Mini-Mac Applicator for HCS-125 Pin and Socket Crimp Terminals
Mini-Mac Applicator
Specification Sheet
Order No. 63892-8000
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 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: 3.18mm (.125") Diameter HCS-125, Pin and Socket Male and Female Crimp Terminal, 16-18 AWG.
Terminal Series No.
2046
2047
8946
8947
Terminal Order No.
18-12-2221
18-12-1221
18-12-2402
18-12-2404
18-12-1404
Wire Size
Insulation Diameter
Strip Length
AWG
mm²
mm
In.
mm
In.
16-18 and (1) 18+ (1) 22 1.30-0.80 2.75-3.05 .108-.120 4.06-5.59 .160-.220
16-18 and (1) 18+ (1) 22 1.30-0.80 2.75-3.05 .108-.120 4.06-5.59 .160-.220
16-18 and (1) 18+ (1) 22 1.30-0.80 2.75-3.05 .108-.120 4.06-5.59 .160-.220
16-18 and (1) 18+ (1) 22 1.30-0.80 2.75-3.05 .108-.120 4.06-5.59 .160-.220
40-07-1303
40-07-1304
DEFINITION OF TERMS
C/L
BEND UP
BRUSH
BELL MOUTH
SEAM
INSULATION
CRIMP
TWISTING
STRIP
LENGTH
CONDUCTOR
CRIMP
CRIMP HEIGHT
BEND
DOWN
C/L
CUT-OFF
TAB
ROLLING
Æ
TERMINAL
LOCATION
Æ
Terminal is to be centrally located between the two (2) cut-off tab edges by one half of the total cut-off tab tolerance.
This illustration is a generic terminal representation and not an exact image of any terminal listed in the scope.
Doc No. ATS-638928000
Revision: A
Release Date: 02-13-07
Revision Date: 02-13-07
UNCONTROLLED COPY
Page 1 of 5
Mini-Mac Applicator for HCS-125 Pin and Socket Crimp Terminals
CRIMP SPECIFICATIONS
Terminal Series No.
2046
2047
8946
8947
Bell mouth
mm In.
mm
5.00-5.16
5.00-5.16
5.00-5.16
5.00-5.16
Æ
Cut-off Tab
In.
.197-.203
.197-.203
.197-.203
.197-.203
Conductor Brush
mm
In.
Terminal Series No.
2046
2047
8946
8947
Bend up Bend down
Degree
Twist Roll
Degree
Punch Width (Ref)
Conductor
Insulation
mm In. mm In.
2.30 .091 3.87 .152
2.30 .091 3.87 .152
2.30 .091 3.87 .152
2.30 .091 3.87 .152
Seam
Seam shall not be open
and no wire allowed out
of the crimping area
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.
Pull Force
Conductor
Terminal Series No.
Crimp Height
Crimp width (REF) Minimum
2
mm
In.
mm
In.
N
Lb.
AWG
mm
16
1.30
1.58-1.66 .062-.066
177.9 40.0
2046
18
0.80
1.52-1.60 .060-.063
115.7 26.0
(1) 18 + (1) 22 0.80+0.35 1.52-1.58 .060-.062
35.6 8.0
16
1.30
1.58-1.66 .062-.066
177.9 40.0
2047
18
0.80
1.52-1.60 .060-.063
115.7 26.0
(1) 18 + (1) 22 0.80+0.35 1.52-1.58 .060-.062
35.6 8.0
16
1.30
1.58-1.66 .062-.066
177.9 40.0
8946
18
0.80
1.52-1.60 .060-.063
115.7 26.0
(1) 18 + (1) 22 0.80+0.35 1.52-1.58 .060-.062
35.6 8.0
16
1.30
1.58-1.66 .062-.066
177.9 40.0
8947
18
0.80
1.52-1.60 .060-.063
115.7 26.0
(1) 18 + (1) 22 0.80+0.35 1.52-1.58 .060-.062
35.6 8.0
For Double Application:
Position smaller wire size on the bottom and larger wire size on top.
Wire Size
ÆÆ
ÆÆ
ÆÆ
ÆÆ
ÆÆ
Pull Force should be measured with no influence from the insulation crimp.
The above specifications are guidelines to an optimum crimp.
Doc No. ATS-638928000
Revision: A
Release Date: 02-13-07
Revision Date: 02-13-07
UNCONTROLLED COPY
Page 2 of 5
Mini-Mac Applicator for HCS-125 Pin and Socket Crimp Terminals
PARTS LIST
Mini-Mac Applicator 63892-8000
Item
Order No
Engineering No.
Description
Quantity
Perishable Tooling
63892-8070
63892-8070
Tool Kit (All “Y” Items)
REF
1
11-18-4979
60805A106
Conductor Punch
1Y
2
11-18-4980
60805A107
Conductor Anvil
1Y
3
11-18-4981
60805A108
Insulation Punch
1Y
4
11-18-4982
60805A109
Insulation Anvil
1Y
5
11-18-4977
60805A104
Cut-Off Punch
1Y
6
11-18-4983
60805A111
Rear Cut-off Die Blade
1Y
Other Components
7
11-18-4810
60800A106
Rear Block
1
8
11-18-4811
60800A107
Compression Spring
1
9
11-18-4815
60800A111
Guide Plate
1
10
11-18-4816
60800A112
Terminal Drag Plate
1
11
11-18-4818
60800A114
Mounting Block
1
12
11-18-4829
60800A125
Wire Stop
1
13
11-18-4848
60800A123
Spring Retainer
1
14
11-18-4849
60800A124
Wire Hold Down Spring
1
15
11-18-4894
60800A129
Knockout Spring
1
16
11-18-4984
60805A112
Plunger
1
17
11-18-4985
60805A115
Tooling Washer
1
18
11-18-5005
60800D112
Hold Down Block
1
19
11-18-5006
60800D113
Spring Retainer
1
20
11-18-5007
60800D114
Compression Spring (Hold Down)
1
21
11-18-5014
60805A121
Hold Down Plunger
1
22
11-18-5015
60805A122
Front Cover
1
23
63803-5111
63803-5111
Conductor Bushing
1
Frame
24
63801-3201
63801-3201
Top
1
25
63801-3282
63801-3282
Base
1
26
63801-6550
63801-6550
Track
1
Hardware
27
N/A
N/A
M3 by 6 Long SHCS
6**
28
N/A
N/A
M3 by 25 Long SHCS
2**
29
N/A
N/A
M4 by 6 Long BHCS
2**
30
N/A
N/A
M4 by 10 Long BHCS
4**
31
N/A
N/A
M4 by 18 Long SHCS
2**
32
N/A
N/A
M5 by 10 Long SHCS
1**
33
N/A
N/A
M8 by 20 Long BHCS
1**
** Available from an industrial supply company such as MSC (1-800-645-7270).
Doc No. ATS-638928000
Revision: A
Release Date: 02-13-07
Revision Date: 02-13-07
UNCONTROLLED COPY
Page 3 of 5
Mini-Mac Applicator for HCS-125 Pin and Socket Crimp Terminals
Assembly Drawing
5
31 (2)
1
3
17
13
19
33
(2)
14
27
29
15
24
9
(2)
23
20
24
21
18
27
10
(2)
26
30 (2)
7
27
22
(2)
25
16
8
(2)
28
11
6
4
2
Figure 1
30
(2)
12
32
Doc No. ATS-638928000
Revision: A
Release Date: 02-13-07
Revision Date: 02-13-07
UNCONTROLLED COPY
Page 4 of 5
Mini-Mac Applicator for HCS-125 Pin and Socket 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 135.80mm (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-638928000
Revision: A
Release Date: 02-13-07
Revision Date: 02-13-07
UNCONTROLLED COPY
Page 5 of 5
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