0638953200

Mini-Mac Applicator for Super Sabre Receptacle Terminals Mini-Mac Applicator Application Tooling Specification Sheet Order No. 63895-3200 FEATURES Directly adapts to most automatic wire processing machines Applicator designed to industry standard mounting and shut height 135.80mm (5.346") Quick setup 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: Super Sabre Receptacle Terminal. Terminal Series Terminal Order No. No. 171825 171825-0100 Insulation Diameter (Reference) mm In. Wire Size AWG 10-12 – – Strip Length mm2 Stranding mm In. – – 4.0 19 ST. at 0.51mm DIA. 4.00-4.60 .157-.181 7.90-8.30 .311-.327 5.0 65 ST. at 0.30mm DIA. SETUP 1. The crimp press must be set to 135.80mm (5.346”). 2. Before crimping, a light vanishing lubricant must be applied to the exterior surface of the terminal’s crimp barrel. See Molex Oiler Assembly, part number 63801-7240. (Not included with the crimp applicator.) 3. Verify that the applicator is properly secured in the press and that the upper crimp tooling does not touch the lower crimp tooling by manually cycling the press before crimping under power. DEFINITION OF TERMS BEND UP ROLLING STRIP LENGTH CONDUCTOR BRUSH BELL MOUTH SEAM TWISTING BEND DOWN WIRE CUT-OFF TAB Doc No. ATS-638953200 Revision: B CONDUCTOR CRIMP HEIGHT Release Date: 10-25-13 Revision Date: 08-21-17 UNCONTROLLED COPY Page 1 of 5 Mini-Mac Applicator for Super Sabre Receptacle Terminals CRIMP SPECIFICATIONS Bell Mouth mm In. Terminal Series No. 171825 Terminal Series No. 0.60-1.20 Bend Up .024-.047 Bend Down Degree (Max) 171825 3 Cut-Off Tab Maximum mm In. 3 Twist 0.14 .005 0.50-2.00 Punch Width (Ref) Conductor mm In. Roll Degree (Max) 4 Conductor Brush mm In. 8 3.60 .142 .020-.079 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. 171825 Wire Size AWG mm2 10 – 12 – – 4.0 – 5.0 Conductor Crimp Height mm In. 2.33-2.43 .092-.096 1.94-2.04 .076-.080 2.06-2.22 .081-.087 2.10-2.26 .082-.089 Conductor Crimp Width mm In. 3.60-3.80 .142-.150 3.60-3.80 .142-.150 3.60-3.80 .142-.150 3.60-3.80 .142-.150 Pull Force Minimum N Lb. 356.0 80.0 311.5 70.0 *320.0 *71.9 *320.0 *71.9 Note * Metric wire pull force: For all 4.0mm2 and 5.0mm2 crimps that were pull tested as part of the original validation, the contact portion of the terminal broke off before the crimp failed. Doc No. ATS-638953200 Revision: B Release Date: 10-25-13 Revision Date: 08-21-17 UNCONTROLLED COPY Page 2 of 5 Mini-Mac Applicator for Super Sabre Receptacle Terminals PARTS LIST Mini-Mac Applicator 63895-3200 Engineering No. Description Quantity Perishable Tooling 63895-3270 63895-3270 Tool Kit (All “Y” Items) REF 63801-5521 63801-5521 Conductor Punch 1Y 1 63455-3601 63455-3601 Conductor Anvil 1Y 2 63443-0037 63443-0037 Front Cut-Off Plunger 1Y 3 63443-0038 63443-0038 Cut-Off Plunger Retainer 1Y 4 Other Components 11-18-4083 60707-8 Front Cover 1 5 63443-0009 63443-0009 Scrap Chute 1 6 63443-0024 63443-0024 Lower Tooling Key 1 7 63443-0090 63443-0090 Wire Stop 1 8 63443-1720 63443-1720 19.00mm-Height Spacer 1 9 63443-2207 63443-2207 Course Spacer (7.00mm) 2 10 63443-2301 63443-2301 Fine Spacer (3.05mm) 1 11 63443-6121 63443-6121 Rear Cover 1 12 63466-0504 63466-0504 Plunger Striker 1 13 63600-1290 63600-1290 Washer 1 14 63700-0539 63700-0539 Cut-Off Plunger Spring 1 15 63803-5133 63803-5133 Conductor Bushing 1 16 Frame 63801-3201 63801-3201 Top 1 17 63801-3281 63801-3281 Base 1 18 63801-4650 63801-4650 Track 1 19 Hardware N/A N/A M3 by 6 Long SHCS 2** 20 N/A N/A M3 by 6 Long FHCS 1** 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 M4 by 50 Long SHCS 2** 24 N/A N/A M5 by 12 Long SHCS 1** 25 N/A N/A M8 by 30 Long BHCS 1** 26 N/A N/A 2mm by 5 Long Dowel Pin 1** 27 ** Available from an industrial supply company such as MSC (1-800-645-7270). Item Doc No. ATS-638953200 Revision: B Order No. Release Date: 10-25-13 Revision Date: 08-21-17 UNCONTROLLED COPY Page 3 of 5 Mini-Mac Applicator for Super Sabre Receptacle Terminals Assembly Drawing 17 1 16 13 14 26 23 (2) 12 17 19 20 (2) 18 5 8 25 3 9 22 10 27 2 10 11 15 8 7 21 4 6 22 Figure 1 24 (2) Doc No. ATS-638953200 Revision: B Release Date: 10-25-13 Revision Date: 08-21-17 UNCONTROLLED COPY Page 4 of 5 Mini-Mac Applicator for Super Sabre Receptacle Terminals NOTES 1. Molex recommends that 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 the work area. 4. Wear safety glasses at all times. 5. For recommended maintenance, refer to the Mini-Mac manual. CAUTION: This applicator must only be used in a press with a shut height of 135.80 mm (5.346”). Tooling damage could result at a lower shut height. 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. Application Tooling Support Phone: (402) 458-TOOL (8665) E-Mail: applicationtooling@molex.com Website: www.molex.com/applicationtooling Molex is a registered trademark of Molex, LLC in the United States of America and may be registered in other countries; all other trademarks listed herein belong to their respective owners. Doc No. ATS-638953200 Revision: B Release Date: 10-25-13 Revision Date: 08-21-17 UNCONTROLLED COPY Page 5 of 5