0638881200

Mini-Mac Applicator “KK®” Crimp Terminals Mini-Mac Applicator Application Tooling Specification Sheet Order No. 63888-1200 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: KK® 3.96 and 5.08mm (.156 and .200") Center Cat Ear Crimp Terminal, 18-26 AWG. Terminal Series No. Wire Size Terminal Order No. 5167 08-70-0012 AWG 18-26 mm² 0.82-0.12 Insulation Diameter Maximum mm In. 2.79 .110 Strip Length mm 2.54-3.18 In. .100-.125 DEFINITION OF TERMS CONDUCTOR CRIMP INSULATION CRIMP CUT-OFF TAB LOCKING TANG HEIGHT BEND UP C/L TERMINAL LOCATION BRUSH SEAM BELL MOUTH STRIP LENGTH ROLLING TWISTING CUT-OFF TAB BEND DOWN CRIMP HEIGHT C/L 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-638881200 Revision: C Release Date: 02-21-07 Revision Date: 11-25-13 UNCONTROLLED COPY Page 1 of 5 Mini-Mac Applicator “KK®” Crimp Terminals CRIMP SPECIFICATIONS Terminal Series No. Bell mouth mm In. 5167 Cut-off Tab mm In. 2.64.-2.80 .104-.110 Conductor Brush mm In. Punch Width (Ref) Seam Terminal Locking Tang Height Bend up Bend down Twist Roll Conductor Insulation Seam shall not be open and Series No. no wire allowed out of the mm In Degree Degree mm In mm In crimping area 5167 0.51-0.77 .020-.030 1.925 .076 2.43 .096 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. Terminal Series No. 5167 Wire Size AWG mm2 18 0.82 20 0.52 22 0.35 24 0.20 26 0.12 Crimp Height mm In. 1.09-1.14 .043-.045 1.02-1.09 .040-.043 0.96-1.02 .038-.040 0.91-0.96 .036-.038 0.86-0.91 .034-.036 Crimp Width (Ref) mm In. Pull Force Minimum N Lb. 111.21 25.0 66.72 15.0 44.48 10.0 35.59 8.0 26.69 6.0 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-638881200 Revision: C Release Date: 02-21-07 Revision Date: 11-25-13 TRACK ADJUSTING SCREW UNCONTROLLED COPY Page 2 of 5 Mini-Mac Applicator “KK®” Crimp Terminals PARTS LIST Mini-Mac Applicator 63888-1200 Item Order No Engineering No. Description Quantity Perishable Tooling 63888-1270 63888-1270 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 11-18-4106 60712-6 Insulation Punch Spacer 1 10 11-18-4332 60703-16 Stripper 1 11 11-18-4471 60712-25 Retainer Block 1 12 11-18-5015 60805A122 Front Cover 1 13 11-40-4085 8301-10 Terminal Stop and Scrape Shield 1 14 63600-4664 63600-4664 Compression Spring 2 15 63803-5120 63803-5120 Conductor Bushing 1 16 63820-0012 63820-0012 Cover-Drag Frame 1 Frame 17 63801-3201 63801-3201 Top 1 18 63801-3283 63801-3283 Base 1 19 63801-6550 63801-6550 Track 1 Hardware 20 N/A N/A M3 by 6 Long SHCS 2** 21 N/A N/A M3 by 8 Long SHCS 2** 22 N/A N/A M4 by 6 Long SHCS 2** 23 N/A N/A M4 by 12 Long BHCS 2** 24 N/A N/A M5 by 10 Long SHCS 1** 25 N/A N/A M8 by 20 Long BHCS 1** 26 N/A N/A #4-40 by .19” Long SHCS 2** 27 N/A N/A #6-32 by 3/8” Long BHCS 2** 28 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-638881200 Revision: C Release Date: 02-21-07 Revision Date: 11-25-13 UNCONTROLLED COPY Page 3 of 5 Mini-Mac Applicator “KK®” Crimp Terminals Assembly Drawing 17 1 22 (2) 15 3 5 9 25 20 (2) 16 23 (2) 8 17 19 18 21 14 (2) (2) 7 12 24 11 26 (2) 13 10 4 27 (2) 6 2 Figure 1 28 Doc No. ATS-638881200 Revision: C Release Date: 02-21-07 Revision Date: 11-25-13 UNCONTROLLED COPY Page 4 of 5 Mini-Mac Applicator “KK®” 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-638881200 Revision: C Release Date: 02-21-07 Revision Date: 11-25-13 UNCONTROLLED COPY Page 5 of 5