Mini-Mac Applicator Specification Sheet Part No. 63801-2900 (Replaces 19814-1000) FEATURES Œ Quick set-up time; plus the crimp height, track and feed adjustments can be preset in applicator Œ Conductor and insulation rings allow quick adjustment for conductor and insulation diameter change Œ Applicator designed to industry standard mounting and shut height 135.80mm (5.346") Œ Directly adapts to most automatic wire processing machines SCOPE Terminal Series Wire Size Insulation Diameter Strip Length No. AWG mm² mm In. mm In. 35725-2600 14-18 2.00-0.80 3.60 Max..142 Max. 4.60-5.50.181-.217 35725-2610 14-18 2.00-0.80 3.60 Max..142 Max. 4.60-5.50.181-.217 DEFINITION OF TERMS WIRE STRIP LENGTH INSULATION CRIMP CUT-OFF TAB BEND UP ROLLING BEND DOWN TWISTING CONDUCTOR CRIMP 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. 63801-2900 Release Date: 12-05-03 UNCONTROLLED COPY Page 1 of 12
CRIMP SPECIFICATIONS Terminal Bell mouth Cut-off Tab Max. Conductor Brush Series No. mm In. mm In. mm In. 35725-2600 N/A N/A.50.020 N/A N/A 35725-2610 N/A N/A.50.020 N/A N/A Terminal Series No. Bend up Bend down Twist Roll Punch Width (Ref) Degree Degree Conductor Insulation mm In mm In 35725-2600 3 5 3 5 4.27.168 4.03.159 35725-2610 3 5 3 5 4.27.168 4.03.159 Seam Seam shall not be open and no wire allowed out of the crimping area After crimping, the conductor profile should measure the following. Terminal Wire Size Crimp Height Pull Force Min. Series No. AWG mm 2 mm In. N Lb. 35725-2600 14 2.00 1.70-1.80.067-.071 222.6 50.0 35725-2600 16 1.30 1.50-1.60.059-.063 133.5 30.0 35725-2600 18 0.80 1.40-1.50.055-.059 89.0 20.0 35725-2600 18 (Dbl.) 0.80 1.50-1.60.059-.063 89.0 20.0 35725-2610 14 2.00 1.70-1.80.067-.071 222.6 50.0 35725-2610 16 1.30 1.50-1.60.059-.063 133.5 30.0 35725-2610 18 0.80 1.40-1.50.055-.059 89.0 20.0 35725-2610 18 (Dbl.) 0.80 1.50-1.60.059-.063 89.0 20.0 Pull Force should be measured with no influence from the insulation crimp. The above specifications are guidelines to an optimum crimp. Doc No. 63801-2900 Release Date: 12-05-03 UNCONTROLLED COPY Page 2 of 12
Main Parts List and Assembly Drawings 63801-2900 Mini-Mac Applicator Back Feed Item Order No. Description Qty Figure 1 63801-2900 Mini-Mac Applicator-Back Feed 1 Figure 1 63801-2950 (Modified) - Back Feed Applicator 2 63801-2997 Upper Tooling Assembly 1 Figure 2 3 63801-2696 Feed Linkage Subassembly 1 Figure 3 4 63801-2698 Frame Subassembly 1 Figure 4 2 3 4 1 MAIN ASSEMBLY Doc No. 63801-2900 Release Date: 12-05-03 UNCONTROLLED COPY Page 3 of 12
PARTS LIST 63801-2900 - Main Assembly Item Order No. Engineering No. Description Qty 1 63801-2916 63801-2916 Blanking Punch 1 Y 2 63801-2706 63801-2706 Anvil 1 Y 3 63801-2910 63801-2910 Cut-off Die 1 Y 4 63801-2938 63801-2938 Die 1 Y 5 11-31-4860 AM-60009A127 Lower Clamp Spring (Assoc.#C0360-045- 1 1500-M) 6 63800-0115 63800-0115 Spacer Tube 1 7 63800-0313 63800-0313 Drag Cam 1 8 63801-2709 63801-2709 Ramp 1 9 63801-2718 63801-2718 Punch Shaft 1 10 63801-2734 63801-2734 Feed Finger 1 11 63801-2737 63801-2737 Terminal Hold Down 1 12 63801-2823 63801-2823 Drag Plate 1 13 63801-2902 63801-2902 Terminal Track 1 14 63801-2905 63801-2905 Terminal Nest 1 15 63801-2907 63801-2907 Terminal Cover 1 16 63801-2908 63801-2908 Terminal Guide L.H. 1 17 63801-2912 63801-2912 Pivot Pin 1 18 63801-2913 63801-2913 Anvil Retainer 1 19 63801-2917 63801-2917 Pivot Punch 1 20 63801-2919 63801-2919 Punch Stop 1 21 63801-2920 63801-2920 Urethane Spring (Modified) 1 22 63801-2922 63801-2922 Drag Frame 1 23 63801-2925 63801-2925 Terminal Guide R.H. 1 24 63801-2929 63801-2929 Stop Pin 1 25 63801-2930 63801-2930 Base Plate 1 26 63801-2937 63801-2937 Support Plate 1 27 63801-2950 63801-2950 Back Feed Applicator-Modified REF 28 69028-0660 69028-0660 Drag Springs (Lee #LC-032E-0MW) 2 29 N/A N/A 6mm Diameter by 20 Long SHLDR Screw 2 30 N/A N/A M2.5 by 6 Long SHCS 1 31 N/A N/A M3 by 5 Long SHCS 2 32 N/A N/A M3 by 6 Long BHCS 1 33 N/A N/A M3 by 8 Long SHCS 1 34 N/A N/A M4 by 8 Long SSS 2 35 N/A N/A M4 by 8 Long BHCS 3 36 N/A N/A M4 by 8 Long SHCS 3 37 N/A N/A M4 by 12 Long BHCS 3 38 N/A N/A M4 by 12 Long SHCS 3 39 N/A N/A M4 by 30 Long SHCS 2 Doc No. 63801-2900 Release Date: 12-05-03 UNCONTROLLED COPY Page 4 of 12
63801-2900 - Main Assembly Item Order No. Engineering No. Description Qty 40 N/A N/A M5 by 10 Long SSS 1 41 N/A N/A M5 by 16 Long SHCS 2 42 N/A N/A M6 by 8 Long Low Head Screw 4 43 N/A N/A M6 by 12 Long BHCS 2 44 N/A N/A M8 by 20 Lg. SSS 1 45 N/A N/A 3mm by 10 Long Dowel Pin 1 46 N/A N/A 4mm by 10 Long Dowel Pin 4 47 N/A N/A 6mm by 10 Long Dowel Pin 2 REF 63801-2970 63801-2970 Tool Kit (All Y Items) REF The following purchased parts are available from an Industrial supply company such as MSC (1-800-645-7270). Doc No. 63801-2900 Release Date: 12-05-03 UNCONTROLLED COPY Page 5 of 12
Assembly Drawing 27 Ref 15 37 33 3 35 16 35 10 36 13 29 46 23 28 8 38 14 2 4 36 45 30 21 17 24 11 34 32 1 34 19 12 31 22 7 6 37 38 18 25 44 9 5 46 39 20 40 41 43 47 26 42 (4) Figure 1 Doc No. 63801-2900 Release Date: 12-05-03 UNCONTROLLED COPY Page 6 of 12
Upper Tooling Parts List 63801-2997 - Upper Tooling Assembly Item Order No. Engineering No. Description Qty 1 11-18-4795 60700-66 Wave Spring Washer 1 2 63800-0106 63800-0106 Insulation Striker 1 3 63800-0129 63800-0129 Washer 3.40mm Thick 1 4 63800-0130 63800-0130 Lug Bolt 1 5 63800-0132 63800-0132 Insulation Adjust Cam 1 6 63801-2735 63801-2735 Feed Cam (Post Feed) 1 7 63801-2736 63801-2736 Ram - Modified 1 8 63801-2738 63801-2738 M5 Screw - Modified 2 9 63801-2935 63801-2935 Feed Cam (Pre Feed) 1 10 69028-0155 69028-0155 Ball Retainer 2 11 69028-0156 69028-0156 Compression Spring 2 12 69028-0806 69028-0806 Conductor Adjust Cam 1 13 69028-0808 69028-0808 Washer 0.15mm Thick 1 14 69028-0809 69028-0809 Washer 0.18mm Thick 1 15 N/A N/A M4 by 8 Long SSS 2 16 N/A N/A M6 by 8 Long SSS 1 17 N/A N/A 6MM Diameter by 10 Long SHLDR Screw 1 18 N/A N/A M8 by 25 Long BHCS 1 Main Assembly Part Numbers (Not included in 63801-2997) 19 63801-2909 63801-2909 Conductor Punch 1 Y 20 63801-2715 63801-2715 Insulation Punch 1 Y 21 11-32-4410 AM- Compression Spring (9.14 OD by 1.14 WD by 1 60099A291 57.2 Lg.) 22 63801-2720 63801-2720 Cut-Off Striker 1 23 63801-2721 63801-2721 Terminal Hold Down Plunger 1 24 63801-2728 63801-2728 Tooling Washer 1 25 N/A N/A M4 by 16 Long SHCS 2 REF 63801-2970 63801-2970 Tool Kit (All Y Items) REF The components indicated with are associated to the Main Assembly The components indicated with are available from an Industrial supply company such as MSC (1-800-645-7270). Doc No. 63801-2900 Release Date: 12-05-03 UNCONTROLLED COPY Page 7 of 12
Upper Tooling Assembly Drawing 4 1 12 10 5 11 13 15 14 9 6 3 21 7 2 22 25 17 8 18 24 20 19 23 16 Figure 2 The components indicated with are associated to the Main Assembly Doc No. 63801-2900 Release Date: 12-05-03 UNCONTROLLED COPY Page 8 of 12
Feed Linkage Subassembly Parts List 63801-2696 - Feed Linkage Subassembly Item Order No. Engineering No. Description Qty 1 11-32-0548 AM- E-Ring #3.2 2 60099M143 2 69028-0640 69028-0640 Extension Spring 1 3 63800-0117 63800-0117 Feed Pawl Lever 1 4 63800-0118 63800-0118 Hinge Bushing 1 5 63800-0121 63800-0121 Lever-Feed Pivot 1 6 63800-0122 63800-0122 Feed Adjusting Screw 1 7 63800-0124 63800-0124 Feed Adjusting Pin 1 8 63800-0127 63800-0127 Torsion Spring 1 9 63800-0140 63800-0140 Cylinder Pin 1 10 63800-0141 63800-0141 Slider 1 11 63800-0142 63800-0142 Roller - Cam Follower 1 12 63800-0143 63800-0143 Pin - Cam Follower 1 13 63801-2620 63801-2620 Feed Lever 1 14 63801-2623 63801-2623 Slider, Feed Cam 1 15 63801-2625 63801-2625 Torsion Spring 1 16 N/A N/A M4 by 12 Long BHCS 1 17 N/A N/A M5 by 10 Long SHCS 1 18 N/A N/A M12 Full Hex Nut 1 19 N/A N/A 3mm by 12 Long Roll Pin 2 20 N/A N/A 5mm by 20 Long Dowel Pin 1 21 N/A N/A 5mm by 25 Long Dowel Pin 1 The components indicated with are available from an Industrial supply company such as MSC (1-800-645-7270). Doc No. 63801-2900 Release Date: 12-05-03 UNCONTROLLED COPY Page 9 of 12
Feed Linkage Subassembly Drawing 6 See Figure 4 16 19 17 2 5 20 21 7 14 11 12 13 15 10 1 9 4 3 8 See Figure 4 18 Figure 3 Doc No. 63801-2900 Release Date: 12-05-03 UNCONTROLLED COPY Page 10 of 12
Frame Subassembly Parts List 63801-2698 - Frame Subassembly Item Order No. Engineering No. Description Qty 1 11-17-3215 60654 Serial Tag (Mini-Mac) 1 2 11-18-0165 60700-65 Mini-Mac Label (Caution 1 3 63801-2601 63801-2601 Frame 1 4 63801-2602 63801-2602 Front Frame 1 5 N/A N/A #2 Drive Screw 2 6 N/A N/A M5 by 45 Long SHCS 4 The components indicated with are available from an Industrial supply company such as MSC (1-800-645-7270). Frame Subassembly Drawing 6 (4) 3 5 1 4 2 Figure 4 Doc No. 63801-2900 Release Date: 12-05-03 UNCONTROLLED COPY Page 11 of 12
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 MiniMac Manual. CAUTION: This applicator should only be used in a press with a shut height of 135.8 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 CAUTION: Molex crimp specifications are valid only when used with Molex terminals, applicators and Molex Application Tooling Group 1150 E. Diehl Road Naperville, IL 60563 Tel: (630) 969-4550 Fax: (630) 505-0049 Visit our Web site at http://www.molex.com Doc No. 63801-2900 Release Date: 12-05-03 UNCONTROLLED COPY Page 12 of 12