63830-0000-“Mini-Fit Sr.” Terminals
Mini-Mac Applicator
Specification Sheet
Order No. 63830-0000
FEATURES
Quick set-up time; plus the crimp height, track and feed adjustments can be preset in applicator
Conductor and insulation rings allow quick adjustment for conductor and insulation diameter change
Applicator designed to industry standard mounting and shut height 135.80mm (5.346")
Directly adapts to most automatic wire processing machines. Optimum terminal feed/indexing can be obtained with the optional
terminal guide assembly, Order No. 63830-0120. See page 6.
SCOPE
Mini-Fit Sr.™ Male and Female Crimp Terminals, 8 AWG
Terminal Series No.
Terminal Order No.
42815-0030
42815-0031
42815-0030
42815-0031
42817-0030
42817-0031
42817-0032
42817-0030
42817-0031
42817-0032
42815-0032
42815-0032
42817-0130
42817-0131
42817-0132
42817-0130
42817-0131
42817-0132
Wire Size
AWG
mm²
8
(2) 12
8
8.50
(2) 3.30
8.50
∗
Insulation Diameter
mm
In.
5.00-6.75
3.50-4.00
5.00-6.75
.197-.266
.138-.157
.197-.266
Strip Length
mm
In.
9.00-10.00
11.00-12.00
9.00-10.00
.354-.394
.433-.472
.354-.394
42815
42817
(2) 12
(2) 3.30
3.50-4.00
.138-.157
11.00-12.00
.433-.472
∗
On Mini-Fit Sr. 8 AWG terminal, the insulation is stripped in both the conductor and insulation grips.
DEFINITION OF TERMS
3.75mm
±
0.20
CONTACT GAP
1.00mm
±
0.20
BEND
UP
SEAM
TWISTING
BEND
DOWN
CONTACT GAP
0.00mm - 0.05mm
INSULATION GAP
0.00mm-1.00mm max.
INSULATION
GRIP AREA
3.75mm
±
0.20
BELL MOUTH
WIRE INSULATION
ROLLING
Doc No. ATS-638300000
Revision: G
Release Date: 11-16-99
Revision Date: 12-22-06
UNCONTROLLED COPY
Page 1 of 7
63830-0000-“Mini-Fit Sr.” Terminals
CRIMP SPECIFICATIONS
Wire Size
AWG
mm²
8
8.50-8.42
(2) 12 (2) 3.30
Bell mouth
mm
In.
.20-.50 .008-.020
.20-.50 .008-.020
Cut-off Tab Max.
mm
In.
.30-.50 .012-.020
.30-.50 .012-.020
Conductor Brush
mm
In.
2.10-3.10 .083-.122
2.10-3.10 .083-.122
Terminal Series No.
42815
42815
42817
42817
Terminal Series No.
42815
42815
42817
42817
Wire Size
AWG
mm²
8
8.50-8.42
(2) 12 (2) 3.30
Bend up Bend down Twist Roll
Degree
3
3
3
3
Degree
4
8
4
8
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
42815
42815
42817
42817
42817
Wire Size
AWG
8
8
(2) 12
8
mm
2
8.50
8.42
(2) 3.30
Conductor
Crimp Height
mm
In.
3.20-3.30
.126-.130
3.40-3.50
.134-.138
3.20-3.30
.126-.130
Crimp Width
mm
In.
3.90
.154
3.90
.154
3.90
.154
Pull Force Min.
N
400.3
400.3
311.4
Lb.
90.0
90.0
70.0
8.50
3.20-3.30
.126-.130
3.90
.154
400.3
90.0
8
8.42
3.40-3.50
.134-.138
3.90
.154
400.3
90.0
(2) 12 (2) 3.30
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.
Pull Force should be measured with no influence from the insulation crimp.
The above specifications are guidelines to an optimum crimp.
Doc No. ATS-638300000
Revision: G
Release Date: 11-16-99
Revision Date: 12-22-06
UNCONTROLLED COPY
Page 2 of 7
63830-0000-“Mini-Fit Sr.” Terminals
Special Note:
EXTRUDED WIRE LENGTH (BRUSH)
BELL MOUTH (FLARE)
0.50mm
REF
INSULATION GRIP
A
5.00mm
REF
A
CUT-OFF TAB LENGTH
Figure 1
WIRE STRANDS
SECTION A-A
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.
Doc No. ATS-638300000
Revision: G
Release Date: 11-16-99
Revision Date: 12-22-06
UNCONTROLLED COPY
Page 3 of 7
63830-0000-“Mini-Fit Sr.” Terminals
PARTS LIST
Mini-Mac Applicator 63830-0000
Item Order No Engineering No.
Description
Quantity
Perishable Tooling
63830-0070
63830-0070
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
63443-0045
63443-0045
Front Cut-off Plunger
1Y
6
63443-0046
63443-0046
Front Cut-off Plunger Retainer
1Y
Other Components
7
11-18-5248
60827A115
Tooling Washer
1
8
63443-0009
63443-0009
Scrap Chute Front
1
9
63443-0021
63443-0021
Lower Tooling Key
1
10
63443-2401
63443-2401
Anvil Mount
1
11
63700-0539
63700-0539
Cut-Off Plunger Spring
1
12
63821-0012
63821-0012
Front Cover
1
13
63821-0015
63821-0015
Wire Stop
1
14
63830-0008
63830-0008
Front Plunger Striker
1
15
63830-0113
63830-0113
Rear Cover
1
15A 63830-0120
63830-0120
Optional Terminal Guide Assembly
0
Frame
16
63800-4300
63800-4300
Mini-Mac Applicator Frame
1
17
69028-0806
69028-0806
Conductor Adjusting Cam
1
Hardware
18
N/A
N/A
M3 by 6 Long SHCS
2**
19
N/A
N/A
M4 by 6 Long SHCS
1**
20
N/A
N/A
M4 by 12 Long BHCS
2**
21
N/A
N/A
M4 by 30 Long SHCS
1**
22
N/A
N/A
M4 by 50 Long SHCS
1**
23
N/A
N/A
M5 by 12 Long SHCS
1**
24
N/A
N/A
M8 by 20 Long BHCS
1**
25
N/A
N/A
2mm by 8 Long Roll Pin
1**
26
N/A
N/A
3mm by 6 Long Roll Pin
1**
** Available from an industrial supply company such as MSC (1-800-645-7270).
Doc No. ATS-638300000
Revision: G
Release Date: 11-16-99
Revision Date: 12-22-06
UNCONTROLLED COPY
Page 4 of 7
63830-0000-“Mini-Fit Sr.” Terminals
Assembly Drawing
17
3
14
7
24
1
16
15
(2) 20
16
(2)
18
13
12
10
2
5
25
26
21
4
9
19
8
Figure 1
11
23
6
22
Doc No. ATS-638300000
Revision: G
Release Date: 11-16-99
Revision Date: 12-22-06
UNCONTROLLED COPY
Page 5 of 7
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