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.
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
08-55-0130
08-56-0109
39-00-0032
39-00-0064
39-00-0372
Wire Size
AWG
mm²
Insulation Diameter
mm
In.
Strip Length
mm
In.
2759
39-00-0374
39-00-0376
39-00-0378
22-30 0.35-0.05
39-00-0380
50-29-1757
22-30 0.35-0.05
22-28 0.35-0.08
0.96-1.20
.038-.047
2.54-3.18 .100-.125
5139
5159
6459
40445
41572
08-70-0064
08-65-0801
08-65-0811
08-65-0813
97-00-0444
0.96-1.20
0.96-1.20
.038-.047
.038-.047
2.54-3.18 .100-.125
2.54-3.18 .100-.125
2.54-3.18 .100-.125
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.
Doc No.: ATS-638882100
Revision: B
Release Date: 04-23-07
Revision Date: 10-18-11
UNCONTROLLED COPY
Page 1 of 6
Mini-Mac Applicator “KK” Terminals
DEFINITION OF TERMS
CONDUCTOR CRIMP
LOCKING TANG
HEIGHT
INSULATION CRIMP
CUT-OFF TAB
TERMINAL
LOCATION
BEND UP
C/L
BRUSH
BELL
MOUTH
SEAM
ROLLING
TWISTING
STRIP LENGTH
CUT-OFF
TAB
CRIMP HEIGHT
BEND
DOWN
C/L
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
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
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
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
Doc No.: ATS-638882100
Revision: B
Release Date: 04-23-07
Revision Date: 10-18-11
UNCONTROLLED COPY
Page 2 of 6
Mini-Mac Applicator “KK” Terminals
After crimping, the conductor profile should measure the following.
Terminal Series No.
Wire Size
AWG mm
2
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
2759
5139
5159
6459
40445
41572
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
3
9
24
19
15
(2)
14
5
(2)
22 (2)
7
18
16
20
(2)
8
12
17
10
23
25
13
4
26
6
2
Figure 1
27
(2)
11
(2)
Doc No.: ATS-638882100
Revision: B
Release Date: 04-23-07
Revision Date: 10-18-11
UNCONTROLLED COPY
Page 5 of 6