0638881000

Mini-Mac Applicator Trifurcon™ Crimp Terminals Mini-Mac Applicator Application Tooling Specification Sheet Order No. 63888-1000 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 Pilot pin in cut-off punch produces symmetrical cut-off tabs and consistent cut-off tab length, see terminal strip adjustment on page 3. SCOPE Products: Trifurcon™ Crimp Terminal, 22-26 AWG. Terminal Series No. 2578 7258 Wire Size Terminal Order No. 08-50-0018 08-50-0111 08-55-0105 08-56-0121 08-59-0101 08-65-0116 50-29-1877 08-04-0001 08-56-0181 Doc No. ATS-638881000 Revision: E 08-50-0061 08-50-0133 08-55-0121 08-56-0161 08-60-0003 40-01-0117 08-50-0065 08-50-0504 08-55-0123 08-56-0162 08-65-0108 40-07-1105 AWG mm² 08-50-0107 08-52-0116 08-56-0107 08-58-0125 22-26 0.35-0.12 08-65-0110 50-29-1767 08-50-0183 08-52-0124 08-56-0123 22-26 0.35-0.12 08-58-0133 08-65-0121 08-65-0126 Release Date: 02-21-07 Revision Date: 11-28-12 Insulation Diameter Maximum mm In. Strip Length mm In. 1.65 .065 2.54-3.18 .100-.125 1.65 .065 2.54-3.18 .100-.125 UNCONTROLLED COPY Page 1 of 6 Mini-Mac Applicator Trifurcon™ Crimp Terminals CONDUCTOR CRIMP DEFINITION OF TERMS INSULATION CRIMP CUT-OFF TAB C/L TERMINAL LOCATION BEND UP LOCKING TANG HEIGHT BRUSH SEAM BELL MOUTH ROLLING TWISTING CUT-OFF TAB STRIP LENGTH BEND DOWN C/L CRIMP HEIGHT Terminal is to be centrally located between the two (2) cut-off tab edges by one half of the total cut-off tab tolerance. CRIMP SPECIFICATIONS Terminal Series No. 2578 7258 Bell mouth (Ref) mm In. 0.08-0.48 .003-.019 0.08-0.48 .003-.019 Cut-off Tab mm 2.64-2.80 2.64-2.80 Terminal Locking Tang Height Bend up Bend down Twist Roll Series No. mm In Degree Degree 2578 0.64-0.76 .025-.030 7258 0.63-0.79 .025-.031 In. .104-.110 .104-.110 Conductor Brush Maximum (Ref) mm In. 1.00 .039 1.00 .039 Punch Width (Ref) Seam Conductor Insulation mm In mm In Seam shall not be open and 1.55 .061 1.95 .077 no wire allowed out of the crimping area 1.55 .061 1.95 .077 NOTE: Some of the specifications in these charts above are intentionally left blank due to the fact that the information does not currently exist. After crimping, the conductor profile should measure the following. Terminal Series No. 2578 7258 Wire Size AWG mm2 22 0.35 24 0.20 26 0.12 22 0.35 24 0.20 26 0.12 Crimp Height mm In. 0.96-1.01 .038-.040 0.91-0.96 .036-.038 0.86-0.91 .034-.036 0.96-1.01 .038-.040 0.91-0.96 .036-.038 0.86-0.91 .034-.036 Crimp Width (Ref) mm In. 1.56 .061 1.56 .061 1.56 .061 1.56 .061 1.56 .061 1.56 .061 Pull Force Minimum N Lb. 44.48 10.0 35.59 8.0 26.69 6.0 44.48 10.0 35.59 8.0 26.69 6.0 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-638881000 Revision: E Release Date: 02-21-07 Revision Date: 11-28-12 UNCONTROLLED COPY Page 2 of 6 Mini-Mac Applicator Trifurcon™ Crimp Terminals Terminal Strip Adjustment The terminal strip hole must be aligned to the pilot pin before crimping under power. Hand cycle the press several times to check the alignment of the pilot pin to the terminal strip hole before crimping under power. Use the track adjusting screw and the terminal position adjusting knob to align the terminal strip hole to the pilot pin. CUT-OFF PUNCH PILOT PIN TERMINAL POSITION ADJUSTING KNOB Figure 1 TERMINAL STRIP Doc No. ATS-638881000 Revision: E Release Date: 02-21-07 Revision Date: 11-28-12 TRACK ADJUSTING SCREW UNCONTROLLED COPY Page 3 of 6 Mini-Mac Applicator Trifurcon™ Crimp Terminals PARTS LIST Mini-Mac Applicator 63888-1000 Item Order No Engineering No. Description Quantity Perishable Tooling 63888-1070 63888-1070 Tool Kit (All “Y” Items) REF 1 11-18-4114 60712-14 Conductor Punch 1Y 2 11-18-4115 60712-15 Conductor Anvil 1Y 3 11-18-4113 60712-13 Insulation Punch 1Y 4 11-18-4116 60712-16 Insulation Anvil 1Y 5 63820-0038 63820-0038 Cut-Off Punch 1Y 6 11-18-4470 60712-24 Cut-Off Insert 1Y Other Components 7 11-18-4006 60703-8 Stripper Blade Holder 1 8 11-18-4103 60712-3 Cover Plate 1 9 11-18-4106 60712-6 Insulation Punch Spacer 1 10 11-18-4332 60703-16 Stripper 1 11 11-18-4471 60712-25 Retainer Block 1 12 11-18-5015 60805A122 Front Cover 1 11-40-4085 8301-10 Terminal Stop and Scrape Shield 1 13 14 63803-5119 63803-5119 Conductor Bushing 1 15 63820-0012 63820-0012 Cover-Drag Frame 1 16 63600-4664 63600-4664 Compression Spring 2 Frame 63801-3201 63801-3201 Top 1 17 63801-3283 63801-3283 Base 1 18 63801-6950 63801-6950 Track 1 19 Hardware 20 N/A N/A M3 by 6 Long SHCS 4** 21 N/A N/A M4 by 6 Long SHCS 2** 22 N/A N/A M4 by 12 Long BHCS 2** 23 N/A N/A M5 by 10 Long SHCS 1** 24 N/A N/A M8 by 20 Long BHCS 1** 25 N/A N/A #4-40 by 5/8” Long SHCS 2** 26 N/A N/A #6-32 by 3/8” Long BHCS 2** 27 N/A N/A #10-32 by 1.120” Long SHCS 1** ** Available from an industrial supply company such as MSC (1-800-645-7270). Doc No. ATS-638881000 Revision: E Release Date: 02-21-07 Revision Date: 11-28-12 UNCONTROLLED COPY Page 4 of 6 Mini-Mac Applicator Trifurcon™ Crimp Terminals Assembly Drawing 17 1 21 (2) 14 3 5 9 24 20 (2) 15 22 (2) 8 17 19 18 20 16 (2) (2) 7 12 23 11 25 (2) 13 10 4 26 (2) 6 2 Figure 1 27 Doc No. ATS-638881000 Revision: E Release Date: 02-21-07 Revision Date: 11-28-12 UNCONTROLLED COPY Page 5 of 6 Mini-Mac Applicator Trifurcon™ 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 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 Mini-Mac Manual. CAUTION: This applicator should only be used in a press with a shut height of 135.8 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 wireprocessing 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. http://www.molex.com Doc No. ATS-638881000 Revision: E Release Date: 02-21-07 Revision Date: 11-28-12 UNCONTROLLED COPY Page 6 of 6