0638934200

Mini-Mac Applicator for Board-In Crimp Terminals Mini-Mac Applicator Application Tooling Specification Sheet Order No. 63893-4200 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 barrel crimp height and .063mm (.0025") for insulation height. See notes on Page 2. Independent adjustment rings allow users to quickly adjust the barrel or insulation crimp height without affecting each other. SCOPE Products: Board-In Crimp Terminal Male, 16-18 AWG. Terminal Series No. Terminal Order No. 4706 02-09-2105 Wire Size AWG 16-18 mm² 1.30-0.80 Insulation Diameter Maximum mm In. 3.05 .120 Strip Length mm 5.97-6.35 In. .235-.250 DEFINITION OF TERMS 2.49 ±.08 mm (.098 ±-.003”) Diameter PC Board Hole INSULATION CRIMP E D WIRE E E-E CONDUCTOR CRIMP 1.57 ± 0.18 mm (.062 ±-.007”) Thick PC Board F Figure 1 Doc No: ATS-638934200 Revision: B Release Date: 08-03-10 Revision Date: 08-10-10 Section E-E UNCONTROLLED COPY Page 1 of 5 Mini-Mac Applicator for Board-In Crimp Terminals CRIMP SPECIFICATIONS After crimping, the conductor profiles should measure the following (See Figure 1). Wire Size Terminal Series No. 4706 AWG 16 18 mm2 1.30 0.80 D (Conductor) mm In. 1.22-1.27 .048-.050 1.22-1.27 .048-.050 Dimensions (Figure 1) E-E (Barrel) F (Ref.) mm In. mm In. 2.29-2.39 .090-.094 1.93-1.98 .076-.078 2.16-2.26 .085-.089 1.93-1.98 .076-.078 Pull Force Minimum N Lb. 13.34 3.0 13.34 3.0
The crimp on this terminal is not an electrical crimp; the final soldering operation is the electrical connection. This minimum force is what should be expected when pulling the terminal with both insulation and conductor crimped. Notes: 1. The Conductor crimp (D dimension on Figure 1) should be set at the maximum height to contain all wire strands, meet minimum pull, and fit into the PCB Hole. The insulation and barrel crimps are adjustable, by the cams (rings) on top of the Mini-Mac ram. The conductor crimp height is not adjustable. Shimming may be required of the conductor punch to optimize this for different wire types. 2. To achieve the reference “D” dimension listed in the chart above, a shim is required. These shims are not supplied with the applicator. The shim should be located between the ram and the conductor punch. See Figure 2. M4 X 8 LONG SHCS (2) CONDUCTOR PUNCH RAM Figure 2 • Doc No: ATS-638934200 Revision: B BARREL PUNCH • SHIM Shim location for Conductor Punch. Release Date: 08-03-10 Revision Date: 08-10-10 UNCONTROLLED COPY Page 2 of 5 Mini-Mac Applicator for Board-In Crimp Terminals PARTS LIST Mini-Mac Applicator 63893-4200 Item Order No Engineering No. Description Quantity Perishable Tooling 63893-4270 63893-4270 Tool Kit (All “Y” Items) REF 1 11-18-4216 60714-12 Conductor Punch 1Y 2 11-18-4210 60714-6 Conductor Anvil 1Y 3 11-18-4214 60714-10 Rear Barrel Punch 1Y 4 11-18-4215 60714-11 Front Barrel Punch 1Y 5 11-18-4211 60714-7 Barrel Form Anvil 1Y 6 63893-4201 63893-4201 Insulation Punch 1Y 7 63893-4202 63893-4202 Insulation Anvil 1Y 8 63893-4204 63893-4204 Front Cut-Off Plunger 1Y 9 11-18-4176 60718-15 Front Plunger Guide Block 1Y Other Components 10 11-18-4083 60707-8 Feed Guide 1 11 11-18-4206 60714-2 Cover Plate 1 12 11-18-4207 60714-3 Wire Stop 1 13 11-18-4208 60714-4 Rear Plunger Retainer 1 14 11-18-4209 60714-5 Insulation Punch Spacer 1 15 11-18-4789 60714B113 Terminal Guide 1 16 11-18-4848 60800A123 Spring Retainer 1 17 11-18-4849 60800A124 Wire Hold-Down Spring 1 18 11-18-4944 60710-21 Cut-off Plunger Spring 2 19 63803-5109 63803-5109 Conductor Bushing 1 20 63893-4203 63893-4203 Plunger Striker 1 Frame 21 63801-3201 63801-3201 Top 1 22 63801-3282 63801-3282 Base 1 23 63801-6550 63801-6550 Track 1 Hardware 24 N/A N/A M3 by 5 Long SHCS 2** 25 N/A N/A M3 by 8 Long SHCS 2** 26 N/A N/A M4 by 8 Long SHCS 2** 27 N/A N/A M4 by 10 Long SHCS 2** 28 N/A N/A M8 by 20 Long BHCS 1** 29 N/A N/A #8-32 by 3/8” Long BHCS 4** 30 N/A N/A #10-32 by 3/4” Long SHCS 1** ** Available from an industrial supply company such as MSC (1-800-645-7270). Doc No: ATS-638934200 Revision: B Release Date: 08-03-10 Revision Date: 08-10-10 UNCONTROLLED COPY Page 3 of 5 Mini-Mac Applicator for Board-In Crimp Terminals Assembly Drawing 3 4 26 (2) 6 19 1 14 16 21 20 28 24 15 (2) 17 (2) 27 21 23 11 25 (2) 22 10 12 13 8 29 (4) (2) 18 2 5 Figure 1 7 30 9 Doc No: ATS-638934200 Revision: B Release Date: 08-03-10 Revision Date: 08-10-10 UNCONTROLLED COPY Page 4 of 5 Mini-Mac Applicator for Board-In 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 135.80 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. Contact Information For more information on Molex application tooling please contact Molex at 1-800-786-6539. http://www.molex.com Doc No: ATS-638934200 Revision: B Release Date: 08-03-10 Revision Date: 08-10-10 UNCONTROLLED COPY Page 5 of 5