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Mini-Mac Applicator for KK® and Trifurcon™ Crimp Terminals Mini-Mac Applicator Application Tooling Specification Sheet Order No. 63888-5000 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 Pilot pin in cut-off punch produces symmetrical cut-off tabs and consistent cut-off tab length, see terminal strip adjustment on page 3 SCOPE Products: KK® and Trifurcon™, 3.96mm (.156") Pitch Crimp Terminal, 18-24 AWG. Terminal Series No. 2477 2478 2878 4838 6438 6838 8993 Wire Size Insulation Diameter Strip Length AWG mm² mm In. mm In. 18 - 24 0.80-0.20 2.79 .110 2.54-3.18 .100-.125 Terminal Order No. 08-50-0109 08-50-0001 08-50-0063 08-50-0119 08-51-0001 08-52-0046 08-52-0811 08-55-0133 08-58-0114 39-00-0133 39-00-0347 50-29-1768 08-50-0115 08-58-0127 08-50-0131 08-55-0144 08-50-0164 08-56-0135 08-50-0024 08-50-0275 08-58-0102 08-58-0118 08-50-0011 Doc No. ATS-638885000 Revision: C 08-56-0113 08-50-0014 08-50-0073 08-50-0146 08-52-0023 08-52-0071 08-53-0004 08-56-0105 08-58-0121 39-00-0286 39-00-0349 40-01-1179 08-50-0015 08-50-0091 08-50-0271 08-52-0027 08-52-0073 08-53-0811 08-56-0153 08-65-0114 39-00-0343 40-01-1118 08-51-0109 08-55-0138 08-55-0125 08-55-0145 08-51-0801 08-56-0137 08-50-0026 08-51-0106 08-58-0105 08-58-0131 08-50-0277 08-52-0126 08-65-0118 08-55-0139 08-55-0147 08-52-0813 08-53-0814 08-50-0028 08-52-0112 08-58-0108 08-58-0187 08-50-0187 08-53-1101 08-58-0110 08-60-0001 08-50-0047 08-50-0105 08-50-0281 08-52-0044 08-52-0114 08-55-0103 08-58-0103 39-00-0103 39-00-0345 50-29-1689 08-55-0142 08-55-0149 05-53-0813 Release Date: 11-14-12 Revision Date: 08-25-14 18 - 24 0.80-0.20 2.79 .110 2.54-3.18 .100-.125 18 - 20 0.80-0.50 2.79 .110 2.54-3.18 .100-.125 18 - 22 0.80-0.35 2.41 .095 2.54-3.18 .100-.125 18 - 24 0.80-0.20 2.41 .095 2.54-3.18 .100-.125 18 - 20 0.80-0.50 2.79 .110 2.54-3.18 .100-.125 18 - 24 0.80-0.20 2.79 .110 2.54-3.18 .100-.125 UNCONTROLLED COPY Page 1 of 6 Mini-Mac Applicator for KK® and Trifurcon™ Crimp Terminals Terminal Series No. 172160 Wire Size AWG mm² Terminal Order No. Insulation Diameter mm In. 172160-1801 172160-1802 172160-1803 172160-1804 18 - 20 0.80-0.50 2.79 .110 172160-1805 172160-1806 Insulation below 1.65mm (.065 inch) diameter may produce loose insulation crimps. Strip Length mm In. 2.54-3.18 .100-.125 DEFINITION OF TERMS C/L CONDUCTOR CRIMP CUT-OFF TAB INSULATION CRIMP LOCKING TANG HEIGHT TERMINAL LOCATION BEND UP BRUSH BELL MOUTH SEAM ROLLING TWISTING CUT-OFF TAB STRIP LENGTH BEND DOWN C/L CRIMP HEIGHT Terminal is to be centrally located between the two (2) cut-off edges, within +/- 0.08mm (+/-.003”). CRIMP SPECIFICATIONS Bell mouth mm In. Terminal Series No. 2477 2478 Terminal Series No. 2477 2478 2878 4838 6438 6838 8993 172160 2878 4838 6438 8993 6838 172160 0.20-0.50 Cut-off Tab mm In. .008-.020 2.72±.08 Locking Tang Height Bend up Bend down Twist Roll mm In 0.64-0.76 0.64-0.76 0.63-0.79 0.64-0.76 0.63-0.79 0.63-0.79 0.38-0.51 0.63-0.79 .025-.030 .025-.030 .025-.031 .025-.030 .025-.031 .025-.031 .015-.020 .025-.031 Degree 3 3 3 3 3 3 3 3 Degree 3 3 3 3 3 3 3 3 4 4 4 4 4 4 4 4 8 8 8 8 8 8 8 8 .107±.003 Conductor Brush mm In. 0.13-0.64 .005-.025 Punch Width (Ref) Conductor Insulation mm In mm In 1.95 .077 2.42 .095 Seam 1.95 .077 2.42 .095 1.95 .077 2.42 .095 Seam shall not be open 1.95 .077 2.42 .095 and no wire allowed out of the crimping area 1.95 .077 2.42 .095 1.95 .077 2.42 .095 1.95 .077 2.42 .095 1.95 .077 2.42 .095 After crimping, the conductor profile should measure the following. Terminal Series No. 2477 08-52-0071 Doc No. ATS-638885000 Revision: C Wire Size AWG mm2 18 0.80 20 0.50 22 0.35 24 0.20 18 0.81 Release Date: 11-14-12 Revision Date: 08-25-14 Crimp Height mm In. 1.09-1.14 .043-.045 1.02-1.09 .040-.043 0.97-1.02 .038-.040 0.91-0.97 .036-.038 1.07-1.17 .042-.046 Pull Force Minimum N Lb. 110 25 66 15 44 10 35 8 110 25 UNCONTROLLED COPY Page 2 of 6 Mini-Mac Applicator for KK® and Trifurcon™ Crimp Terminals Wire Size Crimp Height Pull Force Minimum AWG mm2 mm In. N Lb. 18 0.80 1.09-1.14 .043-.045 111.2 25.0 20 0.50 1.02-1.09 .040-.043 66.7 15.0 2478 22 0.35 0.97-1.02 .038-.040 44.5 10.0 24 0.20 0.91-0.97 .036-.038 35.6 8.0 18 0.80 1.09-1.14 .043-.045 111.2 25.0 2878 20 0.50 1.02-1.09 .040-.043 66.7 15.0 18 0.80 1.09-1.14 .043-.045 111.2 25.0 4838 20 0.50 1.02-1.09 .040-.043 66.7 15.0 22 0.35 0.97-1.02 .038-.040 44.5 10.0 18 0.80 1.09-1.14 .043-.045 111.2 25.0 20 0.50 1.02-1.09 .040-.043 66.7 15.0 6438 22 0.35 0.97-1.02 .038-.040 44.5 10.0 24 0.20 0.91-0.97 .036-.038 35.6 8.0 18 0.80 1.09-1.14 .043-.045 111.2 25.0 6838 20 0.50 1.02-1.09 .040-.043 66.7 15.0 18 0.80 1.09-1.14 .043-.045 111.2 25.0 20 0.50 1.02-1.09 .040-.043 66.7 15.0 8993 22 0.35 0.97-1.02 .038-.040 44.5 10.0 24 0.20 0.91-0.97 .036-.038 35.6 8.0 18 0.80 1.09-1.14 .043-.045 111.2 25.0 172160 20 0.50 1.02-1.09 .040-.043 66.7 15.0 Special for use with 18 AWG UL1015, 16 strand (.010”) diameter wire only. 0.81mm2 .254mm Terminal Series No. 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. Terminal Strip Adjustment The terminal strip hole must be aligned to the pilot pin before crimping under power. Hand cycle the press several times to check the alignment of the pilot pin to the terminal strip hole before crimping under power. Use the track adjusting screw and the terminal position adjusting knob to align the terminal strip hole to the pilot pin. CUT-OFF PUNCH PILOT PIN TERMINAL POSITION ADJUSTING KNOB Figure 1 TERMINAL STRIP Doc No. ATS-638885000 Revision: C Release Date: 11-14-12 Revision Date: 08-25-14 TRACK ADJUSTING SCREW UNCONTROLLED COPY Page 3 of 6 Mini-Mac Applicator for KK® and Trifurcon™ Crimp Terminals PARTS LIST Mini-Mac Applicator 63888-5000 Item Order No Engineering No. Description Quantity Perishable Tooling 63888-5070 63888-5070 Tool Kit (All “Y” Items) REF 1 11-18-4108 60712-8 Conductor Punch 1Y 2 11-18-4110 60712-10 Conductor Anvil 1Y 3 11-18-4107 60712-7 Insulation Punch 1Y 4 11-18-4111 60712-11 Insulation Anvil 1Y 5 63820-0038 63820-0038 Cut-Off Punch 1Y 6 11-18-4470 60712-24 Cut-Off Insert 1Y Other Components 7 11-18-4006 60703-8 Stripper Blade Holder 1 8 11-18-4103 60712-3 Cover Plate 1 9 11-18-4332 60703-16 Stripper 1 10 11-18-4471 60712-25 Retainer Block 1 11 11-18-4631 60750A104 Insulation Punch Spacer 1 12 11-18-4848 60800A123 Spring Retainer 1 13 11-18-4849 60800A124 Wire Hold Down Spring 1 14 11-18-5015 60805A122 Front Cover 1 11-40-4085 8301-10 Terminal Stop and Scrape Shield 1 15 16 63803-5119 63803-5119 Conductor Bushing 1 17 63820-0012 63820-0012 Cover-Drag Frame 1 18 63600-4664 63600-4664 Compression Spring 2 Frame 63801-3201 63801-3201 Top 1 19 63801-3283 63801-3283 Base 1 20 63801-6950 63801-6950 Track 1 21 Hardware 22 N/A N/A M3 by 6 Long SHCS 4** 23 N/A N/A M4 by 6 Long SHCS 2** 24 N/A N/A M4 by 12 Long BHCS 2** 25 N/A N/A M5 by 10 Long SHCS 1** 26 N/A N/A M8 by 20 Long BHCS 1** 27 N/A N/A #4-40 by 5/8” Long SHCS 2** 28 N/A N/A #6-32 by 3/8” Long BHCS 2** 29 N/A N/A #10-32 by 1.120” Long SHCS 1** ** Available from an industrial supply company such as MSC (1-800-645-7270). Doc No. ATS-638885000 Revision: C Release Date: 11-14-12 Revision Date: 08-25-14 UNCONTROLLED COPY Page 4 of 6 Mini-Mac Applicator for KK® and Trifurcon™ Crimp Terminals Assembly Drawing 19 1 23 (2) 16 3 5 12 26 11 13 22 (2) 24 (2) 18 21 19 8 20 22 7 18 (2) (2) 14 25 10 27 6 (2) 9 4 28 (2) 15 2 Figure 1 29 Doc No. ATS-638885000 Revision: C Release Date: 11-14-12 Revision Date: 08-25-14 UNCONTROLLED COPY Page 5 of 6 Mini-Mac Applicator for KK® and Trifurcon™ Crimp Terminals 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 wireprocessing 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. Visit our Web site at http://www.molex.com Doc No. ATS-638885000 Revision: C Release Date: 11-14-12 Revision Date: 08-25-14 UNCONTROLLED COPY Page 6 of 6