0638321000

Mechanical Feed-Dual Carrier Metal Strip Mini-Mac Applicator Application Tooling Specification Mechanical Feed Dual Carrier Metal Strip Order No. 63832-1000 FEATURES % % % % Directly adapts to most crimp presses and automatic wire processors Applicator designed to industry-standard mounting and shut height of 135.80mm (5.346") Conductor and insulation rings allow quick adjustment for conductor and insulation crimp height change Quick set-up time; plus the crimp height, track and feed adjustments can be set without removing the applicator from the crimp press SCOPE Insulation Diameter Max. Strip Length mm In. mm In. 42824-4002 ✴ ✴ 4.20 .165 4.34-5.15 .171-.203 42824-4005 ✴ ✴ 4.20 .165 4.34-5.15 .171-.203 42825-4002 ✴ ✴ 4.20 .165 4.34-5.15 .171-.203 42825-4005 ✴ ✴ 4.20 .165 4.34-5.15 .171-.203 Terminal will accommodate the following wire specification: ✴ THHN stranded wires and TFN solid bare wires Terminal Series No. Wire Size AWG mm² ∗ These terminals require two different applicators depending on the wire combinations to be produced. Applicator 63832-1000 produces: single wire 12; double wire 12+18. Applicator 63832-1100 produces: single wire 10; double wire 12+16, 10+18, and 12+12. DEFINITION OF TERMS BRUSH BEND UP BELL MOUTH CONDUCTOR CRIMP ROLLING SEAM INSULATION CRIMP TWISTING STRIP LENGTH BEND DOWN CUT-OFF TAB CRIMP HEIGHT The above terminal drawing is a generic terminal representation. It is not an image of any terminal listed in the scope. Doc No. 63832-1000 Revision: A Release Date: 12-05-05 Revision Date: 12-05-05 UNCONTROLLED COPY Page 1 of 5 Mechanical Feed-Dual Carrier Metal Strip CRIMP SPECIFICATION Terminal Series No. 42824-4002 42824-4005 42825-4002 42825-4005 mm 0.20-0.60 0.20-0.60 0.20-0.60 0.20-0.60 Bend up Bend down Terminal Series No. 42824-4002 42824-4005 42825-4002 42825-4005 In. .008-.024 .008-.024 .008-.024 .008-.024 Cut-off Tab Max. Front Rear mm In. mm In. 0.60 .024 0.38 .015 0.60 .024 0.38 .015 0.60 .024 0.18 .007 0.60 .024 0.18 .007 Twist Roll Bell mouth Degree 3 3 3 3 Degree 3 3 3 3 4 4 4 4 8 8 8 8 Conductor Brush mm 1.00-1.50 1.00-1.50 1.00-1.50 1.00-1.50 Punch Width (Ref) Conductor Insulation mm In mm In 3.80 .150 4.80 .189 3.80 .150 4.80 .189 3.80 .150 4.80 .189 3.80 .150 4.80 .189 In. .039-.059 .039-.059 .039-.059 .039-.059 Seam Seam shall not be open and no wire allowed out of the crimping area After crimping, the crimp profiles should measure the following: Conductor Insulation Pull Force Min. Crimp Height Crimp Width (Ref) Crimp Height (Ref) Crimp Width (Ref) AWG mm2 mm In. mm In. mm In. mm In. N Lb. 42824-4002 12 3.31 2.01-2.11 .079-.083 3.80-4.00 .150-.158 4.20 max .165 max 5.00 max .197 max 311.5 70.0 42824-4002 12+18 3.31+0.82 2.01-2.11 .079-.083 3.80-4.00 .150-.158 4.20 max .165 max 5.00 max .197 max 89.0 20.0 Terminal Series No. Wire Size 42824-4005 12 3.31 2.01-2.11 .079-.083 3.80-4.00 .150-.158 4.20 max .165 max 5.00 max .197 max 42824-4005 12+18 3.31+0.82 2.01-2.11 .079-.083 3.80-4.00 .150-.158 4.20 max .165 max 5.00 max .197 max 311.5 89.0 70.0 20.0 42825-4002 12 3.31 2.01-2.11 .079-.083 3.80-4.00 .150-.158 4.20 max .165 max 5.00 max .197 max 42825-4002 12+18 3.31+0.82 2.01-2.11 .079-.083 3.80-4.00 .150-.158 4.20 max .165 max 5.00 max .197 max 311.5 89.0 70.0 20.0 42825-4005 12 3.31 2.01-2.11 .079-.083 3.80-4.00 .150-.158 4.20 max .165 max 5.00 max .197 max 42825-4005 12+18 3.31+0.82 2.01-2.11 .079-.083 3.80-4.00 .150-.158 4.20 max .165 max 5.00 max .197 max 311.5 89.0 70.0 20.0 Pull Force should be measured with no influence from the insulation crimp. The above specifications are guidelines to an optimum crimp. * This applicator was qualified to the above specifications with THHN stranded wires and TFN solid bare wires. * All Applications exceeding 12 AWG singles, consult Molex Product Engineering. * Crimping double wires or exceeding maximum insulation diameter specifications may cause terminal insulation grips to score or pierce thru wire insulation. * To achieve optimum performance on double wire applications, smallest wire AWG and solid wire should be positioned in the bottom of the terminal. Doc No. 63832-1000 Revision: A Release Date: 12-05-05 Revision Date: 12-05-05 UNCONTROLLED COPY Page 2 of 5 Mechanical Feed-Dual Carrier Metal Strip PARTS LIST Item 1 2 3 4 11 12 13 14 16 21 22 23 24 25 29 33 35 45 52 53 72 73 81 82 83 91 92 93 94 95 96 97 98 99 Doc No. 63832-1000 Revision: A Mini-Mac Applicator 63832-1000 Engineering No. Description Quantity Perishable Tooling 63832-1070 63832-1070 Tool Kit (All “Y” Items) REF 63473-0001 63473-0001 Conductor Punch 1Y 63445-3862 63445-3862 Conductor Anvil 1Y 63471-0011 63471-0011 Insulation Punch 1Y 63445-4809 63445-4809 Insulation Anvil 1Y 63443-0035 63443-0035 Cut-off Plunger Front 1Y 63466-0201 63466-0201 Cut-off Plunger Rear 1Y 63443-0036 63443-0036 Plunger Retainer Front 1Y 63466-0301 63466-0301 Plunger Retainer Rear 1Y 63443-1401 63443-1401 Cut-off Blade Rear 1Y Other Components (REF 21050) 63466-0504 63466-0504 Cut-off Plunger Striker Front 1 63466-0405 63466-0405 Cut-off Plunger Striker Rear 1 63443-0009 63443-0009 Scrap Chute Front 1 63466-0101 63466-0101 Scrap Chute Rear 1 63700-0539 63700-0539 Cut-Off Plunger Spring 2 63600-0110 63600-0110 M4 Washer, 3 mm Thick 1 63443-0023 63443-0023 Lower Tooling Key 1 63443-2127 63443-2127 Spacer Front 1 63443-0061 63443-0061 Wire Stop 1 63443-0062 63443-0062 Collar-8.00 Lg. 1 63890-0995 63890-0995 Collar-4.05 Lg. 1 11-18-4083 60707-8 Feed Guide 1 63443-6130 63443-6130 Rear Cover 1 Frame 63801-3201 63801-3201 Mechanical Feed Applicator Frame Head REF 63801-3281 63801-3281 Base REF 63801-4650 63801-4650 Track Assembly REF Hardware N/A N/A M3 by 6 Lg. SHCS 2** N/A N/A M4 by 6 Lg SHCS 1** N/A N/A M4 by 12 Lg SHCS 3** N/A N/A M4 by 20 Lg SHCS 2** N/A N/A M4 by 60 Lg. SHCS 2** N/A N/A M5 by 12 Lg. SHCS 1** N/A N/A M8 by 30 Lg. BHCS 1** N/A N/A 3mm by 6 Lg. Roll Pin 1** N/A N/A M4 Flat Washer 2** ** Available from an industrial supply company such as MSC (1-800-645-7270). Order No Release Date: 12-05-05 Revision Date: 12-05-05 UNCONTROLLED COPY Page 3 of 5 Mechanical Feed-Dual Carrier Metal Strip Assembly Drawing (2) 52 53 94 3 22 21 93 (2) 81 97 73 1 91 11 (2) 83 81 72 13 99 95 23 (2) 82 92 (2) 45 12 96 14 16 25 35 2 24 25 4 93 98 33 Doc No. 63832-1000 Revision: A 29 Release Date: 12-05-05 Revision Date: 12-05-05 Figure 1 UNCONTROLLED COPY Page 4 of 5 Mechanical Feed-Dual Carrier Metal Strip 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 with 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 Applicator Manual (Document no. 63880-0000). 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. Molex Application Tooling Group 1150 E. Diehl Road Naperville, IL 60563 Tel: (630) 969-4550 Fax: (630) 505-0049 Visit our Web site at http://www.molex.com Doc No. 63832-1000 Revision: A Release Date: 12-05-05 Revision Date: 12-05-05 UNCONTROLLED COPY Page 5 of 5