Mini-Mac Applicator for Board-In Crimp Terminals
Mini-Mac
Applicator
Application Tooling
Specification Sheet
Order No. 63893-4300
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, 18-24 AWG.
Terminal Series No.
4706
Terminal Order No.
02-07-2101
50-29-1688
Wire Size
AWG
18-24
mm²
0.80-0.20
Insulation Diameter
Maximum
mm
In.
3.05
.120
Strip Length
mm
5.97-6.35
In.
.235-.250
DEFINITION OF TERMS
1.91
±
.08 mm (.075
±
-.003”)
Diameter PC Board Hole
INSULATION
CRIMP
E
D
WIRE
E
CONDUCTOR
CRIMP
E-E
1.57
±
0.18 mm (.062
±
-.007”)
Thick PC Board
Figure 1
F
Section E-E
Doc No: ATS-638934300
Revision: D
Release Date: 02-22-07
Revision Date: 09-23-13
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).
Terminal Series No.
Dimensions (Figure 1)
D (Ref.)(Conductor)
E-E (Barrel)
F (Ref.)
2
AWG mm
mm
In.
mm
In.
mm In.
18
0.80
1.12
.044
1.72-1.78 .068-.070 .055 1.40
20
0.50
1.12
.044
1.72-1.78 .068-.070 .055 1.40
(5)
22 0.35
0.97
.030
1.72-1.78 .068-.070 .055 1.40
(5)
24 0.20
0.97
.030
1.72-1.78 .068-.070 .055 1.40
For the numbers in parentheses follow the number item below.
Wire Size
Pull Force Minimum
(4)
N
Lb.
13.34
3.0
13.34
3.0
13.34
3.0
13.34
3.0
4706
M4 X 8 LONG
SHCS (2)
CONDUCTOR
PUNCH
RAM
BARREL
PUNCH
Figure 2
•
SHIM
•
Notes:
Shim location for Conductor Punch. Shim size should be .25 by 3.2 by 12.7mm
(.010 by 1/8 by 1/2”)
1. To prevent conductor tooling damage with this applicator make sure the shut height of your crimp press is set
to 135.80mm (5.346”) before installing the applicator. Also hand cycle the first crimp to verify tooling
alignment.
2. The reference conductor crimp heights listed in the table above are suggested to achieve the minimum pull
force.
3.
Because the soldering operation between the wire and terminal is the electrical connection and not
the conductor crimp,
the conductor crimp height can deviate from the suggested values listed in the table
above due to wire type or other variables.
4. The minimum pull force for this board-in terminal does include both the insulation and conductor crimps.
5. To achieve the conductor crimp height (D dimension in Figure 1) for 22 and 24ga wire, a 0.25mm (.010”) thick
shim is required if your crimp press is not equipped with adjustable shut height. This shim is not supplied with
the applicator. The shim should be located between the Ram and the Conductor Punch. See Figure 2.
Doc No: ATS-638934300
Revision: D
Release Date: 02-22-07
Revision Date: 09-23-13
UNCONTROLLED COPY
Page 2 of 5
Mini-Mac Applicator for Board-In Crimp Terminals
PARTS LIST
Mini-Mac Applicator 63893-4300
Item Order No Engineering No.
Description
Quantity
Perishable Tooling
63893-4370
63893-4370
Tool Kit (All “Y” Items)
REF
1
11-18-4220
60714-16
Conductor Punch
1Y
2
63801-5977
63801-5977
Insulation Punch
1Y
3
11-18-4787
60714B104
Conductor Anvil
1Y
4
11-18-4212
60714-8
Insulation Anvil
1Y
5
63801-5976
63801-5976
Barrel Form Punch
1Y
6
11-18-4788
60714B109
Barrel Form Anvil
1Y
7
63893-4105
63893-4105
Front Cut-off Plunger
1Y
8
11-18-4176
60718-15
Front Plunger Guide Block
1Y
Other Components
9
11-18-4083
60707-8
Feed Guide
1
10
11-18-4167
60718-6
Plunger Striker
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
11-18-4789
60714B113
Terminal Guide
1
15
11-18-4849
60800A124
Wire Hold Down Spring
1
16
11-18-4944
60710-21
Cut-off Plunger Spring
2
17
63803-5135
63803-5135
Conductor Bushing
1
18
63803-5202
63803-5202
Insulation Bushing
1
Frame
19
63801-3201
63801-3201
Top
1
20
63801-3282
63801-3282
Base
1
21
63801-6550
63801-6550
Track
1
Hardware
22
N/A
N/A
M3 by 5 Long SHCS
2**
23
N/A
N/A
M3 by 8 Long SHCS
2**
24
N/A
N/A
M4 by 8 Long SHCS
2**
25
N/A
N/A
M4 by 10 Long SHCS
2**
26
N/A
N/A
M8 by 20 Long BHCS
1**
27
N/A
N/A
#8-32 by 3/8” Long BHCS
4**
28
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-638934300
Revision: D
Release Date: 02-22-07
Revision Date: 09-23-13
UNCONTROLLED COPY
Page 3 of 5
Mini-Mac Applicator for Board-In Crimp Terminals
Assembly Drawing
5
(2)
24
17
2
10
18
19
26
1
15
22
14
(2)
●
See Wire Hold
Down Assembly
25
11
(2)
21
19
23
20
9
12
13
7
27
16
(2)
3
6
4
28
8
Figure 4
(4)
Doc No: ATS-638934300
Revision: D
Release Date: 02-22-07
Revision Date: 09-23-13
UNCONTROLLED COPY
Page 4 of 5
Mini-Mac Applicator for Board-In Crimp Terminals
●Wire
Hold Down Assembly
The wire hold down spring is assembled onto the outside diameter of the conductor bushing.
The location of the spring on the outside diameter of the bushing should be flush with the bushings surface edge
as shown. There is a clearance groove provided on the punches for the spring to fit between. See Figure 3.
CONDUCTOR
BUSHING
INSULATION
BUSHING
GROOVE IN
PUNCHES
CONDUCTOR
PUNCH
HOLD DOWN
SPRING
Figure 3
HOLD DOWN
SPRING
NOTES
INSULATION
PUNCH
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.
Visit our Web site at http://www.molex.com
Doc No: ATS-638934300
Revision: D
Release Date: 02-22-07
Revision Date: 09-23-13
UNCONTROLLED COPY
Page 5 of 5
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