-0001 Conductor Punch 1Y 2 63830-0002 63830-0002 Conductor Anvil 1Y 3 63830-0003 63830-0003 Insulation Punch 1Y 4 63830-0004 63830-0004 Insulation Anvil 1Y 5 63443-0045 63443-0045 Front Cut-off Plunger 1Y 6 63443-0046 63443-0046 Front Cut-off Plunger Retainer 1Y Other Components 7 11-18-5248 60827A115 Tooling Washer 1 8 63443-0009 63443-0009 Scrap Chute Front 1 9 63443-0021 63443-0021 Lower Tooling Key 1 10 63443-2401 63443-2401 Anvil Mount 1 11 63700-0539 63700-0539 Cut-Off Plunger Spring 1 12 63821-0012 63821-0012 Front Cover 1 13 63821-0015 63821-0015 Wire Stop 1 14 63830-0008 63830-0008 Front Plunger Striker 1 15 63830-0113 63830-0113 Rear Cover 1 15A 63830-0120 63830-0120 Optional Terminal Guide Assembly 0 Frame 16 63800-4300 63800-4300 Mini-Mac Applicator Frame 1 17 69028-0806 69028-0806 Conductor Adjusting Cam 1 Hardware 18 N/A N/A M3 by 6 Long SHCS 2** 19 N/A N/A M4 by 6 Long SHCS 1** 20 N/A N/A M4 by 12 Long BHCS 2** 21 N/A N/A M4 by 30 Long SHCS 1** 22 N/A N/A M4 by 50 Long SHCS 1** 23 N/A N/A M5 by 12 Long SHCS 1** 24 N/A N/A M8 by 20 Long BHCS 1** 25 N/A N/A 2mm by 8 Long Roll Pin 1** 26 N/A N/A 3mm by 6 Long Roll Pin 1** ** Available from an industrial supply company such as MSC (1-800-645-7270). Doc No. ATS-638300000 Revision: G Release Date: 11-16-99 Revision Date: 12-22-06 UNCONTROLLED COPY Page 4 of 7 63830-0000-“Mini-Fit Sr.” Terminals Assembly Drawing 17 1 3 16 14 7 24 15 (2) 20 16 (2) 18 13 12 23 10 2 5 11 25 26 4 21 19 6 22 Doc No. ATS-638300000 Revision: G 9 Figure 1 8 Release Date: 11-16-99 Revision Date: 12-22-06 UNCONTROLLED COPY Page 5 of 7 63830-0000-“Mini-Fit Sr.” Terminals OPERATION: The Optional Terminal Guide Assembly helps to align slightly bent up or down terminals, entering the track. Recommended for use with wire processing equipment, or roughly handled terminal reels. To install the Optional Terminal Guide assembly follow the steps below. 1 2 3 4 Remove the M4 X 12 BHCS (2) from the existing rear cover (Part No. 63830-0113) on the applicator. Remove the 63830-0113 rear cover. Replace it with the 63830-0120 Optional Terminal Guide Assembly. Replace the M4 X 12 BHCS (2). 3 (4) 1 REF (2) 4 2 1 Optional Terminal Guide Assembly 63830-0120 Item Order No Engineering No. Description Quantity 1 63830-0117 63830-0117 Terminal Lead-In 2 2 63830-0118 63830-0118 Rear Cover 1 Hardware 3 N/A N/A M3 by 6 Long SHCS 4** 4 N/A N/A M4 by 12 Long BHCS REF** ** Available from an industrial supply company such as MSC (1-800-645-7270). Doc No. ATS-638300000 Revision: G Release Date: 11-16-99 Revision Date: 12-22-06 UNCONTROLLED COPY Page 6 of 7 63830-0000-“Mini-Fit Sr.” Terminals NOTES 1. 2. 3. 4. 5. Molex recommends an extra perishable tooling kit be maintained at your facility. Verify tooling alignment by manually cycling the press and applicator before crimping under power. Check that all screws are tight. Slugs, terminals, dirt, and oil should be kept clear of work area. Wear safety glasses at all times. For recommended maintenance refer to the Mini-Mac 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. Contact Information For more information on Molex application tooling please contact Molex at 1-800-786-6539. Americas Headquarters Lisle, Illinois 60532 U.S.A. 1-800-78MOLEX amerinfo@molex.com Far East North Headquarters Yamato, Kanagawa, Japan 81-462-65-2324 feninfo@molex.com Far East South Headquarters Jurong, Singapore 65-6-268-6868 fesinfo@molex.com European Headquarters Munich, Germany 49-89-413092-0 eurinfo@molex.com Corporate Headquarters 2222 Wellington Ct. Lisle, IL 60532 U.S.A. 630-969-4550 Fax: 630-969-1352 Visit our Web site at http://www.molex.com Doc No. ATS-638300000 Revision: G Release Date: 11-16-99 Revision Date: 12-22-06 UNCONTROLLED COPY Page 7 of 7