Mini-Mac Applicator for KK® Crimp Terminals
Mini-Mac
Applicator
Application Tooling
Specification Sheet
Order No. 63888-7000
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® Cat Ear and Anti Fish Hook Crimp Terminals, 22-30 AWG.
Terminal
Series No.
4809
8088
08-50-0030
08-55-0110
40-01-0829
08-52-0103
40-07-0812
Terminal Order No.
08-50-0031
08-55-0112
97-00-0450
08-52-0105
97-00-0225
Wire Size
AWG
mm²
Insulation Diameter
mm
In.
Strip Length
mm
In.
08-50-0033 08-50-0135
08-56-0120 08-56-0158 22-30 0.35-0.05 1.12-1.57 .044-.062 2.54-3.18 .100-.125
97-00-0452
08-52-0107 08-65-0105
22-30 0.35-0.05 1.12-1.57 .044-.062 2.54-3.18 .100-.125
97-00-0227
CONDUCTOR CRIMP
INSULATION CRIMP
LOCKING TANG
HEIGHT
C/L
DEFINITION OF TERMS
CUT-OFF TAB
TERMINAL
LOCATION
BEND UP
BRUSH
SEAM
BELL
MOUTH
CUT-OFF
TAB
CRIMP HEIGHT
BEND
DOWN
C/L
ROLLING
TWISTING
STRIP
LENGTH
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-638887000
Revision: B
Release Date: 02-23.-09
Revision Date: 09-13-11
UNCONTROLLED COPY
Page 1 of 5
Mini-Mac Applicator for KK® Crimp Terminals
CRIMP SPECIFICATIONS
Terminal Series No.
4809
8088
Bell mouth
mm In.
Cut-off Tab
mm
In.
1.85-1.98 .073-.078
1.85-1.98 .073-.078
Conductor Brush
mm
In.
Terminal Locking Tang Height Bend up Bend down Twist Roll
Series No.
mm
In
Degree
Degree
4809
0.64
.025
3
3
4
8
8088
0.64
.025
3
3
4
8
Punch Width (Ref)
Seam
Conductor Insulation
mm In mm In
Seam shall not be open and
1.60 .063 1.68 .066 no wire allowed out of the
crimping area
1.60 .063 1.68 .066
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.
Wire Size
AWG
22
24
26
28
30
22
24
26
28
30
mm
2
0.35
0.20
0.12
0.08
0.05
0.35
0.20
0.12
0.08
0.05
Conductor
Crimp Height
Crimp Width (Ref)
mm
In.
mm
In.
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
Pull Force Minimum
N
44.88
35.59
26.69
17.79
13.34
44.88
35.59
26.69
17.79
13.34
Lb.
10.0
8.0
6.0
4.0
3.0
10.0
8.0
6.0
4.0
3.0
4809
8088
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-638887000
Revision: B
Release Date: 02-23.-09
Revision Date: 09-13-11
UNCONTROLLED COPY
Page 2 of 5
Mini-Mac Applicator for KK® Crimp Terminals
PARTS LIST
Mini-Mac Applicator 63888-7000
Item
Order No
Engineering No.
Description
Quantity
Perishable Tooling
63888-7070
63888-7070
Tool Kit (All “Y” Items)
REF
1
11-18-4684
60756A101
Conductor Punch
1Y
2
11-18-4685
60756A102
Conductor Anvil
1Y
3
11-18-4686
60756A103
Insulation Punch
1Y
4
11-18-4687
60756A104
Insulation Anvil
1Y
5
11-18-4688
60756A105
Cut-Off Insert
1Y
6
11-18-4689
60756A106
Cut-off Punch
1Y
Other Components
7
11-18-4003
60703-5
Front Cover
1
8
11-18-4348
60722A108
Tooling Washer
1
9
11-18-4469
60703-20
Retainer Block
1
10
11-18-4678
60756A111
Wire Stop
1
11
11-18-4754
60756A118
Terminal Stop and Scrap Shield
1
12
63803-5105
63803-5105
Conductor Bushing
1
13
63820-0012
63820-0012
Cover-Drag Frame
1
14
63888-7001
63888-7001
Cover Plate
1
Frame
15
63801-3201
63801-3201
Top
1
16
63801-3283
63801-3283
Base
1
17
63443-6204
63443-6204
Track
1
Hardware
18
N/A
N/A
M3 by 6 Long SHCS
2**
19
N/A
N/A
M3 by 8 Long SHCS
2**
20
N/A
N/A
M4 by 8 Long SHCS
2**
21
N/A
N/A
M4 by 12 Long BHCS
2**
22
N/A
N/A
M5 by 10 Long SHCS
1**
23
N/A
N/A
M8 by 20 Long BHCS
1**
24
N/A
N/A
#6-32 by 1/2” Long BHCS
2**
25
N/A
N/A
#10-32 by 1-1/4” Long SHCS
1**
** Available from an industrial supply company such as MSC (1-800-645-7270).
Doc No: ATS-638887000
Revision: B
Release Date: 02-23.-09
Revision Date: 09-13-11
UNCONTROLLED COPY
Page 3 of 5
Mini-Mac Applicator for KK® Crimp Terminals
Assembly Drawing
20
15
(2)
1
12
6
3
8
23
18 (2)
13
21
(2)
15
14
17
19 (2)
16
10
7
9
22
25
11
2
4
5
24
Figure 1
(2)
Doc No: ATS-638887000
Revision: B
Release Date: 02-23.-09
Revision Date: 09-13-11
UNCONTROLLED COPY
Page 4 of 5
Mini-Mac Applicator for 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 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.
http://www.molex.com
Doc No: ATS-638887000
Revision: B
Release Date: 02-23.-09
Revision Date: 09-13-11
UNCONTROLLED COPY
Page 5 of 5
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