0638919500

Mini-Mac Applicator for -“Mini-Fit Sr.” Terminals Mini-Mac Applicator Application Tooling Specification Sheet Order No. 63891-9500 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 6. 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, for fine stranded (2) 12 and 8 AWG wire. Terminal Series No. Terminal Order No. Wire Size AWG mm² 8 N/A N/A ∗∗12 8 N/A ∗Insulation Diameter mm In. 5.00-6.75 .197-.266 3.50-4.00 .138-.157 5.00-6.75 .197-.266 Strip Length mm In. 9.00-10.00 .354-.394 11.00-12.00 .433-.472 9.00-10.00 .354-.394 42815-0030 42815-0031 42815-0032 42815-0134 42817-0030 42817-0130 42817-0031 42817-0131 42817 42817-0032 42817-0132 N/A 3.50-4.00 .138-.157 11.00-12.00 .433-.472 ∗∗12 42817-1034 42817-1134 ∗ On Mini-Fit Sr. 8 AWG terminal, the insulation is stripped in both the conductor and insulation grips. ∗∗ 8 AWG Hi-Flex wire (665 strands). This type of wire has very fine strands. Please note: Extra precaution must be maintained during stripping operation to prevent loosing or breaking strands. Lost or broken strands may result in lower pull force strength and broken strands may cause a possible electric shock or shortage. 1. Crimp terminals to stranded copper wire only. 2. Lubricate terminals plated in precious metals using Molex Oiler 63801-7240. 42815 Doc No: ATS-638919500 Revision: D Release Date: 01-21-10 Revision Date: 09-21-16 UNCONTROLLED COPY Page 1 of 7 Mini-Mac Applicator for -“Mini-Fit Sr.” Terminals DEFINITION OF TERMS INSULATION GRIP AREA 3.75mm ± 0.20 BELL MOUTH 3.75mm ± 0.20 WIRE INSULATION CONTACT GAP 1.00mm ± 0.20 BEND UP SEAM CONTACT GAP 0.00mm - 0.05mm TWISTING ROLLING INSULATION GAP 0.00mm-1.00mm max. BEND DOWN CRIMP SPECIFICATIONS Terminal Series No. 42815 42817 Bell mouth mm In. .20-.50 .008-.020 .20-.50 .008-.020 Terminal Series No. Cut-off Tab Maximum mm In. .30-.50 .012-.020 .30-.50 .012-.020 Bend up Bend down Twist Roll Degree Conductor Brush mm In. 2.10-3.10 .083-.122 2.10-3.10 .083-.122 Punch Width (Ref) Conductor Insulation mm In mm In 3.90 .154 4.80 .189 3.90 .154 4.80 .189 Degree 3 4 8 3 4 8 Seam Seam shall not be open and no wire allowed out of the crimping area 42815 42817 3 3 After crimping, the conductor profile should measure the following. Conductor Pull Force Minimum Crimp Height Crimp Width AWG mm2 mm In. mm In. N Lb. 8 N/A 3.20-3.30 .126-.130 3.90 .154 400.3 90.0 42815 N/A 3.40-3.50 .134-.138 3.90 .154 400.3 90.0 ∗∗ 8 (2) 12 N/A 3.20-3.30 .126-.130 3.90 .154 311.4 70.0 8 N/A 3.20-3.30 .126-.130 3.90 .154 400.3 90.0 42817 N/A 3.40-3.50 .134-.138 3.90 .154 400.3 90.0 ∗∗ 8 (2) 12 N/A 3.20-3.30 .126-.130 3.90 .154 311.4 70.0 8 AWG Hi-Flex wire (665 strands). This type of wire has very fine strands. ∗∗ Please note: Extra precaution must be maintained during stripping operation to prevent loosing or breaking strands. Lost or broken strands may result in lower pull force strength and broken strands may cause a possible electric shock or shortage. Terminal Series No. Wire Size 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-638919500 Revision: D Release Date: 01-21-10 Revision Date: 09-21-16 UNCONTROLLED COPY Page 2 of 7 Mini-Mac Applicator for -“Mini-Fit Sr.” Terminals Special Note: 1. Cut-off Tab length below 0.30mm may cause the box dimension to be under recommendation. See Figure 1. 2. Wire insulation should not be crimped and insulation grip area should be formed to contain wire strands only. 3. Changing the insulation height setting may be needed to achieve the dimensions of the insulation grip in Section A-A. See Figure 1. 4. If wire strands are missed from conductor crimps, the operator should place the wires in the terminal, in the correct location, without using the wire stop/ stripper for locating the wire. EXTRUDED WIRE LENGTH (BRUSH) BELL MOUTH (FLARE) 0.50mm REF INSULATION GRIP A 5.00mm REF A Figure 1 WIRE STRANDS CUT-OFF TAB LENGTH SECTION A-A Doc No: ATS-638919500 Revision: D Release Date: 01-21-10 Revision Date: 09-21-16 UNCONTROLLED COPY Page 3 of 7 Mini-Mac Applicator for -“Mini-Fit Sr.” Terminals PARTS LIST Mini-Mac Applicator 63891-9500 Item Order No Engineering No. Description Quantity Perishable Tooling 63891-9570 63891-9570 Tool Kit (All “Y” Items) REF 1 63830-0001 63830-0001 Conductor Punch 1Y 2 63830-0002 63830-0002 Conductor Anvil 1Y 3 63830-0003 63830-0003 Insulation Punch 1Y 4 63830-0004 63830-0004 Insulation Anvil 1Y 5 63443-0037 63443-0037 Front Cut-off Plunger 1Y 6 63443-0038 63443-0038 Front Cut-off Plunger Retainer 1Y Plunger Retainer (Non Carrier Cut-Off) 6 63443-4204 63443-4204 0 To be used on all wire processors only. Other Components 7 11-18-4848 60800A123 Spring Retainer 1 8 11-18-4849 60800A124 Wire Hold Down Spring 1 9 63443-0009 63443-0009 Scrap Chute Front 1 10 63443-0024 63443-0024 Lower Tooling Key 1 11 63443-1715 63443-1715 Height Spacer 1 12 63443-2209 63443-2209 Course Spacer (9.00mm) 1 13 63443-2306 63443-2306 Fine Spacer (3.30mm) 1 14 63466-0504 63466-0504 Front Plunger Striker 1 15 63700-0539 63700-0539 Cut-Off Plunger Spring 1 16 63803-5105 63803-5105 Conductor Bushing 1 17 63803-5201 63803-5201 Insulation Bushing 1 18 63821-0012 63821-0012 Front Cover 1 19 63821-0015 63821-0015 Wire Stop 1 20 63830-0117 63830-0117 Terminal Lead In 2 21 63830-0118 63830-0118 Rear Cover 1 Frame 22 63801-3201 63801-3201 Top 1 23 63801-3281 63801-3281 Base 1 24 63801-4650 63801-4650 Track 1 Hardware 25 N/A N/A M3 by 6 Long FHCS 1** 26 N/A N/A M3 by 6 Long SHCS 2** 27 N/A N/A M4 by 6 Long SHCS 5** 28 N/A N/A M4 by 12 Long BHCS 2** 29 N/A N/A M4 by 50 Long SHCS 2** 30 N/A N/A M5 by 12 Long SHCS 1** 31 N/A N/A M8 by 25 Long BHCS 1** 32 N/A N/A 2mm by 5 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. Doc No: ATS-638919500 Revision: D Release Date: 01-21-10 Revision Date: 09-21-16 UNCONTROLLED COPY Page 4 of 7 Mini-Mac Applicator for -“Mini-Fit Sr.” Terminals Assembly Drawing 22 1 16 3 7 14 27 (4) 31 17 8 28 (2) 22 20 (2) 24 21 23 (2) 19 26 30 18 2 5 4 12 32 15 13 11 10 25 6 (2) 29 Doc No: ATS-638919500 Revision: D 9 Figure 2 27 Release Date: 01-21-10 Revision Date: 09-21-16 UNCONTROLLED COPY Page 5 of 7 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) REFERNCE 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-638919500 Revision: D Release Date: 01-21-10 Revision Date: 09-21-16 UNCONTROLLED COPY Page 6 of 7 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-638919500 Revision: D Release Date: 01-21-10 Revision Date: 09-21-16 UNCONTROLLED COPY Page 7 of 7