0638914100

Mini-Mac Applicator for “.062” Standard Pin and Socket Terminals Mini-Mac Applicator Application Tooling Specification Sheet Order No. 63891-4100 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: 1.57mm (.062") Diameter, Standard .062" Pin and Socket Crimp Terminal 24-30 AWG. Terminal Series No. 1854 1855 2189 2190 4559 Terminal Order No. 02-06-2131 02-06-6137 02-06-6145 39-00-0280 02-06-1131 02-06-5130 02-06-5147 39-00-0338 02-06-1231 02-06-5212 02-06-2231 02-06-1109 02-06-2134 02-06-6138 04-01-0809 39-00-0336 02-06-1141 02-06-5137 04-01-0810 39-00-0340 02-06-3202 02-06-6130 02-06-6143 02-06-4202 02-06-5211 02-06-6207 02-06-1143 02-06-5138 02-06-5203 Doc No. ATS-638914100 Release Date: 12-15-06 Revision: C Revision Date: 10-24-13 Wire Size AWG mm² Insulation Diameter mm In. Strip Length mm In. 24-30 0.20-0.05 1.78 Max. .070 Max. 3.18-3.96 .125-.156 22-28 0.33-0.08 1.50 Max. .059 Max. 3.18-3.96 .125-.156 24-30 0.20-0.05 1.78 Max. .070 Max. 3.18-3.96 .125-.156 22-28 0.33-0.08 1.50 Max. .059 Max. 3.18-3.96 .125-.156 24-30 0.20-0.05 1.78 Max. .070 Max. 3.18-3.96 .125-.156 24-30 24-30 0.20-0.05 0.20-0.05 1.78 Max. 1.78 Max. .070 Max. .070 Max. 3.18-3.96 3.18-3.96 .125-.156 .125-.156 UNCONTROLLED COPY Page 1 of 6 Mini-Mac Applicator for “.062” Standard Pin and Socket Terminals DEFINITION OF TERMS BEND UP STRIP LENGTH BELL MOUTH SEAM CUT-OFF TAB ROLLING CONDUCTOR BRUSH TWISTING BEND DOWN INSULATION CRIMP CONDUCTOR CRIMP The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the scope. CRIMP SPECIFICATIONS Terminal Series No. 1854 39-00-0280 1854 39-00-0336 Only 1855 39-00-0338 1855 39-00-0340 Only 2189 2190 4559 Wire Size AWG mm² 24-30 0.20-0.05 Bell mouth mm In. 0.10-0.60 .004-.024 22-28 0.33-0.08 0.10-0.60 .004-.024 0.50 .019 .25-1.00 .010-.039 24-30 0.20-0.05 0.10-0.60 .004-.024 0.13 .005 .25-1.00 .010-.039 22-28 0.33-0.08 0.10-0.60 .004-.024 0.50 .019 .25-1.00 .010-.039 24-30 24-30 24-30 0.20-0.05 0.20-0.05 0.20-0.05 0.10-0.60 0.10-0.60 0.10-0.60 .004-.024 .004-.024 .004-.024 0.13 0.13 0.13 .005 .005 .005 .25-1.00 .25-1.00 .25-1.00 .010-.039 .010-.039 .010-.039 Wire Size Terminal Series No. 1854 1855 2189 2190 4559 AWG mm² 22-30 22-30 24-30 24-30 24-30 0.33-0.05 0.33-0.05 0.20-0.05 0.20-0.05 0.20-0.05 Doc No. ATS-638914100 Release Date: 12-15-06 Revision: C Revision Date: 10-24-13 Cut-off Tab Maximum mm In. 0.13 .005 Conductor Brush mm In. .25-1.00 .010-.039 Punch Width mm (Ref) Conductor Insulation Seam mm In mm In 1.65 .065 1.65 .065 Seam shall not be open 1.65 .065 1.65 .065 and no wire allowed out of 1.65 .065 1.65 .065 the crimping area. 1.65 .065 1.65 .065 1.65 .065 1.65 .065 UNCONTROLLED COPY Page 2 of 6 Mini-Mac Applicator for “.062” Standard Pin and Socket Terminals After crimping, the conductor profile should measure the following. Terminal Series No. 1854 1854 39-00-0280 39-00-0336 Only 1855 1855 39-00-0338 39-00-0340 Only 2189 2190 4559 Wire Size AWG 24 26 28 30 22 24 26 28 24 26 28 30 22 24 26 28 24 26 28 30 24 26 28 30 24 26 28 30 mm2 0.20 0.12 0.08 0.05 0.33 0.20 0.12 0.08 0.20 0.12 0.08 0.05 0.33 0.20 0.12 0.08 0.20 0.12 0.08 0.05 0.20 0.12 0.08 0.05 0.20 0.12 0.08 0.05 Conductor Pull Force Min. Crimp Height Crimp Width mm In. mm In. N Lb. 0.79-0.84 .031-.033 1.65-1.73 .065-.068 22.3 5.00 0.74-0.79 .029-.031 1.65-1.73 .065-.068 13.4 3.00 0.68-0.76 .027-.030 1.65-1.73 .065-.068 8.9 2.00 0.63-0.68 .025-.027 1.65-1.73 .065-.068 6.7 1.50 0.78-0.83 .031-.033 1.65-1.73 .065-.068 39.2 8.8 0.73-0.78 .029-.031 1.65-1.73 .065-.068 29.0 6.6 0.69-0.74 .027-.029 1.65-1.73 .065-.068 19.6 4.4 0.64-0.69 .025-.027 1.65-1.73 .065-.068 9.8 2.2 0.79-0.84 .031-.033 1.65-1.73 .065-.068 22.3 5.00 0.74-0.79 .029-.031 1.65-1.73 .065-.068 13.4 3.00 0.68-0.76 .027-.030 1.65-1.73 .065-.068 8.9 2.00 0.63-0.68 .025-.027 1.65-1.73 .065-.068 6.7 1.50 0.78-0.83 .031-.033 1.65-1.73 .065-.068 39.2 8.8 0.73-0.78 .029-.031 1.65-1.73 .065-.068 29.0 6.6 0.69-0.74 .027-.029 1.65-1.73 .065-.068 19.6 4.4 0.64-0.69 .025-.027 1.65-1.73 .065-.068 9.8 2.2 0.79-0.84 .031-.033 1.65-1.73 .065-.068 22.3 5.00 0.74-0.79 .029-.031 1.65-1.73 .065-.068 13.4 3.00 0.68-0.76 .027-.030 1.65-1.73 .065-.068 8.9 2.00 0.63-0.68 .025-.027 1.65-1.73 .065-.068 6.7 1.50 0.79-0.84 .031-.033 1.65-1.73 .065-.068 22.3 5.00 0.74-0.79 .029-.031 1.65-1.73 .065-.068 13.4 3.00 0.68-0.76 .027-.030 1.65-1.73 .065-.068 8.9 2.00 0.63-0.68 .025-.027 1.65-1.73 .065-.068 6.7 1.50 0.64-0.69 .025-.027 1.65-1.73 .065-.068 22.3 5.00 0.56-0.61 .022-.024 1.65-1.73 .065-.068 13.4 3.00 0.53-0.58 .021-.023 1.65-1.73 .065-.068 8.9 2.00 0.51-0.56 .020-.022 1.65-1.73 .065-.068 6.7 1.50 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-638914100 Release Date: 12-15-06 Revision: C Revision Date: 10-24-13 UNCONTROLLED COPY Page 3 of 6 Mini-Mac Applicator for “.062” Standard Pin and Socket Terminals PARTS LIST Mini-Mac Applicator 63891-4100 Item Order No Engineering No. Description Quantity Perishable Tooling 63891-4170 63891-4170 Tool Kit (All “Y” Items) REF 1 11-18-4120 60707-9 Conductor Punch 1Y 2 11-18-4122 60707-11 Combination Anvil 1Y 3 11-18-4121 60707-10 Insulation Punch 1Y 4 11-17-3076 7163-30 Front Cut-Off Plunger 1Y 5 11-17-3079 7163-33 Rear Cut-Off Plunger 1Y 6 11-17-2136 7163-4 Rear Cut-Off Die Blade 1Y 7 11-18-4246 60707-18 Front Cut-off Plunger Retainer 1Y 8 11-18-4247 60707-19 Rear Cut-off Plunger Retainer 1Y Other Components 9 11-17-2140 7163-8 Insulation Punch Spacer 1 10 11-17-2152 7163-14 Hold Down Pad 1 11 11-18-4079 60707-4 Cover Plate 1 12 11-18-4081 60707-6 Front Plunger Striker 1 13 11-18-4082 60707-7 Rear Plunger Striker 1 14 11-18-4083 60707-8 Feed Guide 1 15 11-18-5060 60707-21 Cut-off Plunger Spring 2 63443-0090 63443-0090 Wire Stop 1 16 63803-5127 63803-5127 Conductor Bushing 1 17 Frame 18 63801-3201 63801-3201 Top 1 19 63801-3282 63801-3282 Base 1 20 63801-6550 63801-6550 Track 1 Hardware 21 N/A N/A M3 by 8 Long SHCS 2** 22 N/A N/A M4 by 6 Long SHCS 1** 23 N/A N/A M4 by 12 Long BHCS 2** 24 N/A N/A M4 by 20 Long SHCS 2** 25 N/A N/A M5 by 14 Long SHCS 1** 26 N/A N/A M8 by 20 Long BHCS 1** 27 N/A N/A #6-32 by 3/8” Long BHCS 4** 28 N/A N/A #6-32 by 1/2” Long FHCS 1** 29 N/A N/A #6-32 Hex Jam Nut 1** 30 N/A N/A #8-32 by 3/8” Long SHCS 2** 31 N/A N/A #8-32 by 3/8” Long BHCS 1** 32 N/A N/A 5/64 by 3/8” Long Roll Pin 2** ** Available from an industrial supply company such as MSC (1-800-645-7270). Doc No. ATS-638914100 Release Date: 12-15-06 Revision: C Revision Date: 10-24-13 UNCONTROLLED COPY Page 4 of 6 Mini-Mac Applicator for “.062” Standard Pin and Socket Terminals Assembly Drawing 18 1 3 24 17 13 (2) 12 29 9 10 26 28 23 (2) 11 18 20 (2) 21 19 14 16 25 5 4 30 22 (2) 27 (2) 15 16 (4) 31 7 8 6 2 Figure 1 32 (2) Doc No. ATS-638914100 Release Date: 12-15-06 Revision: C Revision Date: 10-24-13 UNCONTROLLED COPY Page 5 of 6 Mini-Mac Applicator for “.062” Standard Pin and Socket 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 MiniMac 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. Visit our Web site at http://www.molex.com Doc No. ATS-638914100 Release Date: 12-15-06 Revision: C Revision Date: 10-24-13 UNCONTROLLED COPY Page 6 of 6