0638814600

Mechanical Feed Metal Strip Applicator Mini-Mac Applicator Mechanical Feed-Metal Strip Application Tooling Specification Sheet Order No. 63881-4600 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: Insulkrimp™ Quick Disconnect Terminals Metal Strip, 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: ATS-638814600 Revision: C Release Date: 05-27-11 Revision Date: 05-16-12 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. Wire Size Insulation Diameter Maximum Strip Length AWG mm² mm In. mm In. 19017-0070 BBZ-2132 14-16 2.00-1.30 3.70 .145 6.35 .250 19017-0071 BBZ-2135 14-16 2.00-1.30 3.70 .145 6.35 .250 19017-0072 BBZ-2138 14-16 2.00-1.30 3.70 .145 6.35 .250 19017-0073 BBZ-2138-032 14-16 2.00-1.30 3.70 .145 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. Terminal No. Terminal Eng. No. 13 12 Figure 1 Wire Size Insulation Diameter Maximum Strip Length AWG mm² mm In. mm In. 19017-0074 BBZ-2141 14-16 2.00-1.30 3.70 .145 6.35 .250 19274-0004 BBZ-2141-LIF 14-16 2.00-1.30 3.70 .145 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. Terminal No. Terminal Eng. No. 12 13 Figure 2 Doc No: ATS-638814600 Revision: C Release Date: 05-27-11 Revision Date: 05-16-12 UNCONTROLLED COPY Page 2 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. MWID OR MAX INSULATION DIAMETER Insulated Female Quick Disconnect TERMINAL STRIP BRUSH STRIP LENGTH MALE QD TAPE OR MOLDED REF FEMALE QD WIRE STOP TAB SIZE CUT-OFF TAB TAB SIZE Figure 3 CRIMP SPECIFICATIONS Wire Size AWG mm² 16 14 1.30 2.00 “X” Dimension Conductor Crimp Mean Go No Go In mm In mm In mm .084 2.13 .081 2.06 .091 2.31 .084 2.13 .081 2.06 .091 2.31 Terminal Series No. 19017 19274 Pull Force Minimum Lbs N 30.0 50.0 133.5 222.6 Cut-off Tab Maximum mm In. 0.25 .010 0.25 .010 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-638814600 Revision: C Release Date: 05-27-11 Revision Date: 05-16-12 UNCONTROLLED COPY Page 3 of 7 Mechanical Feed Metal Strip Applicator Tool Calibration CONDUCTOR CRIMP DIE To recalibrate this applicator, make sure the power is completely shut off on the press. USE SOFT METAL SLUG METHOD E2 1. The Mini-Mac applicator must be properly installed in the press. 2. Crimping dies must be properly installed in the Mini-Mac “X” CRIMP applicator. HEIGHT 3. The recommended method of measuring the crimp height of E1 the conductor dies is the soft metal slug method. See CRIMP PROFILE Figure 4. Use soft metal slug (solder) method to measure the 4. The slug must have a diameter 0.51mm (.020”) larger than “X” dimension. Verify tooling crimp height calibration the “X” No Go dimension before crimping. by referring to the Go/No Go dimensions shown in 5. Place the soft metal slug (solder) into the nest of the bottom the chart on page 3. die and crimp (by hand cycling the press) similar to a terminal. The crimp height can be measured with a blade Figure 4 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 MiniMac Applicator Manual Section 2.1 for adjustments. Doc No: ATS-638814600 Revision: C Release Date: 05-27-11 Revision Date: 05-16-12 UNCONTROLLED COPY Page 4 of 7 Mechanical Feed Metal Strip Applicator PARTS LIST Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Mini-Mac Applicator 63881-4600 Engineering No. Description Quantity Perishable Tooling 63881-4670 63881-4670 Tool Kit (All “Y” Items) REF 63465-0079 63465-0079 Conductor Punch 1Y 63464-0068 63464-0068 Conductor Anvil 1Y 63463-0046 63463-0046 Insulation Punch 1Y 63462-0050 63462-0050 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 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 1 •Spacer (5.40mm) 63466-1075 63466-1075 1 •Spacer (7.50mm) 63466-0921 63466-0921 Terminal Stripping Blade 1 63600-1290 63600-1290 Washer 1 63890-0866 63890-0866 Collar-6.40 Long 1 63890-0867 63890-0867 Collar-7.70 Long 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 1 63801-3281 63801-3281 Base 1 63801-4550 63801-4550 Track Assembly 1 Hardware N/A N/A M4 by 10 Long SHCS 2** N/A N/A M4 by 12 Long SHCS 1** N/A N/A M4 by 20 Long SHCS 4** N/A N/A M4 by 40 Long SHCS 1** N/A N/A M4 by 45 Long SHCS 1** N/A N/A M8 by 30 Long BHCS 1** N/A N/A 3mm by 6 Long Roll Pin 1** ** Available from an industrial supply company such as MSC (1-800-645-7270). Order No • See spacer assembly notes on page 2. Note: Crimp profiles used in 63881-4600 are equivalent to 19288-0104 / ATP-BB-275, (UL file number E79133). Doc No: ATS-638814600 Revision: C Release Date: 05-27-11 Revision Date: 05-16-12 UNCONTROLLED COPY Page 5 of 7 Mechanical Feed Metal Strip Applicator Assembly Drawing 20 16 25 17 1 (2) 8 3 15 28 20 25 (2) 14 23 18 (2) 5 6 • 4 12 10 22 7 13 2 • 19 26 9 24 29 27 21 11 Figure 5 • Doc No: ATS-638814600 Revision: C See spacer assembly notes on page 2. Release Date: 05-27-11 Revision Date: 05-16-12 UNCONTROLLED COPY Page 6 of 7 Mechanical Feed Metal Strip Applicator NOTES 1. Molex recommends an extra perishable tooling kit be maintained at your facility. 2. Verify tooling alignment by manually cycling the press with 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 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 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. Contact Information For more information on Molex application tooling please contact Molex at 1-800-786-6539. Visit our Web site at http://www.molex.com Doc No: ATS-638814600 Revision: C Release Date: 05-27-11 Revision Date: 05-16-12 UNCONTROLLED COPY Page 7 of 7