Mini-Mac Applicator for
1.57mm (.062”) diameter
Crimp Terminals
Mini-Mac Applicator
Specification Sheet
Order No. 63893-6100
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: 1.57mm (.062”) diameter pin and socket crimp terminals, 24-28 AWG.
Terminal Series No.
5008
5009
Terminal Order No.
08-70-0003
08-70-0004
08-70-1015
08-70-1017
Wire Size
AWG
24-28
24-28
mm²
0.20-0.09
0.20-0.09
Insulation Diameter
Maximum
mm
In.
2.40
.094
2.40
.094
Strip Length
mm
2.70-3.30
2.70-3.30
In.
.106-.130
.106-.130
DEFINITION OF TERMS
BEND UP
BELL
MOUTH
SEAM
ROLLING
BRUSH
CONDUCTOR
CRIMP
INSULATION
CRIMP
STRIP
LENGTH
CUT-OFF
TAB
TWISTING
BEND
DOWN
CRIMP HEIGHT
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the
scope.
Doc No: ATS-638936100
Revision: B
Release Date: 12-12-07
Revision Date: 03-27-08
UNCONTROLLED COPY
Page 1 of 5
Mini-Mac Applicator for
1.57mm (.062”) diameter
Crimp Terminals
CRIMP SPECIFICATIONS
Bell mouth
mm
In.
0.20-0.50 .008-.020
0.20-0.50 .008-.020
Cut-off Tab Maximum
mm
In.
0.30
.012
0.30
.012
Conductor Brush
mm
In.
0.00-1.00 .000-.040
0.00-1.00 .000-.040
Seam
Seam shall not be open
and no wire allowed out
of the crimping area
Terminal Series No.
5008
5009
Terminal Series No.
5008
5009
Bend up Bend down
Degree
3
3
3
3
Twist Roll
Degree
4
15
4
15
Punch Width (Ref)
Conductor Insulation
mm
In.
mm
In.
1.40 .055 2.51 .099
1.40 .055 2.51 .099
NOTE:
Some of the specifications in these charts above are intentionally left blank due to the fact that
the information does not currently exist.
After crimping, the conductor profile should measure the following.
Wire Size
Terminal Series No.
AWG
5008
24
26
28
24
26
28
mm
2
Conductor
Pull Force
Crimp Height
Crimp Width (Ref.) Minimum
mm
0.75-0.80
0.69-0.74
0.60-0.65
0.75-0.80
0.69-0.74
0.60-0.65
In.
.030-.032
.027-.029
.024-.026
.030-.032
.027-.029
.024-.026
mm
1.40
1.40
1.40
1.40
1.40
1.40
In.
.055
.055
.055
.055
.055
.055
N
44.5
26.7
13.3
44.5
26.7
13.3
Lb.
10.0
6.0
3.0
10.0
6.0
3.0
5009
0.20
0.13
0.09
0.20
0.13
0.09
Pull Force should be measured with no influence from the insulation crimp.
The above specifications are guidelines to an optimum crimp.
Doc No: ATS-638936100
Revision: B
Release Date: 12-12-07
Revision Date: 03-27-08
UNCONTROLLED COPY
Page 2 of 5
Mini-Mac Applicator for
1.57mm (.062”) diameter
Crimp Terminals
PARTS LIST
Mini-Mac Applicator 63893-6100
Item Order No Engineering No.
Description
Quantity
Perishable Tooling
63893-6170
63893-6170
Tool Kit (All “Y” Items)
REF
1
11-18-4879
60762B101
Conductor Punch
1Y
2
11-18-4877
60762B102
Combination Anvil
1Y
3
11-18-4878
60762B103
Insulation Punch
1Y
4
11-18-4652
60758A107
Front Cut-Off Plunger
1Y
5
11-18-4653
60758A108
Front Plunger Retainer
1Y
Other Components (REF 936150)
6
11-18-4022
60704-10
Terminal Hold Down Adapter
1
7
11-18-4034
60705A108
Front Plunger Striker
1
8
11-18-4083
60707-8
Feed Gude
1
9
11-18-5318
60832A115
Tooling Washer
1
10
11-18-4741
60762A108
Spacer
1
11
11-18-4778
60762A113
Hold Down Pad
1
12
11-24-1067
4996-4
Cut-off Plunger Spring
1
13
63443-0090
63443-0090
Wire Stop
1
14
63443-6116
63443-6116
Rear Cover
1
15
63803-5132
63803-5132
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 6 Long SHCS
1**
21
N/A
N/A
M4 by 12 Long BHCS
2**
22
N/A
N/A
M4 by 12 Long SHCS
2**
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
#6-32 by 3/8” Long BHCS
1**
26
N/A
N/A
#6-32 by 1/2” Long FHCS
1**
27
N/A
N/A
#6-32 Hex Jam Nut
1**
28
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-638936100
Revision: B
Release Date: 12-12-07
Revision Date: 03-27-08
UNCONTROLLED COPY
Page 3 of 5
Mini-Mac Applicator for
1.57mm (.062”) diameter
Crimp Terminals
Assembly Drawing
16
1
22 (2)
3
15
6
27
7
9
24
11
(2) 21
14
26
18
(2) 19
16
8
17
13
23
10
20
4
12
5
25
2
28
(4)
13
Figure 1
Doc No: ATS-638936100
Revision: B
Release Date: 12-12-07
Revision Date: 03-27-08
UNCONTROLLED COPY
Page 4 of 5
Mini-Mac Applicator for
1.57mm (.062”) diameter
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-638936100
Revision: B
Release Date: 12-12-07
Revision Date: 03-27-08
UNCONTROLLED COPY
Page 5 of 5
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