0638812100

Mechanical Feed Metal Strip Applicator Mini-Mac Applicator Application Tooling Specification Mechanical Feed-Metal Strip Order No. 63881-2100 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 Metal strip fed low profile FIQD Terminals 10-12 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 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 *Military Class 2 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. 63881-2100 Revision: C Release Date: 12-15-04 Revision Date: 09-30-05 UNCONTROLLED COPY Page 1 of 6 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. 19606-0004 19606-0004 Wire Size AWG mm² 10-12 3.30-5.00 Insulation Diameter Max. mm In. 5.84 .230 Strip Length mm In. .344 8.73 DEFINITION OF TERMS The following illustrations are a generic terminal representation and not an exact image of any terminal listed in the scope. Fully Insulated Female Quick Disconnect MWID OR MAX INSULATION DIAMETER STRIP LENGTH BRUSH TERMINAL STRIP MALE QD TAPE OR MOLDED REF FEMALE QD WIRE STOP TAB SIZE CUT-OFF TAB TAB SIZE Figure 1 Doc No. 63881-2100 Revision: C Release Date: 12-15-04 Revision Date: 09-30-05 UNCONTROLLED COPY Page 2 of 6 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 2). 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 E1 “X” CRIMP HEIGHT 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 2 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 10 5.25 .114 2.90 .111 2.82 .117 2.97 80.0 355.9 12 3.30 .114 2.90 .111 2.82 .117 2.97 70.0 311.4 Terminal Series No. 19606-0004 Cut-off Tab Max. mm In. 0.38 .015 Pull Force should be measured with no influence from the insulation crimp. The above specifications are guidelines to an optimum crimp. Doc No. 63881-2100 Revision: C Release Date: 12-15-04 Revision Date: 09-30-05 UNCONTROLLED COPY Page 3 of 6 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 63881-2100 Order No Engineering No. Description Quantity Perishable Tooling 63881-2170 63881-2170 Tool Kit (All “Y” Items) REF 63465-0023 63465-0023 Conductor Punch 1Y 63464-0022 63464-0022 Conductor Anvil 1Y 63463-0022 63463-0022 Insulation Punch 1Y 63462-0024 63462-0024 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. 12150) 63466-0404 63466-0404 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 63466-1040 63466-1089 Spacer 1 63466-1089 63466-1040 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 45 Lg. SHCS 1** N/A N/A M4 by 50Lg. 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). Note: Crimp profiles used in 63881-2100 are equivalent to 19031-0041and 19031-0042. Doc No. 63881-2100 Revision: C Release Date: 12-15-04 Revision Date: 09-30-05 UNCONTROLLED COPY Page 4 of 6 Mechanical Feed Metal Strip Applicator Assembly Drawing 81 52 93 (2) 53 1 22 3 51 97 81 93 (2) 72 83 12 14 25 42 35 4 16 91 (2) 36 2 96 94 24 92 82 98 95 33 Figure 3 Doc No. 63881-2100 Revision: C Release Date: 12-15-04 Revision Date: 09-30-05 UNCONTROLLED COPY Page 5 of 6 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. 63881-2100 Revision: C Release Date: 12-15-04 Revision Date: 09-30-05 UNCONTROLLED COPY Page 6 of 6