Mini-Mac Applicator for -“Mini-Fit Sr.” Terminals
Mini-Mac
Applicator
Application Tooling
Specification Sheet
Order No. 63891-1000
FEATURES
Directly adapts to most automatic wire processing machines. This applicator ships from the factory set-up in the
up-stroke condition for bench-top operation; however it will directly adapt to most automatic wire processing
machines. Please review the applicator manual that shipped with your tool and is linked on the Molex website.
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.
Optimum terminal feed/indexing can be obtained with the optional terminal guide assembly, Order No.
63830-0120. See page 6.
Easy change-over for terminal feeding (up-stroke or down-stroke). Applicator shipped as up-stroke.
SCOPE
Products: Mini-Fit Sr. ™ Male and Female Crimp Terminals, 8 and (2) 12 AWG.
Terminal Series No.
Terminal Order No.
Wire Size
AWG mm²
8
(2) 12
N/A
N/A
∗Insulation
Diameter
mm
In.
5.00-6.75
3.50-4.00
.197-.266
.138-.157
Strip Length
mm
In.
9.00-10.00
11.00-12.00
.354-.394
.433-.472
.354-.394
.433-.472
42815
42815-0030
42815-0031
42815-0032
42815-0134
42817-0030 42817-0130
8
N/A 5.00-6.75 .197-.266 9.00-10.00
42817-0031 42817-0131
42817
42817-0032 42817-0132 (2) 12 N/A 3.50-4.00 .138-.157 11.00-12.00
42817-1034 42817-1134
∗On
Mini-Fit Sr. 8 AWG terminal, the insulation is stripped in both the conductor and insulation grips.
1. Crimp terminals to stranded copper wire only.
2. Lubricate terminals plated in precious metals using Molex Oiler 63801-7240.
Doc No: ATS-638911000
Revision: D
Release Date: 12-13-06
Revision Date: 09-21-16
UNCONTROLLED COPY
Page 1 of 7
Mini-Mac Applicator for -“Mini-Fit Sr.” Terminals
DEFINITION OF TERMS
3.75mm
±
0.20
CONTACT GAP
1.00mm
±
0.20
BEND
UP
SEAM
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
BEND
DOWN
TWISTING
CRIMP SPECIFICATIONS
Terminal Series No.
42815
42817
Bell mouth
mm
In.
.20-.50 .008-.020
.20-.50 .008-.020
Cut-off Tab Maximum
mm
In.
.30-.50
.012-.020
.30-.50
.012-.020
Twist Roll
Degree
4
8
4
8
Conductor Brush
mm
In.
2.10-3.10 .083-.122
2.10-3.10 .083-.122
Terminal Series No.
42815
42817
Bend up Bend down
Degree
3
3
3
3
Punch Width (Ref)
Conductor Insulation
mm
In
mm
In
3.90 .154 4.80 .189
3.90 .154 4.80 .189
Seam
Seam shall not be open and no wire allowed out of the crimping area
After crimping, the conductor profile should measure the following.
Conductor
Pull Force
Minimum
Terminal Series No.
Crimp Height
Crimp Width
2
AWG
mm
mm
In.
mm
In.
N
Lb.
8
N/A
3.20-3.30
.126-.130
3.90
.154
400.3
90.0
42815
8
N/A
3.40-3.50
.134-.138
3.90
.154
400.3
90.0
(2) 12
N/A
3.20-3.30
.126-.130
3.90
.154
311.4
70.0
8
N/A
3.20-3.30
.126-.130
3.90
.154
400.3
90.0
42817
8
N/A
3.40-3.50
.134-.138
3.90
.154
400.3
90.0
(2) 12
N/A
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.
Wire Size
Tool Qualification Notes:
1. Pull Force should be measured with no influence from the insulation crimp.
2. The above specifications are guidelines to an optimum crimp.
Doc No: ATS-638911000
Revision: D
Release Date: 12-13-06
Revision Date: 09-21-16
UNCONTROLLED COPY
Page 2 of 7
Mini-Mac Applicator for -“Mini-Fit Sr.” Terminals
Special Note:
EXTRUDED WIRE LENGTH
(BRUSH)
BELL MOUTH (FLARE)
0.50mm
REF
INSULATION GRIP
A
5.00mm
REF
A
WIRE STRANDS
CUT-OFF TAB LENGTH
SECTION A-A
Figure 1
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-638911000
Revision: D
Release Date: 12-13-06
Revision Date: 09-21-16
UNCONTROLLED COPY
Page 3 of 7
Mini-Mac Applicator for -“Mini-Fit Sr.” Terminals
PARTS LIST
Mini-Mac Applicator 63891-1000
Item Order No Engineering No.
Description
Quantity
Perishable Tooling
63891-1070
63891-1070
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
Plunger Retainer (Non Carrier Cut-Off)
6
63443-4202
63443-4202
0
To be used on all wire processors only.
Other Components
7
11-18-5248
60827A115
Tooling Washer
1
8
63443-0009
63443-0009
Scrap Chute Front
1
9
63443-0024
63443-0024
Lower Tooling Key
1
10
63443-1715
63443-1715
Height Spacer
1
11
63443-2209
63443-2209
Course Spacer (9.00mm)
1
12
63443-2306
63443-2306
Fine Spacer (3.30mm)
1
13
63700-0539
63700-0539
Cut-Off Plunger Spring
1
14
63803-5105
63803-5105
Conductor Bushing
1
15
63821-0012
63821-0012
Front Cover
1
16
63821-0015
63821-0015
Wire Stop
1
17
63830-0008
63830-0008
Front Plunger Striker
1
18
63830-0117
63830-0117
Terminal Lead In
2
19
63830-0118
63830-0118
Rear Cover
1
Frame
20
63801-3201
63801-3201
Top
1
21
63801-3281
63801-3281
Base
1
22
63801-4650
63801-4650
Track
1
Hardware
23
N/A
N/A
M3 by 6 Long FHCS
1**
24
N/A
N/A
M3 by 6 Long SHCS
2**
25
N/A
N/A
M4 by 6 Long SHCS
5**
26
N/A
N/A
M4 by 12 Long BHCS
2**
27
N/A
N/A
M4 by 50 Long SHCS
2**
28
N/A
N/A
M5 by 12 Long SHCS
1**
29
N/A
N/A
M8 by 20 Long BHCS
1**
30
N/A
N/A
2mm by 8 Long Roll Pin
1**
** Fastener parts can be obtained through most industrial supply houses by using the generic
descriptions listed above in the parts list table.
Abbreviation descriptions: SHCS = Socked Head Cap Screw, FHCS = Flat Head Cap Screw,
SSS = Socket Set Screw, BHCP = Button Head Cap Screw, Roll Pin = Spiral Pin.
Doc No: ATS-638911000
Revision: D
Release Date: 12-13-06
Revision Date: 09-21-16
UNCONTROLLED COPY
Page 4 of 7
Mini-Mac Applicator for -“Mini-Fit Sr.” Terminals
Assembly Drawing
1
3
17
(4)
25
29
7
14
20
26 (2)
18 (2)
20
22
19
(2)
24
15
2
4
11
5
30
13
9
23
Figure 1
6
(2) 27
8
25
12
10
21
16
28
Doc No: ATS-638911000
Revision: D
Release Date: 12-13-06
Revision Date: 09-21-16
UNCONTROLLED COPY
Page 5 of 7
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