Mini-Mac Applicator for CP2.8 and CPX2.8 CMC Crimp Terminals
Doc No: ATS-638951000 Release Date: 10-21-08 UNCONTROLLED COPY Page 1 of 5
Revision: C Revision Date: 03-24-10
CONDUCTOR
BRUSH
STRIP LENGTH
SEAM
CONDUCTOR
CRIMP
CUT-OFF
TAB
BELL MOUTH
BEND UP
TWISTING
ROLLING
BEND
DOWN
WIRE
SEAL
0.80 (REF)
SEAL POSITION
Mini-Mac Applicator
Application Tooling Specification
Mechanical Feed-Front Metal Strip
Order No. 63895-1000
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: CP2.8 and CPX2.8 Receptacle Crimp Terminals, >2.0 – 3.0 mm2 type ID and IR wire.
Wire Size and Type
Insulation Diameter
Strip Length Terminal
Series No.
Terminal
Order No. mm² Type mm In. mm In.
98910-1029
98910-1129
98910 98910-2029
98910-2129
>2.0 – 3.0 ID & IR 2.65-3.45 .104-.136 4.90-5.10
.193-.201
64324-1029
64324-1129
64324 64324-2029
64324-2129
>2.0 – 3.0 ID & IR 2.65-3.45 .104-.136 4.90-5.10
.193-.201
See crimp specification for the individual Insulation Diameter.
DEFINITION OF TERMS
The above terminal drawing is a generic terminal representation. It is not an image of any terminal listed in the
scope.
Mini-Mac Applicator for CP2.8 and CPX2.8 CMC Crimp Terminals
Doc No: ATS-638951000 Release Date: 10-21-08 UNCONTROLLED COPY Page 2 of 5
Revision: C Revision Date: 03-24-10
CRIMP SPECIFICATION
Bell mouth Cut-off Tab Maximum
Conductor Brush
Terminal Series No. mm In. mm In. mm In.
98910 0.40-0.60 .016-.024 0.30 .012 0.20-0.60 .008-.024
64324 0.40-0.60 .016-.024 0.30 .012 0.20-0.60 .008-.024
Not to exceed above the conductor crimp height.
Bend up Bend down Twist Roll Punch Width (Ref)
Conductor Insulation
Terminal
Series No. Degree Degree mm In mm In
98910 2 2 2 3 2.80 .110 4.85 .191
64324 2 2 2 3 2.80 .110 4.85 .191
Seam
Seam shall not be
open and no wire allowed
out of the crimping area
After crimping, the crimp profiles should measure the following:
Conductor
Wire Size
Crimp Height Crimp Width (Ref.)
Pull Force Minimum
Terminal Series No.
mm2 mm In. mm In. N Lb.
2.50 1.80-1.90
.071-.075
2.89 .114 235.0 52.8
98910 3.00 1.95-2.05
.077-.081
2.90 .114 260.0 58.5
2.50 1.80-1.90
.071-.075
2.89 .114 235.0 52.8
64324 3.00 1.95-2.05
.077-.081
2.90 .114 260.0 58.5
Insulation
Wire Size
Insulation Diameter
Single Wire Seal Crimp Height Crimp Width
(Ref.)
Terminal Series No.
mm2 mm In. Order No. Color
mm In. mm In.
2.50 2.65-3.00 .104-.118 4.80-5.00
.189-.197
5.02 .198
98910 3.00 3.25-3.45 .128-.136 0643251188
Grey 5.10-5.30
.201-.209
5.05 .199
2.50 2.65-3.00 .104-.118 4.80-5.00
.189-.197
5.02 .198
64324 3.00 3.25-3.45 .128-.136 0643251188
Grey 5.10-5.30
.201-.209
5.05 .199
* 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 for CP2.8 and CPX2.8 CMC Crimp Terminals
Doc No: ATS-638951000 Release Date: 10-21-08 UNCONTROLLED COPY Page 3 of 5
Revision: C Revision Date: 03-24-10
PARTS LIST
Mini-Mac Applicator 63895-1000
Item Order No Engineering No. Description Quantity
Perishable Tooling
63895-1070 63895-1070 Tool Kit (All “Y” Items) REF
1 63465-0058 63465-0058 Conductor Punch 1 Y
2 63455-0061 63455-0061 Conductor Anvil 1 Y
3 63463-0038 63463-0038 Insulation Punch 1 Y
4 63456-0055 63456-0055 Insulation Anvil 1 Y
5 63443-0037 63443-0037 Cut-off Plunger Front 1 Y
6 63443-0038 63443-0038 Plunger Retainer Front 1 Y
Other Components
7 11-18-4094 60709A111 Feed Guide 1
8 63443-0009 63443-0009 Scrap Chute Front 1
9 63443-0024 63443-0024 Key 1
10 63443-0090 63443-0090 Wire Stop 1
11 63443-1712 63443-1712 18.20mm Height Spacer 1
12 63443-2201 63443-2201 1.00mm Course Spacer 1
13 63443-2214 63443-2214 14.00mm Course Spacer 1
14 63443-2312 63443-2312 3.60mm Fine Spacer 1
15 63443-6121 63443-6121 Rear Cover 1
16 63443-3701 63443-3701 Striker Screw 1
17 63443-3801 63443-3801 Front Plunger Striker 1
18 63700-0225 63700-0225 Compression Spring 1
19 63700-0539 63700-0539 Cut-Off Plunger Spring 1
20 63890-0063 63890-0063 Terminal Hold Down-For CP2.8 1
21 63890-0067 63890-0067 Holder Front 1
22 63890-0068 63890-0068 Holder Rear 1
23 63890-0866 63890-0866 Collar-6.40 Long 2
Frame
24 63801-3201 63801-3201 Top 1
25 63801-3281 63801-3281 Base 1
26 63801-4650 63801-4650 Track 1
Hardware
27 N/A N/A M3 by 5 Long Flat Point SSS 2**
28 N/A N/A M3 by 6 Long FHCS 1**
29 N/A N/A M3 by 6 Long SHCS 2**
30 N/A N/A M3 by 10 Long SHCS 1**
31 N/A N/A M4 by 6 Long SHCS 2**
32 N/A N/A M4 by 12 Long BHCS 2**
33 N/A N/A M4 by 16 Long SHCS 2**
34 N/A N/A M4 by 55 Long SHCS 2**
35 N/A N/A M5 by 12 Long SHCS 1**
36 N/A N/A M8 by 30 Long BHCS 1**
37 N/A N/A 2mm by 8 Long Dowel Pin 1**
** Available from an industrial supply company such as MSC (1-800-645-7270).
Mini-Mac Applicator for CP2.8 and CPX2.8 CMC Crimp Terminals
Doc No: ATS-638951000 Release Date: 10-21-08 UNCONTROLLED COPY Page 4 of 5
Revision: C Revision Date: 03-24-10
Figure 1
1
23
31
13
7
28
10
17
23
21
12
19
8
26
9
24
(2)
(2)
2
10
18
3
20
14
(2)
11
6
4
15
22
5
25
29
30
32
24
33
34
35
36
37
(2)
16
27
(2)
31
Assembly Drawing
Mini-Mac Applicator for CP2.8 and CPX2.8 CMC Crimp Terminals
Doc No: ATS-638951000 Release Date: 10-21-08 UNCONTROLLED COPY Page 5 of 5
Revision: C Revision Date: 03-24-10
NOTES
1. Molex recommends an extra perishable tooling kit be maintained at your facility.
2. Verify tooling alignment by manually cycling the press with 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 Applicator Manual (Document no. 63880-0000).
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.
Americas Headquarters
Lisle, Illinois 60532 U.S.A.
1-800-78MOLEX
amerinfo@molex.com
Far East North Headquarters
Yamato, Kanagawa, Japan
81-462-65-2324
feninfo@molex.com
Far East South Headquarters
Jurong, Singapore
65-6-268-6868
fesinfo@molex.com
European Headquarters
Munich, Germany
49-89-413092-0
eurinfo@molex.com
Corporate Headquarters
2222 Wellington Ct.
Lisle, IL 60532 U.S.A.
630-969-4550
Fax: 630-969-1352
Visit our Web site at http://www.molex.com
