0638912000

Mini-Mac Applicator for “Mini-Fit Sr.” Terminals Mini-Mac Applicator Application Tooling Specification Sheet Order No. 63891-2000 FEATURES Directly adapts to most automatic wire processing machines. This applicator ships from the factory set-up in the up-stroke condition for bench-top operation; however it will directly adapt to most automatic wire processing machines. Please review the applicator manual that shipped with your tool and is linked on the Molex website. 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. Optimum terminal feed/indexing can be obtained with the optional terminal guide assembly, Order No. 638300120. See page 5. Easy change-over for terminal feeding (up-stroke or down-stroke). Applicator shipped as up-stroke. SCOPE Products: Mini-Fit Sr. ™ Male and Female Crimp Terminals, 14 to 16 AWG Terminal Series No. Terminal Order No. Wire Size AWG mm² Insulation Diameter Maximum mm In. 42815-0040 42815-0041 42815-0042 14-16 N/A 3.33 42815-0049 42815-0144 42817-0040 42817-0041 42817-0042 42817-0049 42817-0140 42817-0141 42817 14-16 N/A 3.33 42817-0142 42817-0149 42817-1044 42817-1144 (1) Crimp terminals to stranded copper wire only. (2) Lubricate terminals plated in precious metals using Molex Oiler 63801-7240. 42815 Doc No: ATS-638912000 Revision: D Release Date: 12-13-06 Revision Date: 09-21-16 Strip Length mm In. 0.131 4.25-4.75 .167-.187 0.131 4.25-4.75 .167-.187 UNCONTROLLED COPY Page 1 of 6 Mini-Mac Applicator for “Mini-Fit Sr.” Terminals DEFINITION OF TERMS WIRE INSULATION 3.75mm ± 0.20 3.75mm ± 0.20 CONTACT GAP 1.00mm ± .20 BEND UP BELL MOUTH SEAM CONTACT GAP 0.00mm - 0.05mm TWISTING ROLLING BEND DOWN CRIMP SPECIFICATIONS Terminal Series No. 42815 42817 Bell mouth mm In. 0.20-0.50 .008-.020 0.20-0.50 .008-.020 Terminal Series No. Bend up Bend down Twist Roll Degree 42815 42817 Cut-off Tab Maximum mm In. 0.50 .020 0.50 .020 3 3 Degree 4 8 4 8 Conductor Brush mm In. 0.25-0.75 .010-.030 0.25-0.75 .010-.030 Punch Width (Ref) Conductor Insulation mm In mm In 3.20 .126 4.50 .177 3.20 .126 4.50 .177 3 3 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 42817 Wire Size AWG 14 16 14 16 mm2 N/A N/A N/A N/A Conductor Crimp Height Crimp Width mm In. mm In. 1.89-1.99 .074-.078 3.20 .126 1.82-1.92 .072-.075 3.20 .126 1.89-1.99 .074-.078 3.20 .126 1.82-1.92 .072-.075 3.20 .126 Pull Force Minimum N Lb. 222.4 50.00 133.4 30.00 222.4 50.00 133.4 30.00 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-638912000 Revision: D Release Date: 12-13-06 Revision Date: 09-21-16 UNCONTROLLED COPY Page 2 of 6 Mini-Mac Applicator for “Mini-Fit Sr.” Terminals PARTS LIST Mini-Mac Applicator 63891-2000 Engineering No. Description Quantity Perishable Tooling 63891-2070 63891-2070 Tool Kit (All “Y” Items) REF 1 63830-0301 63830-0301 Conductor Punch 1Y 2 63830-0302 63830-0302 Conductor Anvil 1Y 3 63830-0305 63830-0305 Insulation Punch 1Y 4 63445-4502 63445-4502 Insulation Anvil 1Y 5 63443-0045 63443-0045 Front Cut-off Plunger 1Y 6 63443-0046 63443-0046 Front Cut-off Plunger Retainer 1Y Plunger Retainer (Non Carrier Cut-Off) 0 6 63443-4202 63443-4202 To be used on all wire processors only. Other Components 7 63443-0009 63443-0009 Scrap Chute Front 1 8 63443-0024 63443-0024 Lower Tooling Key 1 9 63443-0050 63443-0050 Tooling Washer 1 10 63443-1703 63443-1703 Height Spacer 1 11 63443-2214 63443-2214 Course Spacer (14.00mm) 1 12 63443-2308 63443-2308 Fine Spacer (3.40mm) 1 13 63700-0539 63700-0539 Cut-Off Plunger Spring 1 14 63803-5105 63803-5105 Conductor Bushing 1 15 63821-0012 63821-0012 Front Cover 1 16 63821-0015 63821-0015 Wire Stop 1 17 63830-0117 63830-0117 Terminal Lead In 2 18 63830-0118 63830-0118 Rear Cover 1 19 63830-3001 63830-3001 Front Plunger Striker 1 Frame 20 63801-3201 63801-3201 Top 1 21 63801-3281 63801-3281 Base 1 22 63801-4650 63801-4650 Track 1 Hardware 23 N/A N/A M3 by 6 Long FHCS 1** 24 N/A N/A M3 by 6 Long SHCS 2** 25 N/A N/A M4 by 6 Long SHCS 5** 26 N/A N/A M4 by 12 Long BHCS 2** 27 N/A N/A M4 by 50 Long SHCS 2** 28 N/A N/A M5 by 12 Long SHCS 1** 29 N/A N/A M8 by 20 Long BHCS 1** 30 N/A N/A 2mm by 8 Long Roll Pin 1** ** Fastener parts can be obtained through most industrial supply houses by using the generic descriptions listed above in the parts list table. Abbreviation descriptions: SHCS = Socked Head Cap Screw, FHCS = Flat Head Cap Screw, SSS = Socket Set Screw, BHCP = Button Head Cap Screw, Roll Pin = Spiral Pin. Item Doc No: ATS-638912000 Revision: D Order No Release Date: 12-13-06 Revision Date: 09-21-16 UNCONTROLLED COPY Page 3 of 6 Mini-Mac Applicator for “Mini-Fit Sr.” Terminals Assembly Drawing 20 1 3 14 19 9 25 (4) 29 20 26 (2) 17 (2) 22 21 18 16 (2) 24 28 10 15 2 4 11 5 12 30 8 13 Figure 1 23 6 (2) 27 Doc No: ATS-638912000 Revision: D 7 25 Release Date: 12-13-06 Revision Date: 09-21-16 UNCONTROLLED COPY Page 4 of 6 Mini-Mac Applicator for “Mini-Fit Sr.” Terminals Older Version Applicators Older versions of this applicator can be updated with the Terminal Guide Assembly please order the parts below. The 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 Terminal Guide assembly follow the steps below. 1. 2. 3. 4. Remove the (2) M4 by 12 BHCS from the existing rear cover. Remove the rear cover Replace it with the 63830-0120 Terminal Guide Assembly. Replace the (2) M4 by 12 BHCS. 1 3 (4) M4 by 12.0mm LONG BHCS (2) REFERENCE 2 1 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 M4 by 6 Long SHCS 4** ** Fastener parts can be obtained through most industrial supply houses by using the generic descriptions listed above in the parts list table. Abbreviation descriptions: SHCS = Socked Head Cap Screw, FHCS = Flat Head Cap Screw, SSS = Socket Set Screw, BHCP = Button Head Cap Screw, Roll Pin = Spiral Pin. Doc No: ATS-638912000 Revision: D Release Date: 12-13-06 Revision Date: 09-21-16 UNCONTROLLED COPY Page 5 of 6 Mini-Mac Applicator for “Mini-Fit Sr.” 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. 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 CAUTION 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. Molex tooling crimp specifications are valid only when used with Molex terminals and tooling manufactured by Molex or authorized distributors (“Molex Tooling”). When using tooling other than Molex Tooling with specific Molex specific connector systems listed in our ATS documents, the Molex tooling qualification does not apply and the responsibility for full qualification of the connector system is that of the customer. Molex accepts no liability for connector performance or tooling support where tooling other than Molex Tooling is used, or where Molex Tooling is modified. A-620 and other industry standards do not supersede the manufacturer’s specifications. Some terminals designed over 20 years ago may not meet the desired physical attributes for some of today’s standards. However, these terminals will still perform electrically at an acceptable quality level based on the qualification testing and years of successful performance in the field. Contact Information Application Tooling Support 2200 Wellington Court Lisle, IL 60532 USA Direct +1-402-458-TOOL (8665) Visit our website at www.molex.com/applicationtooling Doc No: ATS-638912000 Revision: D Release Date: 12-13-06 Revision Date: 09-21-16 UNCONTROLLED COPY Page 6 of 6