63891-4000 Datasheet by Molex

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Order No. 63891-4000 Wire Size Insulation Diameter Strip Length AWG mm2 mm In. mm In. 02-06-21 01 02—06-61 16 39—00-0278 02-06-61 00 02—06-61 18 39—00-0328 02-06-61 01 04—01-0805 39—00-0329 02-06-61 05 02-06-1 1 01 02—06-5105 39—00-0279 02-06-1 1 18 02—06-5108 39—00-0332 02-06-51 00 04—01-0806 39—00-0333 02-06-51 01 02-06-2201 02—06-6205 02-06-6201 02—06-621 1 02-06-1 201 02—06-5201 02-06-3200 02—06-5205 02-06-5142 0 80—020 1.52-3 05 060-.120 3.18-3.96 125-156 02-06-6140 0 80—020 1.52-3 05 060-.120 3.18-3.96 125-156 02-06-1 1 39 0 80—020 1.52-3 05 060-.120 3.18-3.96 125-156
Mini-Mac Applicator for “.062” Standard Pin and Socket Terminals
Doc No: ATS-638914000 Release Date: 12-13-06 UNCONTROLLED COPY Page 1 of 6
Revision: C Revision Date: 08-06-15
Mini-Mac
Applicator
Application Tooling
Specification Sheet
Order No. 63891-4000
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, Standard .062" Pin and Socket Crimp Terminals, 18-24 AWG.
Terminal Series No.
Terminal Order No.
Wire Size
Insulation Diameter
AWG
mm²
mm
In.
mm
In.
1560
02-06-2101
02-06-6116
39-00-0278
18-24
0.80-0.20
1.52-3.05
.060-.120
3.18-3.96
.125-.156
02-06-6100
02-06-6118
39-00-0328
02-06-6101
04-01-0805
39-00-0329
02-06-6105
1561
02-06-1101
02-06-5105
39-00-0279
18-24
0.80-0.20
1.52-3.05
.060-.120
3.18-3.96
.125-.156
02-06-1118
02-06-5108
39-00-0332
02-06-5100
04-01-0806
39-00-0333
02-06-5101
1786
02-06-2201
02-06-6205
18-24
0.80-0.20
1.52-3.05
.060-.120
3.18-3.96
.125-.156
02-06-6201
02-06-6211
1787
02-06-1201
02-06-5201
18-24
0.80-0.20
1.52-3.05
.060-.120
3.18-3.96
.125-.156
02-06-3200
02-06-5205
6770
02-06-5142
18-24
0.80-0.20
1.52-3.05
.060-.120
3.18-3.96
.125-.156
6772
02-06-6140
18-24
0.80-0.20
1.52-3.05
.060-.120
3.18-3.96
.125-.156
7291
02-06-1139
18-24
0.80-0.20
1.52-3.05
.060-.120
3.18-3.96
.125-.156
BEND UP EELL MOUTH ‘ SEAM \ / INSULATION ROLLING CONDUCTOR COND.CRIMF Wire Size Bell mouth Cut-off Tab Maximum Conductor Erush AWG mm2 mm In. mm In. mm In. 18-24 0.80—0.20 0.10-0.60 .004- 024 0.13 .005 .25—1.00 010—039 18-24 0.80—0.20 0.10-0.60 .004- 024 0.13 .005 .25—1.00 010—039 18-24 0.80—0.20 0.10-0.60 .004- 024 0.13 .005 .25—1.00 010—039 18-24 0.80—0.20 0.10-0.60 .004- 024 0.13 .005 .25—1.00 010—039 18-24 0.80—0.20 0.10-0.60 .004- 024 0.13 .005 .25—1.00 010—039 18-24 0.80—0.20 0.10-0.60 .004- 024 0.13 .005 .25—1.00 010—039 18-24 0.80—0.20 0.10-0.60 .004- 024 0.13 .005 .25—1.00 010—039 Punch Width mm (Ref) Conductor Insulation mm2 mm In mm In 0.80-0.20 1.95 .077 2.83 .111 0.80-0.20 1.95 .077 2.83 .111 0.80-0.20 1.95 .077 2.83 .111 0.80-0.20 1.95 .077 2.83 .111 0.80-0.20 1.95 .077 2.83 .111 0.80-0.20 1.95 .077 2.83 .111 0.80-0.20 1.95 .077 2.83 .111
Mini-Mac Applicator for “.062” Standard Pin and Socket Terminals
Doc No: ATS-638914000 Release Date: 12-13-06 UNCONTROLLED COPY Page 2 of 6
Revision: C Revision Date: 08-06-15
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
BELL MOUTH
COND.CRIMP
HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
CUT-OFF TAB
SEAM
DEFINITION OF TERMS
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the scope.
CRIMP SPECIFICATIONS
Terminal Series No.
Wire Size
Bell mouth
Cut-off Tab Maximum
Conductor Brush
AWG
mm²
mm
In.
mm
In.
mm
In.
1560
18-24
0.80-0.20
0.10-0.60
.004-.024
0.13
.005
.25-1.00
.010-.039
1561
18-24
0.80-0.20
0.10-0.60
.004-.024
0.13
.005
.25-1.00
.010-.039
1786
18-24
0.80-0.20
0.10-0.60
.004-.024
0.13
.005
.25-1.00
.010-.039
1787
18-24
0.80-0.20
0.10-0.60
.004-.024
0.13
.005
.25-1.00
.010-.039
6770
18-24
0.80-0.20
0.10-0.60
.004-.024
0.13
.005
.25-1.00
.010-.039
6772
18-24
0.80-0.20
0.10-0.60
.004-.024
0.13
.005
.25-1.00
.010-.039
7291
18-24
0.80-0.20
0.10-0.60
.004-.024
0.13
.005
.25-1.00
.010-.039
Terminal Series No.
Wire Size
Bend up Bend down
Twist Roll
Punch Width mm (Ref)
Conductor
Insulation
AWG
mm²
Degree
Degree
mm
In
mm
In
1560
18-24
0.80-0.20
3
3
5
10
1.95
.077
2.83
.111
1561
18-24
0.80-0.20
3
3
5
10
1.95
.077
2.83
.111
1786
18-24
0.80-0.20
3
3
5
10
1.95
.077
2.83
.111
1787
18-24
0.80-0.20
3
3
5
10
1.95
.077
2.83
.111
6770
18-24
0.80-0.20
3
3
5
10
1.95
.077
2.83
.111
6772
18-24
0.80-0.20
3
3
5
10
1.95
.077
2.83
.111
7291
18-24
0.80-0.20
3
3
5
10
1.95
.077
2.83
.111
Seam
Seam shall not be open and no wire allowed out of the crimping area.
18 AWG UL Style 1015 may have pinched strands or an open seam.
This condition is normal and does not affect crimp performance. The customer should
determine suitability for the end application.
Conductor Crimp Height Crimp Width mm In. mm In. 1.04—1 07 .041- 042 1.95-2.06 077-.061 096-1 02 .038- 040 1.95-2.06 077-.061 091-0 96 .036- 036 1.95-2.06 077-.061 066-0 91 .034- 036 1.95-2.06 077-.061 1.04—1 07 .041- 042 1.95-2.06 077-.061 096-1 02 .038- 040 1.95-2.06 077-.061 091-0 96 .036- 036 1.95-2.06 077-.061 066-0 91 .034- 036 1.95-2.06 077-.061 1.04—1 07 .041- 042 1.95-2.06 077-.061 096-1 02 .038- 040 1.95-2.06 077-.061 091-0 96 .036- 036 1.95-2.06 077-.061 066-0 91 .034- 036 1.95-2.06 077-.061 1.04—1 07 .041- 042 1.95-2.06 077-.061 096-1 02 .038- 040 1.95-2.06 077-.061 091-0 96 .036- 036 1.95-2.06 077-.061 066-0 91 .034- 036 1.95-2.06 077-.061 1.04—1 07 .041- 042 1.95-2.06 077-.061 096-1 02 .038- 040 1.95-2.06 077-.061 091-0 96 .036- 036 1.95-2.06 077-.061 066-0 91 .034- 036 1.95-2.06 077-.061 1.04—1 07 .041- 042 1.95-2.06 077-.061 096-1 02 .038- 040 1.95-2.06 077-.061 091-0 96 .036- 036 1.95-2.06 077-.061 066-0 91 .034- 036 1.95-2.06 077-.061 1.04—1 07 .041- 042 1.95-2.06 077-.061 096-1 02 .038- 040 1.95-2.06 077-.061 091-0 96 .036- 036 1.95-2.06 077-.061 066-0 91 .034- 036 1.95-2.06 077-.061 Tool Qualification Notes:
Mini-Mac Applicator for “.062” Standard Pin and Socket Terminals
Doc No: ATS-638914000 Release Date: 12-13-06 UNCONTROLLED COPY Page 3 of 6
Revision: C Revision Date: 08-06-15
After crimping, the conductor profile should measure the following.
Terminal Series No.
Wire Size
Conductor
Pull Force Minimum
Crimp Height
Crimp Width
AWG
mm2
mm
In.
mm
In.
N
Lb.
1560
18
0.80
1.04-1.07
.041-.042
1.95-2.06
.077-.081
89.0
20.00
20
0.50
0.96-1.02
.038-.040
1.95-2.06
.077-.081
66.7
15.00
22
0.35
0.91-0.96
.036-.038
1.95-2.06
.077-.081
44.5
10.00
24
0.20
0.86-0.91
.034-.036
1.95-2.06
.077-.081
35.6
8.00
1561
18
0.80
1.04-1.07
.041-.042
1.95-2.06
.077-.081
89.0
20.00
20
0.50
0.96-1.02
.038-.040
1.95-2.06
.077-.081
66.7
15.00
22
0.35
0.91-0.96
.036-.038
1.95-2.06
.077-.081
44.5
10.00
24
0.20
0.86-0.91
.034-.036
1.95-2.06
.077-.081
35.6
8.00
1786
18
0.80
1.04-1.07
.041-.042
1.95-2.06
.077-.081
89.0
20.00
20
0.50
0.96-1.02
.038-.040
1.95-2.06
.077-.081
66.7
15.00
22
0.35
0.91-0.96
.036-.038
1.95-2.06
.077-.081
44.5
10.00
24
0.20
0.86-0.91
.034-.036
1.95-2.06
.077-.081
35.6
8.00
1787
18
0.80
1.04-1.07
.041-.042
1.95-2.06
.077-.081
89.0
20.00
20
0.50
0.96-1.02
.038-.040
1.95-2.06
.077-.081
66.7
15.00
22
0.35
0.91-0.96
.036-.038
1.95-2.06
.077-.081
44.5
10.00
24
0.20
0.86-0.91
.034-.036
1.95-2.06
.077-.081
35.6
8.00
6770
18
0.80
1.04-1.07
.041-.042
1.95-2.06
.077-.081
89.0
20.00
20
0.50
0.96-1.02
.038-.040
1.95-2.06
.077-.081
66.7
15.00
22
0.35
0.91-0.96
.036-.038
1.95-2.06
.077-.081
44.5
10.00
24
0.20
0.86-0.91
.034-.036
1.95-2.06
.077-.081
35.6
8.00
6772
18
0.80
1.04-1.07
.041-.042
1.95-2.06
.077-.081
89.0
20.00
20
0.50
0.96-1.02
.038-.040
1.95-2.06
.077-.081
66.7
15.00
22
0.35
0.91-0.96
.036-.038
1.95-2.06
.077-.081
44.5
10.00
24
0.20
0.86-0.91
.034-.036
1.95-2.06
.077-.081
35.6
8.00
7291
18
0.80
1.04-1.07
.041-.042
1.95-2.06
.077-.081
89.0
20.00
20
0.50
0.96-1.02
.038-.040
1.95-2.06
.077-.081
66.7
15.00
22
0.35
0.91-0.96
.036-.038
1.95-2.06
.077-.081
44.5
10.00
24
0.20
0.86-0.91
.034-.036
1.95-2.06
.077-.081
35.6
8.00
Tool Qualification Notes:
1. Pull Force should be measured with no influence from the insulation crimp.
2. The above specifications are guidelines to an optimum crimp.
Mini-Mac Applicator 63891-4000 Item I Order No. l Engineering No. l Description I Quantity Perishable Tooling 63891-4070 63891-4070 Tool Kit (All “Y" Items) REF 63891-4001 63891-4001 Conductor Punch l Y ll-18-4078 60707-3 Combination Anvil l Y ll-18-4077 60707-2 Insulation Punch l Y ll-17—3076 7163-30 Front Cut-Off Plunger l Y ll-17—3079 7163-33 Rear Cut-Off Plunger l Y ll-17—2l36 7l63-4 Rear Cut-Off Die Blade l Y ll-18—4246 60707-18 Front Cut-off Plunger Retainer I Y ll-18—4247 60707-19 Rear Cut-off Plunger Retainer I Y Other Components ll-17—2l40 7l63-8 Insulation Punch Spacer ll-17—2l52 7163-14 Hold Down Pad l l-18-4079 60707-4 Cover Plate l l-18-4081 60707-5 Front Plunger Striker l l-18—4082 60707-7 Rear Plunger Striker ll-18-4083 60707-8 Feed Guide I l-18—5060 60707-21 Cut-off Plunger Spring 63443-0090 63443-0090 Wire Stop 63803-5124 63803-5124 Conductor Bushing Frame 63801-3201 63801-3201 Top 63801-3282 63801-3282 Base l 63801-6550 63801-6550 Track l Hardware N/A N/A M3 by 8 Long SHCS 2" N/A N/A M4 by 6 Long SHCS 1" N/A N/A M4 by l2 Long BHCS 2" N/A N/A M4 by 20 Long SHCS 2" N/A N/A M5 by l4 Long SHCS 1" N/A MA M8 by 20 Long BHCS 1" N/A N/A #6-32 by 3/8" Long BHCS 4" N/A N/A #6-32 by l/Z" Long FHCS 1" N/A N/A #6-32 Hex Jam Nut 1" N/A N/A #8-32 by 3/8" Long SHCS 2" N/A N/A #8-32 by 3/8" Long BHCS 1" N/A N/A 5/64 by 3/8" Long Roll Pin 2" " Available from an industrial supply company such as MSC (1-800-645-7270).
Mini-Mac Applicator for “.062” Standard Pin and Socket Terminals
Doc No: ATS-638914000 Release Date: 12-13-06 UNCONTROLLED COPY Page 4 of 6
Revision: C Revision Date: 08-06-15
PARTS LIST
Mini-Mac Applicator 63891-4000
Item
Order No.
Engineering No.
Description
Quantity
Perishable Tooling
63891-4070
63891-4070
Tool Kit (All Y Items)
REF
1
63891-4001
63891-4001
Conductor Punch
1 Y
2
11-18-4078
60707-3
Combination Anvil
1 Y
3
11-18-4077
60707-2
Insulation Punch
1 Y
4
11-17-3076
7163-30
Front Cut-Off Plunger
1 Y
5
11-17-3079
7163-33
Rear Cut-Off Plunger
1 Y
6
11-17-2136
7163-4
Rear Cut-Off Die Blade
1 Y
7
11-18-4246
60707-18
Front Cut-off Plunger Retainer
1 Y
8
11-18-4247
60707-19
Rear Cut-off Plunger Retainer
1 Y
Other Components
9
11-17-2140
7163-8
Insulation Punch Spacer
1
10
11-17-2152
7163-14
Hold Down Pad
1
11
11-18-4079
60707-4
Cover Plate
1
12
11-18-4081
60707-6
Front Plunger Striker
1
13
11-18-4082
60707-7
Rear Plunger Striker
1
14
11-18-4083
60707-8
Feed Guide
1
15
11-18-5060
60707-21
Cut-off Plunger Spring
2
16
63443-0090
63443-0090
Wire Stop
1
17
63803-5124
63803-5124
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 6 Long SHCS
1**
23
N/A
N/A
M4 by 12 Long BHCS
2**
24
N/A
N/A
M4 by 20 Long SHCS
2**
25
N/A
N/A
M5 by 14 Long SHCS
1**
26
N/A
N/A
M8 by 20 Long BHCS
1**
27
N/A
N/A
#6-32 by 3/8 Long BHCS
4**
28
N/A
N/A
#6-32 by 1/2 Long FHCS
1**
29
N/A
N/A
#6-32 Hex Jam Nut
1**
30
N/A
N/A
#8-32 by 3/8 Long SHCS
2**
31
N/A
N/A
#8-32 by 3/8 Long BHCS
1**
32
N/A
N/A
5/64 by 3/8 Long Roll Pin
2**
** Available from an industrial supply company such as MSC (1-800-645-7270).
Mini-Mac Applicator for “.062” Standard Pin and Socket Terminals
Doc No: ATS-638914000 Release Date: 12-13-06 UNCONTROLLED COPY Page 5 of 6
Revision: C Revision Date: 08-06-15
(2)
17
28
18
1
10
25
13
23
26
18
3
14
5
12
9
21
11
24
(2)
(2)
(2)
6
8
31
2
32
7
4
15
30
16
(2)
(2)
Figure 1
29
27
(4)
16
22
20
19
Assembly Drawing
Mini-Mac Applicator for “.062” Standard Pin and Socket Terminals
Doc No: ATS-638914000 Release Date: 12-13-06 UNCONTROLLED COPY Page 6 of 6
Revision: C Revision Date: 08-06-15
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 135.8 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 manual.
CAUTION: Molex crimp specifications are valid only when used with Molex terminals, applicators and tooling.
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