0638928100

Mini-Mac Applicator for HCS-125 Pin and Socket Crimp Terminals Mini-Mac Applicator Specification Sheet Order No. 63892-8100 FEATURES Œ Œ Œ Œ Œ 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, 10-14 AWG. Terminal Series No. Terminal Order No. 1900 1901 18-12-2601 18-12-1601 Wire Size Insulation Diameter Strip Length AWG mm² mm In. mm In. 10-14 and (1) 12+ (1) 18 5.0-2.0 4.57 .180 Max. 4.06-5.59 .160-.220 10-14 and (1) 12+ (1) 18 5.0-2.0 4.57 .180 Max. 4.06-5.59 .160-.220 DEFINITION OF TERMS C/L LOCATION BEND UP BRUSH BELL MOUTH ÆTERMINAL ROLLING SEAM INSULATION CRIMP CUT-OFF TAB TWISTING BEND DOWN STRIP LENGTH CONDUCTOR CRIMP CRIMP HEIGHT C/L ÆTerminal 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-638928100 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. Bell mouth mm In. 1900 1901 Terminal Series No. ÆCut-off Tab mm 5.00-5.16 5.00-5.16 Bend up Bend down Twist Roll Degree Degree 1900 1901 In. .197-.203 .197-.203 Conductor Brush mm In. Punch Width (Ref) Conductor Insulation mm In. mm In. 3.85 .152 5.00 .197 3.85 .152 5.00 .197 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 Crimp Height Crimp width (REF) Minimum 2 mm In. mm In. N Lb. AWG mm 10 5.00 2.03-2.16 080-.085 356.0 80.0 12 3.30 1.96-2.08 .077-.082 311.4 70.0 14 2.00 1.80-1.91 .071-.075 266.9 60.0 (1) 12 + (1) 18 3.30+0.80 2.03-2.16 .080-.085 89.0 20.0 10 5.00 2.03-2.16 080-.085 356.0 80.0 12 3.30 1.96-2.08 .077-.082 311.4 70.0 14 2.00 1.80-1.91 .071-.075 266.9 60.0 (1) 12 + (1) 18 3.30+0.80 2.03-2.16 .080-.085 89.0 20.0 For Double Application: Position smaller wire size on the bottom and larger wire size on top. Wire Size Terminal Series No. 1900 ÆÆ 1901 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-638928100 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 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Doc No. ATS-638928100 Revision: A Mini-Mac Applicator 63892-8100 Engineering No. Description Quantity Perishable Tooling 63892-8170 63892-8170 Tool Kit (All “Y” Items) REF 11-18-4986 60805B106 Conductor Punch 1Y 11-18-4987 60805B107 Conductor Anvil 1Y 11-18-4988 60805B108 Insulation Punch 1Y 11-18-4989 60805B109 Insulation Anvil 1Y 11-18-4977 60805A104 Cut-Off Punch 1Y 11-18-4983 60805A111 Rear Cut-off Die Blade 1Y Other Components 11-18-4810 60800A106 Rear Block 1 11-18-4811 60800A107 Compression Spring 1 11-18-4815 60800A111 Guide Plate 1 11-18-4816 60800A112 Terminal Drag Plate 1 11-18-4818 60800A114 Mounting Block 1 11-18-4829 60800A125 Wire Stop 1 11-18-4848 60800A123 Spring Retainer 1 11-18-4849 60800A124 Wire Hold Down Spring 1 11-18-4894 60800A129 Knockout Spring 1 11-18-4984 60805A112 Plunger 1 11-18-4985 60805A115 Tooling Washer 1 11-18-5005 60800D112 Hold Down Block 1 11-18-5006 60800D113 Spring Retainer 1 11-18-5007 60800D114 Compression Spring (Hold Down) 1 11-18-5014 60805A121 Hold Down Plunger 1 11-18-5015 60805A122 Front Cover 1 63803-5111 63803-5111 Conductor Bushing 1 Frame 63801-3201 63801-3201 Top 1 63801-3282 63801-3282 Base 1 63801-6550 63801-6550 Track 1 Hardware N/A N/A M3 by 6 Long SHCS 6** N/A N/A M3 by 25 Long SHCS 2** N/A N/A M4 by 6 Long BHCS 2** N/A N/A M4 by 10 Long BHCS 4** N/A N/A M4 by 18 Long SHCS 2** N/A N/A M5 by 10 Long SHCS 1** N/A N/A M8 by 20 Long BHCS 1** ** Available from an industrial supply company such as MSC (1-800-645-7270). Order No 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 18 23 3 20 17 21 24 13 19 33 (2) 27 29 14 27 15 9 24 (2) 30 (2) 26 10 (2) 7 27 25 (2) 22 16 8 (2) 12 32 28 11 30 (2) 6 4 2 Figure 1 Doc No. ATS-638928100 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. Americas Headquarters Far East North Headquarters Far East South Headquarters European Headquarters Corporate Headquarters -JTMF
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 Visit our Web site at http://www.molex.com Doc No. ATS-638928100 Revision: A Release Date: 02-13-07 Revision Date: 02-13-07 UNCONTROLLED COPY Page 5 of 5