0638326100

Mini-Mac™ Applicator for Power Contact Crimp Terminals Mini-Mac™ Applicator Application Tooling Specification Sheet Order No. 63832-6100 FEATURES Directly adapts to most automatic wire processing machines 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: Male and Female Power Contact Crimp Terminals, 14-16 AWG, 18 AWG Doubles, and 16 AWG Doubles. Terminal Series No. 44262 44262-4306 44262-4336 44262-4406 44262-4436 44262-4506 44262-4536 44262-6410 44262-6411 Insulation Diameter Maximum mm In. Wire Size Terminal Order No. 44262-6412 44262-6420 44262-6422 44262-6421 AWG mm² 14-16 18 (2) 16 (2) 2.00-1.30 0.80 (2) 1.30 (2) N/A N/A Strip Length mm In. 6.35 .25 14-16 2.00-1.30 18 (2) 0.80 (2) N/A N/A 6.35 .25 16 (2) 1.30 (2) 63832-6100 Applicator is set up to crimp male terminals. To crimp female terminals, perishable tooling setup needs to be changed. No additional parts are required. See Changeover Parts on page 3 for each terminal listed. 173693 173693-4636 DEFINITION OF TERMS BELL MOUTH STRIP LENGTH CONDUCTOR BRUSH BEND UP ROLLING TWISTING BEND DOWN WIRE CUT-OFF CONDUCTOR TAB CRIMP SEAM The above terminal drawing is a generic terminal representation. It is not an image of any terminal listed in the scope. Doc No: ATS-638326100 Revision: G1 Release Date: 06-05-07 Revision Date: 02-14-17 UNCONTROLLED COPY Page 1 of 6 Mini-Mac™ Applicator for Power Contact Crimp Terminals CRIMP SPECIFICATION Bell Mouth mm In. Terminal Series No. 44262 173693 0.25-1.25 Bend Up Terminal Series No. .010-.049 Bend Down Twist Degree 44262 173693 3 Cut-Off Tab Maximum mm In. 0.50 Roll Degree 3 3 3 Conductor Brush mm In. .020 0.64-1.90 Punch Width (Ref) Conductor Insulation mm In mm In 3.90 .154 N/A N/A .025-.075 Seam Seam shall not be open and no wire allowed out of the crimping area After crimping, the crimp profiles should measure the following: Terminal Series No. 44262 173693 Wire Size AWG 14 16 18 (2) 16 (2) 14 16 18 (2) 16 (2) mm2 2.00 1.30 0.80 (2) 1.30 (2) 2.00 1.30 0.80 (2) 1.30 (2) Conductor Crimp Height Crimp Width (Ref.) mm In. mm In. 2.65-2.75 .104-.108 4.00 .158 2.50-2.60 .098-.102 4.00 .158 2.55-2.65 .100-.104 4.00 .158 2.65-2.75 .104-.108 4.00 .158 2.65-2.75 .104-.108 4.00 .158 2.50-2.60 .098-.102 4.00 .158 2.55-2.65 .100-.104 4.00 .158 2.65-2.75 .104-.108 4.00 .158 Pull Force Minimum N 222.41 133.45 88.96 133.45 222.41 133.45 88.96 133.45 Lb. 50.0 30.0 20.0 30.0 50.0 30.0 20.0 30.0 *This applicator was qualified to the above specifications with UL 1015 wire. The above specifications are guidelines to an optimum crimp. Doc No: ATS-638326100 Revision: G1 Release Date: 06-05-07 Revision Date: 02-14-17 UNCONTROLLED COPY Page 2 of 6 Mini-Mac™ Applicator for Power Contact Crimp Terminals Changeover Parts The following charts show the different locations for the spacers when crimping male or female terminals: Terminal Series No. Terminal Order No. 44262-6410 44262-6411 44262-6412 44262-6420 44262 (Male) 44262-6421 44262-6422 173693 173693-4636 Note: To properly crimp these terminals, assemble spacers with cutoff tooling as shown in Figure 1. See also parts list and assembly drawing. 13 12 11 Figure 1 Item No. Order No. Description 11 63443-1719 18.90mm Spacer 12 63443-1734 20.40mm Spacer 13 63443-2212 12.00mm Spacer Terminal Series No. 44262 (Female) Terminal Order No. 44262-4306 44262-4336 44262-4406 44262-4436 Note: To properly crimp these terminals, assemble spacers with cutoff tooling as shown in Figure 1. See also parts list and assembly drawing. Item No. Order No. Description 11 63443-1719 18.90mm Spacer 13 63443-2212 12.00mm Spacer 12 63443-1734 20.40mm Spacer 12 13 11 Figure 2 Doc No: ATS-638326100 Revision: G1 Release Date: 06-05-07 Revision Date: 02-14-17 UNCONTROLLED COPY Page 3 of 6 Mini-Mac™ Applicator for Power Contact Crimp Terminals PARTS LIST Mini-Mac Applicator 63832-6100 Engineering No. Description Quantity Perishable Tooling 63832-6170 63832-6170 Tool Kit (All “Y” Items) REF 1 63465-0050 63465-0050 Conductor Punch 1Y 2 63455-0046 63455-0046 Conductor Anvil 1Y 3 63443-0095 63443-0095 Front Cut-Off Plunger 1Y 4 63890-0487 63890-0487 Front Plunger Retainer 1Y Other Components (REF 326150) 5 63821-0012 63821-0012 Feed Guide 1 6 11-18-4848 60800A123 Spring Retainer 1 7 11-18-4849 60800A124 Wire Hold Down Spring 1 8 63443-0024 63443-0024 Key 1 9 63821-0015 63821-0015 Wire Stop 1 10 63443-1719 63443-1719 18.90mm Spacer 1 11 63443-1734 63443-1734 20.40mm Spacer 1 12 63443-2212 63443-2212 12.00mm Spacer 1 13 63443-6130 63443-6130 Rear Cover 1 14 63466-0509 63466-0509 Striker-Flat Bottom 1 15 63700-0539 63700-0539 Compression Spring 1 16 63890-0866 63890-0866 Bushing-Punch (Conductor) 1 Frame 63801-3201 63801-3201 Top 1 17 63801-3281 63801-3281 Base 1 18 63801-4650 63801-4650 Track 1 19 Hardware 20 N/A N/A M3 by 6 Long FHCS 1** 21 N/A N/A M3 by 6 Long SHCS 2** 22 N/A N/A M4 by 12 Long BHCS 2** 23 N/A N/A M4 by 50 Long SHCS 2** 24 N/A N/A M5 by 12 Long SHCS 1** 25 N/A N/A M8 by 30 Long BHCS 1** 26 N/A N/A 2mm by 5 Long Roll Pin 1** ** Available from an industrial supply company such as MSC (1-800-645-7270). Item Order No See spacer assembly notes on page 3. Doc No: ATS-638326100 Revision: G1 Release Date: 06-05-07 Revision Date: 02-14-17 UNCONTROLLED COPY Page 4 of 6 Mini-Mac™ Applicator for Power Contact Crimp Terminals Assembly Drawing 17 1 6 16 7 14 25 22 (2) 17 13 19 21 (2) 18 5 9 24 3 12 26 11 10 15 8 2 Figure 1 20 4 (2) 23 Doc No: ATS-638326100 Revision: G1 See spacer assembly notes on page 3. Release Date: 06-05-07 Revision Date: 02-14-17 UNCONTROLLED COPY Page 5 of 6 Mini-Mac™ Applicator for Power Contact Crimp Terminals NOTES 1. Molex recommends an extra perishable tooling kit be maintained at your facility. 2. Verify tooling alignment by manually cycling the press with 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 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. Application Tooling Support Phone: +1-402-458-TOOL (8665) E-Mail: applicationtooling@molex.com Website: www.molex.com/applicationtooling Doc No: ATS-638326100 Revision: G1 Release Date: 06-05-07 Revision Date: 02-14-17 UNCONTROLLED COPY Page 6 of 6