Mini-Mac Applicator for Board-In Crimp Terminals
Mini-Mac Applicator
Specification Sheet
Order No. 63893-8000
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 barrel crimp
height and .063mm (.0025") for insulation height. See notes on Page 2.
Independent adjustment rings allow users to quickly adjust the barrel or insulation crimp height without affecting each other.
SCOPE
Products: Board-In Crimp Terminal, 22-26 AWG.
Terminal
Series No.
42001
Terminal Order No.
40-01-0610
40-02-0601
40-08-0605
40-08-0606
Wire Size
AWG
22-26
mm²
0.12-0.35
Insulation Diameter Max.
mm
1.52
In.
.060
Strip Length
mm
4.32-4.83
In.
.170-.190
PC Board Hole
“A” Diameter
mm
In.
1.29
±
.05
.051
±
.002
DEFINITION OF TERMS
PC Board Hole
A Diameter
INSULATION
CRIMP
E
D
WIRE
E
CONDUCTOR
CRIMP
E-E
1.57
±
0.20 mm (.062
±
-.008”)
Thick PC Board
Figure 1
F
Section E-E
Doc No. ATS-638938000
Revision: A
Release Date: 03-02-07
Revision Date: 03-02-07
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
22
24
26
mm
0.35
0.20
0.12
2
42001
Dimensions (Figure 1)
D Max.
E-E
mm In
mm
In.
0.97 .038 1.12-1.19 .044-.047
0.97 .038 1.12-1.19 .044-.047
0.97 .038 1.12-1.19 .044-.047
F (Ref.)
mm In.
0.97 .038
0.97 .038
0.97 .038
Pull Force Min.
N
13.30
13.30
13.30
Lb.
3.0
3.0
3.0
✹
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-638938000
Revision: A
Release Date: 03-02-07
Revision Date: 03-02-07
UNCONTROLLED COPY
Page 2 of 5
Mini-Mac Applicator for Board-In Crimp Terminals
PARTS LIST
Mini-Mac Applicator 63893-8000
Item Order No Engineering No.
Description
Quantity
Perishable Tooling
63893-8070
63893-8070
Tool Kit (All “Y” Items)
REF
1
11-18-4664
60757A104
Conductor Punch
1Y
2
11-18-4662
60757A102
Combination Anvil
1Y
3
11-18-4663
60757A103
Insulation Punch
1Y
4
11-18-4661
60757A101
Barrel Form Punch
1Y
5
11-18-4665
60757A105
Cut-Off Plunger and Wire Stop
1Y
6
11-18-4666
60757A106
Rear Plunger Retainer
1Y
7
11-18-4652
60758A107
Front Cut-Off Plunger
1Y
8
11-18-4653
60758A108
Front Plunger Retainer
1Y
Other Components (REF 938050)
9
11-18-4034
60705A108
Front Plunger Striker
1
10
11-18-4083
60707-8
Feed Guide
1
11
11-18-4643
60755A108
Gathering Bar Spring
1
12
11-18-4654
60758A109
Tooling Washer
1
13
11-18-4667
60757A107
Rear Plunger Striker
1
14
11-18-4721
60757A114
Gathering Bar
1
15
11-24-1067
4996-4
Cut-off Plunger Spring
2
16
63443-6111
63443-6111
Rear Cover
1
17
63803-5116
63803-5116
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 8 Long SHCS
2**
22
N/A
N/A
M4 by 10 Long BHCS
2**
23
N/A
N/A
M4 by 16 Long SHCS
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 5/8” Long SHCS
2**
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-638938000
Revision: A
Release Date: 03-02-07
Revision Date: 03-02-07
UNCONTROLLED COPY
Page 3 of 5
Mini-Mac Applicator for Board-In Crimp Terminals
Assembly Drawing
13
23
4
3
9
12
24
11
14
22
16
(2)
18
1
26
(2)
17
(2)
20
18
(2)
21
10
5
7
(2) 15
8
2
Figure 1
6
19
25
27 (4)
Doc No. ATS-638938000
Revision: A
Release Date: 03-02-07
Revision Date: 03-02-07
UNCONTROLLED COPY
Page 4 of 5
Mini-Mac Applicator for Board-In Crimp Terminals
NOTES
1.
2.
3.
4.
5.
Molex recommends an extra perishable tooling kit be maintained at your facility.
Verify tooling alignment by manually cycling the press and applicator before crimping under power. Check that all screws are tight.
Slugs, terminals, dirt, and oil should be kept clear of work area.
Wear safety glasses at all times.
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.
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Visit our Web site at http://www.molex.com
Doc No. ATS-638938000
Revision: A
Release Date: 03-02-07
Revision Date: 03-02-07
UNCONTROLLED COPY
Page 5 of 5
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