0638882100

Mini-Mac Applicator “KK” Terminals Mini-Mac Applicator Application Tooling Specification Sheet Order No. 63888-2100 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® Crimp Terminal and Cat Ear Crimp Terminals, 22-30 AWG. Use with smaller wire insulation diameters. Terminal Series No. 2759 5139 5159 6459 40445 41572 Terminal Order No. 08-50-0113 08-50-0159 08-50-0274 08-51-0101 08-51-0108 08-55-0101 08-70-0046 08-70-0048 08-52-0101 08-52-0118 08-52-0121 08-50-0321 08-65-0804 Doc No.: ATS-638882100 Revision: B 08-55-0130 08-56-0109 39-00-0032 39-00-0064 39-00-0372 Wire Size AWG mm² 39-00-0374 39-00-0376 39-00-0378 22-30 0.35-0.05 39-00-0380 50-29-1757 08-70-0064 08-65-0801 08-65-0811 08-65-0813 97-00-0444 22-30 0.35-0.05 22-28 0.35-0.08
Insulation Diameter mm In. 0.96-1.20 .038-.047 2.54-3.18 .100-.125 0.96-1.20 0.96-1.20 .038-.047 .038-.047 2.54-3.18 .100-.125 2.54-3.18 .100-.125 08-65-0815 08-65-0817 22-30 0.35-0.05 0.96-1.20 .038-.047 40-07-0815 97-00-0920 22-30 0.35-0.05 0.96-1.20 .038-.047 22-30 0.35-0.05 0.96-1.20 .038-.047
For larger Insulation Diameters use 63888-2000 Applicator. Release Date: 04-23-07 Revision Date: 10-18-11 Strip Length mm In. UNCONTROLLED COPY 2.54-3.18 .100-.125 2.54-3.18 .100-.125 2.54-3.18 .100-.125 Page 1 of 6 Mini-Mac Applicator “KK” Terminals 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 by 1/2 of the total cut-off tab tolerance. CRIMP SPECIFICATIONS Terminal Series No. 2759 5139 5159 6459 40445 41572 Bell mouth mm In. 0.20-0.50 .008-.020 0.20-0.50 .008-.020 0.20-0.50 .008-.020 0.20-0.50 .008-.020 0.20-0.50 .008-.020 0.20-0.50 .008-.020 Cut-off Tab mm In. 1.98-1.85 .078-.073 1.98-1.85 .078-.073 1.98-1.85 .078-.073 1.98-1.85 .078-.073 1.98-1.85 .078-.073 1.98-1.85 .078-.073 Terminal Locking Tang Height Bend up Bend down Twist Roll Series No. mm In Degree Degree 2759 0.51-0.64 .020-.025 3 3 4 8 5139 0.34-0.60 .013-.024 3 3 4 8 5159 0.40-0.55 .016-.022 3 3 4 8 6459 0.51-0.64 .020-.025 3 3 4 8 40445 0.51-0.64 .020-.025 3 3 4 8 41572 0.51-0.64 .020-.025 3 3 4 8 Doc No.: ATS-638882100 Revision: B Release Date: 04-23-07 Revision Date: 10-18-11 Conductor Brush mm In. .00-1.0 .000-.040 .00-1.0 .000-.040 .00-1.0 .000-.040 .00-1.0 .000-.040 .00-1.0 .000-.040 .00-1.0 .000-.040 Punch Width (Ref) Conductor Insulation mm In mm In Seam 1.38 .054 1.60 .063 1.38 .054 1.60 .063 Seam shall not be open and 1.38 .054 1.60 .063 no wire allowed out of the crimping area 1.38 .054 1.60 .063 1.38 .054 1.60 .063 1.38 .054 1.60 .063 UNCONTROLLED COPY Page 2 of 6 Mini-Mac Applicator “KK” Terminals After crimping, the conductor profile should measure the following. Terminal Series No. 2759 5139 5159 6459 40445 41572 Wire Size AWG mm2 22 0.35 24 0.20 26 0.12 28 0.08 30 0.05 22 0.35 24 0.20 26 0.12 28 0.08 30 0.05 22 0.35 24 0.20 26 0.12 28 0.08 22 0.35 24 0.20 26 0.12 28 0.08 30 0.05 22 0.35 24 0.20 26 0.12 28 0.08 30 0.05 22 0.35 24 0.20 26 0.12 28 0.08 30 0.05 Crimp Height mm In. 0.79-0.84 .031-.033 0.73-0.79 .029-.031 0.71-0.76 .028-.030 0.68-0.73 .027-.029 0.66-0.71 .026-.028 0.79-0.84 .031-.033 0.74-0.79 .029-.031 0.68-0.74 .027-.029 0.66-0.71 .026-.028 0.63-0.66 .026-.027 0.79-0.84 .031-.033 0.74-0.79 .029-.031 0.68-0.74 .027-.029 0.66-0.71 .026-.028 0.79-0.84 .031-.033 0.74-0.79 .029-.031 0.68-0.74 .027-.029 0.66-0.71 .026-.028 0.63-0.66 .026-.027 0.79-0.84 .031-.033 0.74-0.79 .029-.031 0.68-0.74 .027-.029 0.66-0.71 .026-.028 0.63-0.66 .026-.027 0.79-0.84 .031-.033 0.74-0.79 .029-.031 0.68-0.74 .027-.029 0.66-0.71 .026-.028 0.63-0.66 .026-.027 Crimp Width (Ref) mm In. 1.37 .054 1.37 .054 1.37 .054 1.37 .054 1.37 .054 1.37 .054 1.37 .054 1.37 .054 1.37 .054 1.37 .054 1.37 .054 1.37 .054 1.37 .054 1.37 .054 1.37 .054 1.37 .054 1.37 .054 1.37 .054 1.37 .054 1.37 .054 1.37 .054 1.37 .054 1.37 .054 1.37 .054 1.37 .054 1.37 .054 1.37 .054 1.37 .054 1.37 .054 Pull Force Minimum N Lb. 44.88 10.0 35.59 8.0 17.79 4.0 13.34 3.0 8.89 2.0 44.88 10.0 35.59 8.0 17.79 4.0 13.34 3.0 8.89 2.0 44.88 10.0 35.59 8.0 17.79 4.0 13.34 3.0 44.88 10.0 35.59 8.0 17.79 4.0 13.34 3.0 8.89 2.0 44.88 10.0 35.59 8.0 17.79 4.0 13.34 3.0 8.89 2.0 44.88 10.0 35.59 8.0 17.79 4.0 13.34 3.0 8.89 2.0 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. Doc No.: ATS-638882100 Revision: B Release Date: 04-23-07 Revision Date: 10-18-11 UNCONTROLLED COPY Page 3 of 6 Mini-Mac Applicator “KK” Terminals PARTS LIST Mini-Mac Applicator 63888-2100 Item Order No Engineering No. Description Quantity Perishable Tooling 63888-2170 63888-2170 Tool Kit (All “Y” Items) REF 1 11-18-5258 60703C131 Conductor Punch 1Y 2 11-18-5259 60703C132 Conductor Anvil 1Y 3 63891-0030 63891-0030 Insulation Punch 1Y 4 63891-0080 63891-0080 Insulation Anvil 1Y 5 11-18-4009 60703-11 Cut-Off Punch 1Y 6 11-18-4468 60703-19 Cut-off Insert 1Y Other Components 7 11-18-4001 60703-3 Cover Plate 1 8 11-18-4003 60703-5 Front Cover 1 9 11-18-4004 60703-6 Insulation Punch Spacer 1 10 11-18-4006 60703-8 Stripper Blade Holder 1 11 11-18-4332 60703-16 Stripper 1 12 11-18-4469 60703-20 Retainer Block 1 11-40-4085 8301-10 Terminal Stop and Scrape Shield 1 13 14 63803-5117 63803-5117 Conductor Bushing 1 15 63820-0012 63820-0012 Cover-Drag Frame 1 Frame 63801-3201 63801-3201 Top 1 16 63801-3283 63801-3283 Base 1 17 63801-6950 63801-6950 Track 1 18 Hardware 19 N/A N/A M3 by 6 Long SHCS 2** 20 N/A N/A M3 by 8 Long SHCS 2** 21 N/A N/A M4 by 6 Long SHCS 2** 22 N/A N/A M4 by 12 Long BHCS 2** 23 N/A N/A M5 by 10 Long SHCS 1** 24 N/A N/A M8 by 20 Long BHCS 1** 25 N/A N/A #4-40 by .19” Long SHCS 2** 26 N/A N/A #6-32 by 3/8” Long BHCS 2** 27 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-638882100 Revision: B Release Date: 04-23-07 Revision Date: 10-18-11 UNCONTROLLED COPY Page 4 of 6 Mini-Mac Applicator “KK” Terminals Assembly Drawing 16 1 21 (2) 14 3 5 9 24 19 (2) 15 22 (2) 7 16 18 17 20 10 (2) 8 23 12 25 (2) 13 11 4 26 (2) 6 2 Figure 1 27 Doc No.: ATS-638882100 Revision: B Release Date: 04-23-07 Revision Date: 10-18-11 UNCONTROLLED COPY Page 5 of 6 Mini-Mac Applicator “KK” 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 MiniMac 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. http://www.molex.com Doc No.: ATS-638882100 Revision: B Release Date: 04-23-07 Revision Date: 10-18-11 UNCONTROLLED COPY Page 6 of 6