Mini-Mac Applicator for Board-In Crimp Terminals
Mini-Mac Applicator
Specification Sheet
Order No. 63892-5100
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 conductor or insulation crimp height without
affecting each other.
SCOPE
Products: Board-In Crimp Terminal, 22-26 AWG.
Insulation Diameter
Wire Size
Strip Length
Terminal
Terminal
Terminal Order No.
IPC/WHMA-A620
Series No.
Maximum
AWG
mm²
mm
In.
mm
In.
mm
In.
4811
16-02-0034 16-02-0047 22-26 0.12-0.35 1.30-1.52 .051-.060 1.52 .060 5.97-6.35 .235-.250
41817
16-02-0118
22-26 0.12-0.35 1.30-1.52 .051-.060 1.52 .060 5.97-6.35 .235-.250
5190
08-70-0060 39-00-0193 22-26 0.12-0.35 1.30-1.70 .051-.067 1.70 .067 5.97-6.35 .235-.250
To achieve optimum IPC-A620 insulation crimps, use this insulation OD range.
Overall insulation OD specification for terminal.
Terminal
Series No.
4811
41817
5190
PC Board Hole
Terminal Order No.
“A” Diameter
AWG
mm²
mm
In.
16-02-0034 16-02-0047 22-26 0.12-0.35 1.30±.06 .051±.002
16-02-0118
22-26 0.12-0.35 1.30±.06 .051±.002
08-70-0060 39-00-0193 22-26 0.12-0.35 1.24±.08 .048±.003
Wire Size
Doc No: ATS-638925100
Revision: B
Release Date: 01-23-07
Revision Date: 08-20-09
UNCONTROLLED COPY
Page 1 of 5
Mini-Mac Applicator for Board-In Crimp Terminals
DEFINITION OF TERMS
PC Board Hole
A Diameter
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
CRIMP SPECIFICATIONS
After crimping, the conductor profiles should measure the following (See Figure 1).
Terminal Series No.
Wire Size
AWG
22
24
26
22
24
26
22
24
26
mm
2
0.35
0.20
0.12
0.35
0.20
0.12
0.35
0.20
0.12
Dimensions (Figure 1)
D
E-E
mm
In
mm
In.
0.88-0.97 .035-.038 1.19-1.24 047-.049
0.88-0.97 .035-.038 1.19-1.24 .047-.049
0.88-0.97 .035-.038 1.19-1.24 .047-.049
0.88-0.97 .035-.038 1.19-1.24 047-.049
0.88-0.97 .035-.038 1.19-1.24 .047-.049
0.88-0.97 .035-.038 1.19-1.24 .047-.049
0.88-0.97 .035-.038 1.12-1.17 .044-.046
0.88-0.97 .035-.038 1.12-1.17 .044-.046
0.88-0.97 .035-.038 1.12-1.17 .044-.046
F (Ref.)
mm In.
0.97 .038
0.97 .038
0.97 .038
0.97 .038
0.97 .038
0.97 .038
0.97 .038
0.97 .038
0.97 .038
Pull Force
Minimum
N
Lb.
13.30 3.0
13.30 3.0
13.30 3.0
13.30 3.0
13.30 3.0
13.30 3.0
13.30 3.0
13.30 3.0
13.30 3.0
4811-1
41817
5190
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. The insulation and barrel crimps are adjustable, by the
cams (rings) on top of the Mini-Mac ram. The conductor crimp height is not adjustable. Shimming may be
required of the conductor punch to optimize this for different wire types.
Doc No: ATS-638925100
Revision: B
Release Date: 01-23-07
Revision Date: 08-20-09
UNCONTROLLED COPY
Page 2 of 5
Mini-Mac Applicator for Board-In Crimp Terminals
PARTS LIST
Mini-Mac Applicator 63892-5100
Item Order No Engineering No.
Description
Quantity
Perishable Tooling
63892-5170
63892-5170
Tool Kit (All “Y” Items)
REF
1
11-18-4272
60702A103
Conductor Punch
1Y
2
11-18-4295
60702A202
Combination Anvil
1Y
3
11-18-4294
60702A201
Insulation Punch
1Y
4
11-18-4271
60702A102
Barrel Form Punch
1Y
5
11-18-4032
60705A106
Cut-Off Plunger
1Y
6
11-18-4033
60705A107
Cut-off Plunger Retainer
1Y
7
11-18-4276
60702A107
Rear Cut-Off Plunger and Wire Stop
1Y
8
11-18-4277
60702A108
Rear Cut-off Plunger Retainer
1Y
Other Components
9
11-18-4034
60705A108
Front Plunger Striker
1
10
11-18-4083
60707-8
Feed Guide
1
11
11-18-4278
60702A109
Rear Plunger Striker
1
12
11-18-4279
60702A110
Tooling Washer
1
13
11-18-4282
60702A113
Rear Cover
1
14
11-24-1067
4996-4
Cut-off Plunger Spring
2
15
63803-5108
63803-5108
Conductor Bushing
1
Frame
16
63801-3201
63801-3201
Top
1
17
63801-3282
63801-3282
Base
1
18
63801-6550
63801-6550
Track
1
Hardware
19
N/A
N/A
M3 by 8 Long SHCS
2**
20
N/A
N/A
M4 by 8 Long SHCS
2**
21
N/A
N/A
M4 by 8 Long BHCS
2**
22
N/A
N/A
M8 by 20 Long BHCS
1**
23
N/A
N/A
#6-32 by 3/8” Long BHCS
1**
24
N/A
N/A
#6-32 by 3/8” Long SHCS
1**
25
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-638925100
Revision: B
Release Date: 01-23-07
Revision Date: 08-20-09
UNCONTROLLED COPY
Page 3 of 5
Mini-Mac Applicator for Board-In Crimp Terminals
Assembly Drawing
4
24
3
9
12
22
16
15
1
11
20
(2)
(2)
13
21
18
16
(2)
19
10
7
5
(2) 14
6
2
8
23
25
(4)
17
Figure 1
Doc No: ATS-638925100
Revision: B
Release Date: 01-23-07
Revision Date: 08-20-09
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.
Americas Headquarters
Lisle, Illinois 60532 U.S.A.
1-800-78MOLEX
amerinfo@molex.com
Far East North Headquarters
Yamato, Kanagawa, Japan
81-462-65-2324
feninfo@molex.com
Far East South Headquarters
Jurong, Singapore
65-6-268-6868
fesinfo@molex.com
European Headquarters
Munich, Germany
49-89-413092-0
eurinfo@molex.com
Corporate Headquarters
2222 Wellington Ct.
Lisle, IL 60532 U.S.A.
630-969-4550
Fax: 630-969-1352
Visit our Web site at http://www.molex.com
Doc No: ATS-638925100
Revision: B
Release Date: 01-23-07
Revision Date: 08-20-09
UNCONTROLLED COPY
Page 5 of 5
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