0638810900

Mechanical Feed Metal Strip Applicator Mini-Mac Applicator Application Tooling Specification Mechanical Feed-Metal Strip Order No. 63881-0900 FEATURES % % % % Directly adapts to most crimp presses and automatic wire processors Applicator designed to industry-standard mounting and shut height of 135.80mm (5.346") Conductor and insulation rings allow quick adjustment for conductor and insulation crimp height change Quick set-up time; plus the crimp height, track and feed adjustments can be set without removing the applicator from the crimp press SCOPE Products: Avikrimp QD Terminals 14-16 AWG Testing Mechanical The tensile test, or pull test, is a means of evaluating the mechanical properties of the crimped connections. The following chart shows the UL and government specifications (MIL-T-7928) for various wire sizes. The tensile strength is shown in pounds and indicates the minimum acceptable force to break or separate the terminal from the conductor. Color Code Wire Size (AWG) *UL - 486 A *UL – 486 C *UL – 310 *Military Class 2 Yellow Yellow Red Red Red Blue Blue Yellow Yellow Red Blue 26 24 22 20 18 16 14 12 10 8 6 3 5 8 13 20 30 50 70 80 90 100 N/A N/A 8 10 10 15 25 35 40 45 50 N/A N/A 8 13 20 30 50 70 80 N/A N/A 7 10 15 19 38 50 70 110 150 225 300 *UL - 486 A - Terminals (Copper conductors only) *UL - 486 C - Butt Splices, Parallel Splices, Closed End Connectors, and Wire Nuts *UL - 310 - Quick Disconnects, Flag and Couplers *Military Class 2- Military Approved Terminals only as listed Doc No. 63881-0900 Revision: C Release Date: 12-15-04 Revision Date: 09-30-05 UNCONTROLLED COPY Page 1 of 7 Mechanical Feed Metal Strip Applicator Product List The following is a partial list of the product order numbers and their specifications that this tool is designed to run. Updates to this list are available on www.molex.com. Terminal No. Terminal Eng. No. 19019-0079 19019-0080 19019-0112 BBZ-8138 BBZ-8138-032 SPL-0471 Wire Size AWG mm² 14-16 2.00-1.30 14-16 2.00-1.30 14-16 2.00-1.30 Insulation Diameter Max. mm In. 3.60 .142 3.50 .138 3.50 .138 Strip Length mm In. 6.35 .250 6.35 .250 6.35 .250 Note: To process these terminals, assemble spacers with cutoff tooling as shown in Figure 1. See also parts list and assembly drawing. 36 35 Figure 1 Terminal No. Terminal Eng. No. 19019-0036 BBZ-8141 Wire Size AWG mm² 14-16 2.00-1.30 Insulation Diameter Max. mm In. 3.50 .138 Strip Length mm In. 6.35 .250 Note: To process this terminal, assemble spacers with cutoff tooling as shown in Figure 2. See also parts list and assembly drawing. 35 36 Figure 2 Doc No. 63881-0900 Revision: C Release Date: 12-15-04 Revision Date: 09-30-05 UNCONTROLLED COPY Page 2 of 7 Mechanical Feed Metal Strip Applicator Tool Calibration To recalibrate this applicator, make sure the power is completely shut off on the press. 1. The Mini-Mac applicator must be properly installed in the press. 2. Crimping dies must be properly installed in the Mini-Mac applicator. 3. The recommended method of measuring the crimp height of the conductor dies is the soft metal slug method, (See Figure 3). 4. The slug must have a diameter 0.51mm (.020”) larger than the “X” No Go dimension before crimping. 5. Place the soft metal slug (solder) into the nest of the bottom die and crimp (by hand cycling the press) similar to a terminal. The crimp height can be measured with a blade type micrometer or dial caliper, (Dimension “X”). 6. Adjustment of the crimp height can be accomplished by indexing the conductor cam. The letter “A” gives the loosest position and “K” gives the tightest position. A total adjustment of 0.50mm (.020”) can be achieved by adjusting the conductor cam. Note: If the crimp height is too tight on the setting “A”, check the shut height of the press. See the Industrial Mini-Mac Applicator Manual Section 2.1 for adjustments. CONDUCTOR CRIMP DIE USE SOFT METAL SLUG METHOD E2 “X” CRIMP HEIGHT E1 CRIMP PROFILE Use soft metal slug (solder) method to measure the “X” dimension. Verify tooling crimp height calibration by referring to the Go/No Go dimensions shown in the chart below. Figure 3 CRIMP SPECIFICATIONS Wire Size “X” Dimension Conductor Crimp Pull Force Min. Mean Go No Go AWG mm² Lbs N In mm In mm In mm 16 1.30 .094 2.39 .091 2.31 .098 2.49 30.0 133.5 14 2.00 .094 2.39 .091 2.31 .098 2.49 50.0 222.6 Terminal Series No. 19019-00** Cut-off Tab Max. mm In. 0.25 .010 Pull Force should be measured with no influence from the insulation crimp. The above specifications are guidelines to an optimum crimp. Doc No. 63881-0900 Revision: C Release Date: 12-15-04 Revision Date: 09-30-05 UNCONTROLLED COPY Page 3 of 7 Mechanical Feed Metal Strip Applicator DEFINITION OF TERMS The following illustrations are a generic terminal representation and not an exact image of any terminal listed in the scope. Insulated Female Quick Disconnect TERMINAL STRIP MWID OR MAX INSULATION DIAMETER BRUSH STRIP LENGTH MALE QD TAPE OR MOLDED REF FEMALE QD TAB SIZE WIRE STOP CUT-OFF TAB TAB SIZE Figure 1 Doc No. 63881-0900 Revision: C Release Date: 12-15-04 Revision Date: 09-30-05 UNCONTROLLED COPY Page 4 of 7 Mechanical Feed Metal Strip Applicator PARTS LIST Item 1 2 3 4 12 14 16 22 24 25 33 ✴ 35 ✴ 36 42 51 52 53 72 96 81 82 83 91 92 93 94 95 97 98 Mini-Mac Applicator 63881-0900 Order No Engineering No. Description Quantity Perishable Tooling 63881-0970 63881-0970 Tool Kit (All “Y” Items) REF 63465-0026 63465-0026 Conductor Punch 1Y 63464-0025 63464-0025 Conductor Anvil 1Y 63463-0025 63463-0025 Insulation Punch 1Y 63462-0027 63462-0027 Insulation Anvil 1Y 63466-0201 63466-0201 Cut-off Plunger Rear 1Y 63466-0301 63466-0301 Rear Plunger Retainer 1Y 63466-0002 63466-0002 Cut-Off Blade 1Y Other Components (REF 10250) 63466-0403 63466-0403 Cut-off Plunger Striker (Rear) 1 63466-0101 63466-0101 Scrap Chute 1 63700-0539 63700-0539 Cut-Off Plunger Spring 1 63443-0021 63443-0021 Lower Tooling Key 1 63466-1054 63466-1054 Spacer 1 63466-1075 63466-1075 Spacer 1 63466-0921 63466-0921 Terminal Stripping Blade 1 63600-1290 63600-1290 Washer 1 63890-0866 63890-0866 Collar-6.40 Lg. 1 63890-0867 63890-0867 Collar-7.70 Lg. 1 63801-4510 63801-4510 Terminal Guide Front 1 63600-0110 63600-0110 M4 Washer, 3mm Thick 1 Frame 63801-3201 63801-3201 Mechanical Feed Applicator Frame Head REF 63801-3281 63801-3281 Base REF 63801-4550 63801-4550 Track Assembly REF Hardware N/A N/A M4 by 10 Lg SHCS 2** N/A N/A M4 by 12 Lg SHCS 1** N/A N/A M4 by 20 Lg SHCS 4** N/A N/A M4 by 40 Lg. SHCS 1** N/A N/A M4 by 45 Lg. SHCS 1** N/A N/A M8 by 30 Lg. BHCS 1** N/A N/A 3mm by 6 Lg. Roll Pin 1** ** Available from an industrial supply company such as MSC (1-800-645-7270). ✴ See spacer assembly notes on page 2. Note: Crimp profiles used in 63881-0900 are equivalent to 19292-0005/MMZ-BB-575, (UL file number E79133). Doc No. 63881-0900 Revision: C Release Date: 12-15-04 Revision Date: 09-30-05 UNCONTROLLED COPY Page 5 of 7 Mechanical Feed Metal Strip Applicator Assembly Drawing 81 52 93 (2) 53 1 22 3 51 97 81 93 (2) 72 83 12 14 ✴ 35 4 25 16 36 2 ✴ 42 91 (2) 96 94 24 92 82 98 95 33 Figure 5 ✴ Doc No. 63881-0900 Revision: C Release Date: 12-15-04 Revision Date: 09-30-05 See spacer assembly notes on page 2. UNCONTROLLED COPY Page 6 of 7 Mechanical Feed Metal Strip Applicator NOTES 1. 2. 3. 4. 5. Molex recommends an extra perishable tooling kit be maintained at your facility. Verify tooling alignment by manually cycling the press with applicator before crimping under power. Check that all screws are tight. Slugs, terminals, dirt, and oil should be kept clear of work area. Wear safety glasses at all times. For recommended maintenance refer to the Mini-Mac Applicator Manual (Document no. 63880-0000). CAUTION: This applicator should only be used in a press with a shut height of 135.80 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. Contact Information For more information on Molex application tooling please contact Molex at 1-800-786-6539. Molex Application Tooling Group 1150 E. Diehl Road Naperville, IL 60563 Tel: (630) 969-4550 Fax: (630) 505-0049 Visit our Web site at http://www.molex.com Doc No. 63881-0900 Revision: C Release Date: 12-15-04 Revision Date: 09-30-05 UNCONTROLLED COPY Page 7 of 7