Mini-Mac Applicator for Power 60 Amp Crimp Terminals
Mini-Mac
Applicator
Air Feed
Application Tooling
Specification Sheet
Order No.63832-0800
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.
Molex applicators with air feed require presses equipped with an air valve. Molex presses with air valves
include the TM-4000 (63801-7600).
SCOPE
Products: Power 60 Amp Crimp Terminals, 10 AWG
Terminal
Series No.
46819
Insulation Diameter
Maximum
Terminal Order No.
AWG mm²
mm
In.
46819-0011
10
5.00
9.00
.354
Overall insulation OD specification for terminal.
Wire Size
Strip Length
mm
8.00-9.00
In.
.315-.354
Note:
The 63832-0800 applicator must be used with TM-4000 (63801-7600) or an equivalent press with no less
than 3 tons.
DEFINITION OF TERMS
STRIP LENGTH
BELL MOUTH
BRUSH
ROLLING
TWISTING
CONDUCTOR
CRIMP HEIGHT
BEND
DOWN
BEND UP
SEAM
CUT-OFF
TAB
WIRE
Doc No: ATS-638320800
Revision: C
Release Date: 07-09-09
Revision Date: 06-14-12
UNCONTROLLED COPY
Page 1 of 5
Mini-Mac Applicator for Power 60 Amp Crimp Terminals
CRIMP SPECIFICATION
Terminal Series No.
46819
Bell mouth
mm
In.
0.25-1.25 .010-.049
Cut-off Tab Maximum
mm
In.
0.35
.014
Conductor Brush
mm
In.
1.00-2.50
.039-.098
Seam
Seam shall not be
open and no wire allowed
out of the crimping area
Bend up Bend down
Terminal Series No.
46819
3
Degree
3
Twist Roll
Degree
3
3
Punch Width (Ref)
Conductor
mm
In
4.90
.193
After crimping, the crimp profiles should measure the following.
Terminal Series No.
46819
Wire Size
AWG
10
mm
2
5.00
Conductor
Crimp Height
Crimp Width (Ref.)
mm
In.
mm
In.
2.85-2.95 .112-.116
5.00
.197
Pull Force Minimum
N
600.51
Lb.
135.00
Tool Qualification Notes:
1.
The above specifications are guidelines to an optimum crimp.
Doc No: ATS-638320800
Revision: C
Release Date: 07-09-09
Revision Date: 06-14-12
UNCONTROLLED COPY
Page 2 of 5
Mini-Mac Applicator for Power 60 Amp Crimp Terminals
PARTS LIST
Mini-Mac Applicator 63832-0800
Item Order No Engineering No.
Description
Quantity
Perishable Tooling
63832-0870
63832-0870
Tool Kit (All “Y” Items)
REF
1
63465-0070
63465-0070
Conductor Punch
1Y
2
63455-0072
63455-0072
Conductor Anvil
1Y
3
63443-0095
63443-0095
Front Cut-Off Plunger
1Y
4
63890-0487
63890-0487
Front Plunger Retainer
1Y
Other Components
5
11-18-4848
60800A123
Spring Retainer
1
6
11-18-4849
60800A124
Wire Hold Down Spring
1
7
63443-0007
63443-0007
Scrap Chute Front
1
8
63443-0025
63443-0025
Key
1
9
63443-1225
63443-1225
Wire Stop
1
10
63443-1715
63443-1715
Height Spacer (18.50mm)
11
63443-2214
63443-2214
Coarse Spacer (14.00mm)
1
12
63443-2304
63443-2304
Fine Spacer (3.20mm)
1
13
63466-0512
63466-0512
Striker
1
14
63700-0539
63700-0539
Compression Spring
1
15
63801-3511
63801-3511
Feed Finger
1
16
63821-0012
63821-0012
Feed Guide
1
17
63832-0602
63832-0602
Rear Cover
1
18
63890-0866
63890-0866
Bushing-Punch (Conductor)
1
Frame
63801-3301
63801-3301
Top
1
19
63801-3281
63801-3281
Base
1
20
63801-4650
63801-4650
Track
1
21
63801-3501
63801-3501
Air-Feed Assembly
1
22
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
1**
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 30 Long BHCS
1**
30
N/A
N/A
2mm by 5 Long Roll Pin
1**
** Available from an industrial supply company such as MSC (1-800-645-7270).
Doc No: ATS-638320800
Revision: C
Release Date: 07-09-09
Revision Date: 06-14-12
UNCONTROLLED COPY
Page 3 of 5
Mini-Mac Applicator for Power 60 Amp Crimp Terminals
Assembly Drawing
19
1
5
13
29
18
22
6
(2)
26
19
14
21
(2)
24
16
3
30
2
11
15
10
8
23
4
(2)
27
7
25
Figure 1
12
20
17
9
28
Doc No: ATS-638320800
Revision: C
Release Date: 07-09-09
Revision Date: 06-14-12
UNCONTROLLED COPY
Page 4 of 5
Mini-Mac Applicator for Power 60 Amp 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 with 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 Applicator Manual (Document no. 63880-0000).
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-638320800
Revision: C
Release Date: 07-09-09
Revision Date: 06-14-12
UNCONTROLLED COPY
Page 5 of 5
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