Mini-Mac Applicator for Board-In Crimp Terminals
Mini-Mac
Applicator
Application Tooling
Specification Sheet
Order No. 63891-8000
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
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: Board-In-Crimp Terminal, 18-24 AWG.
Terminal Series No.
5298
Terminal Order No.
08-70-0106
39-00-0132
39-00-0230
39-00-0276
39-00-0277
98-00-0193
98-00-0194
Wire Size
AWG
mm²
18-24
0.80-0.20
Insulation Diameter
mm
In.
1.70-3.05
.067-.120
Strip Length
mm
In.
5.00-6.00
.200-.240
DEFINITION OF TERMS
INSULATION
CRIMP
1.80 +0.10/0.00mm (.071 +.004/.000”)
Diameter PC Board Hole
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-638918000
Revision: B
Release Date: 01-03-07
Revision Date: 09-29-10
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.
Wire Size
AWG
18
20
22
24
mm
2
0.80
0.50
0.35
0.20
mm
1.14
1.14
1.14
1.14
D
In
.045
.045
.045
.045
Dimensions (Figure 1)
E-E
mm
In.
1.70-1.78 .067-.070
1.70-1.78 .067-.070
1.70-1.78 .067-.070
1.70-1.78 .067-.070
F (Ref.)
mm In.
1.40 .055
1.40 .055
1.40 .055
1.40 .055
Pull Force
Minimum
N
Lb.
13.30 3.0
13.30 3.0
13.30 3.0
13.30 3.0
5298
Ψ
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. Shimming may be required of the conductor punch to
optimize this for different wire types.
Doc No: ATS-638918000
Revision: B
Release Date: 01-03-07
Revision Date: 09-29-10
UNCONTROLLED COPY
Page 2 of 5
Mini-Mac Applicator for Board-In Crimp Terminals
PARTS LIST
Mini-Mac Applicator 63891-8000
Item Order No Engineering No.
Description
Quantity
Perishable Tooling
63891-8070
63891-8070
Tool Kit (All “Y” Items)
REF
1
11-18-4393
60730A104
Conductor Punch
1Y
2
11-18-4391
60730A102
Combination Anvil
1Y
3
11-18-5343
60730B138
Insulation Punch
1Y
4
11-18-5342
60730B136
Barrel Form Punch
1Y
5
11-18-4032
60705A106
Cut-Off Plunger
1Y
6
11-18-4033
60705A107
Cut-off Plunger Retainer
1Y
7
11-18-5406
60730B105
Knock-Out Blade
1Y
Other Components
8
11-18-4034
60705A108
Front Plunger Striker
1
9
11-18-4083
60707-8
Feed Guide
1
10
11-18-4277
60702A108
Rear Plunger Retainer
1
11
11-18-4278
60702A109
Rear Plunger Striker
1
11-18-4394
60758A109
Wire Stop
1
12
13
11-18-4654
60702A110
Tooling Washer
1
14
11-18-5116
60804A141
Compression Spring (Knock-Out)
1
15
11-24-1067
4996-4
Cut-off Plunger Spring
2
16
63443-6130
63443-6130
Rear Cover
1
17
63803-5109
63803-5109
Conductor Bushing
1
Frame
18
63801-3201
63801-3201
Top
1
19
63801-3282
63801-3282
Base
1
20
63801-6550
63801-6550
Track
1
Hardware
21
N/A
N/A
M3 by 6 Long SHCS
2**
22
N/A
N/A
M4 by 8 Long SHCS
2**
23
N/A
N/A
M4 by 12 Long BHCS
2**
24
N/A
N/A
M8 by 20 Long BHCS
1**
25
N/A
N/A
#6-32 by 3/8 Long BHCS
1**
26
N/A
N/A
#6-32 by 3/8 Long SHCS
1**
27
N/A
N/A
#8-32 by 3/8 Long BHCS
4**
** Available from an industrial supply company such as MSC (1-800-645-7270).
Doc No: ATS-638918000
Revision: B
Release Date: 01-03-07
Revision Date: 09-29-10
UNCONTROLLED COPY
Page 3 of 5
Mini-Mac Applicator for Board-In Crimp Terminals
Assembly Drawing
4
17
3
8
13
24
14
18
1
11
26
22 (2)
23 (2)
16
7
20
(2)
21
9
132
5
(2) 15
10
25
18
19
6
27
2
(4)
Figure 2
Doc No: ATS-638918000
Revision: B
Release Date: 01-03-07
Revision Date: 09-29-10
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-638918000
Revision: B
Release Date: 01-03-07
Revision Date: 09-29-10
UNCONTROLLED COPY
Page 5 of 5
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