0638851000

Air Feed Mylar Tape Applicator Mini-Mac Applicator Air Feed-Mylar Tape Application Tooling Specification Sheet Order No. 63885-1000 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: Krimptite™, Insulkrimp™, and Versakrimp Ring Tongue, Spade Tongue, Hook Tongue, Flanged Spade Tongue, Rectangular Tongue, Snap Spades, Mulit-Stud Ring, Temp Terminals, Butt Splices and Step Down Butt Splices 10–12 AWG and 14–16 AWG Heavy Duty. 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 Yellow Yellow Red Red Red Blue Blue Yellow Yellow Red Blue Wire Size (AWG) 26 24 22 20 18 16 14 12 10 8 6 *UL - 486 A *UL – 486 C *UL – 310 *Military Class 2 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-638851000 Revision: E Release Date: 12-23-04 Revision Date: 11-04-10 UNCONTROLLED COPY Page 1 of 8 Air Feed Mylar Tape 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 Order No. Terminal Eng. No. 19044-0019 19044-0020 19044-0021 19044-0022 19044-0023 19044-0024 19044-0025 19044-0026 19044-0027 19044-0164 19054-0023 19054-0024 19054-0025 19054-0123 19056-0078 19056-0080 19056-0082 19056-0084 19056-0086 19056-0088 19056-0090 19056-0096 19056-0098 19056-0100 19056-0122 19056-0124 19056-0126 19056-0128 19069-0147 19069-0148 19069-0149 19069-0150 19069-0208 19069-0212 19069-0218 19069-0221 19069-0225 19069-0232 19069-0235 19069-0237 19069-0243 19069-0246 19069-0443 19079-0012 19087-0146 19087-0148 19087-0150 19087-0152 19087-0154 19093-0066 19093-0068 19093-0070 19093-0072 19093-0074 19098-0062 19098-0064 19098-0066 B-128-04HDT B-128-06HDT B-128-08HDT B-130-10HDT B-130-14HDT B-130-56HDT B-136-04HDT B-136-06HDT B-136-08HDT B-128-10HDT B-236-04HDXT B-236-06HDXT B-236-08HDXT B-240-10HDXT B-328-04HDT B-328-06HDT B-328-08HDT B-328-10HDT B-330-10HDT B-330-14HDT B-330-56HDT B-336-04HDT B-336-06HDT B-336-08HDT B-340-10HDT B-340-14HDT B-340-38HDT B-340-56HDT C-128-04T C-128-06T C-130-38T C-136-04T C-128-08T C-128-10T C-130-10T C-130-14T C-130-56T C-136-06T C-136-08T C-140-10T C-140-38T C-140-56T C-101-14T C-1006-MST C-1103-08T C-1106-06T C-112-06T C-112-08T C-112-10T C-3103-08T C-3106-06T C-312-06T C-312-08T C-312-10T C-1196-06T C-1197-08T C-1198-10T Wire Size AWG 14-16HD 14-16HD 14-16HD 14-16HD 14-16HD 14-16HD 14-16HD 14-16HD 14-16HD 14-16HD 14-16HD 14-16HD 14-16HD 14-16HD 14-16HD 14-16HD 14-16HD 14-16HD 14-16HD 14-16HD 14-16HD 14-16HD 14-16HD 14-16HD 14-16HD 14-16HD 14-16HD 14-16HD 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 Doc No. ATS-638851000 Revision: E mm² 2.00-1.30 2.00-1.30 2.00-1.30 2.00-1.30 2.00-1.30 2.00-1.30 2.00-1.30 2.00-1.30 2.00-1.30 2.00-1.30 2.00-1.30 2.00-1.30 2.00-1.30 2.00-1.30 2.00-1.30 2.00-1.30 2.00-1.30 2.00-1.30 2.00-1.30 2.00-1.30 2.00-1.30 2.00-1.30 2.00-1.30 2.00-1.30 2.00-1.30 2.00-1.30 2.00-1.30 2.00-1.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 Insulation Diameter Maximum mm In 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 Strip Length mm 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.94 7.94 7.94 7.94 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 In .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .313 .313 .313 .313 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 Release Date: 12-23-04 Revision Date: 11-04-10 Terminal Order No. Terminal Eng. No. Wire Size AWG mm² 19098-0070 C-1710-06T 10-12 5.00-3.30 19098-0075 C-1719-10T 10-12 5.00-3.30 19098-0086 C-1199-14T 10-12 5.00-3.30 19098-0087 C-1710-05T 10-12 5.00-3.30 19098-0088 C-1711-08T 10-12 5.00-3.30 19098-0089 C-1712-10T 10-12 5.00-3.30 19098-0091 C-1718-08T 10-12 5.00-3.30 19117-0057 B-117-10HDT 14-16HD 2.00-1.30 19117-0086 B-117-06HDT 14-16HD 2.00-1.30 19117-0087 B-117-08HDT 14-16HD 2.00-1.30 19118-0081 C-1104-08T 10-12 5.00-3.30 19118-0083 C-1104-10T 10-12 5.00-3.30 19118-0084 C-117-06T 10-12 5.00-3.30 19118-0087 C-117-08T 10-12 5.00-3.30 19118-0090 C-117-10T 10-12 5.00-3.30 19118-0128 C-1101-08T 10-12 5.00-3.30 19118-0129 C-1104-06T 10-12 5.00-3.30 19119-0063 B-217-06HDXT 14-16HD 2.00-1.30 19119-0064 B-217-08HDXT 14-16HD 2.00-1.30 19119-0065 B-217-10HDXT 14-16HD 2.00-1.30 19123-0056 B-317-06HDT 14-16HD 2.00-1.30 19123-0057 B-317-08HDT 14-16HD 2.00-1.30 19123-0058 B-317-10HDT 14-16HD 2.00-1.30 19124-0062 C-3101-08T 10-12 5.00-3.30 19124-0064 C-3104-06T 10-12 5.00-3.30 19124-0068 C-317-06T 10-12 5.00-3.30 19124-0070 C-317-08T 10-12 5.00-3.30 19124-0072 C-317-10T 10-12 5.00-3.30 19129-0006 C-1105-08T 10-12 5.00-3.30 19129-0079 C-1102-08T 10-12 5.00-3.30 19129-0080 C-1481-08T 10-12 5.00-3.30 19129-0081 C-1481-10T 10-12 5.00-3.30 19140-0136 B-141-06HDT 14-16HD 2.00-1.30 19140-0137 B-141-08HDT 14-16HD 2.00-1.30 19140-0138 B-141-10HDT 14-16HD 2.00-1.30 19141-0080 C-1105-06T 10-12 5.00-3.30 19141-0082 C-141-06T 10-12 5.00-3.30 19141-0084 C-141-08T 10-12 5.00-3.30 19141-0086 C-141-10T 10-12 5.00-3.30 19141-0089 C-168-14T 10-12 5.00-3.30 19141-0091 C-168-56T 10-12 5.00-3.30 19146-0073 B-341-06HDT 14-16HD 2.00-1.30 19146-0074 B-341-08HDT 14-16HD 2.00-1.30 19146-0075 B-341-10HDT 14-16HD 2.00-1.30 19147-0084 C-3102-08T 10-12 5.00-3.30 19147-0087 C-3105-06T 10-12 5.00-3.30 19147-0089 C-3105-08T 10-12 5.00-3.30 19147-0091 C-3105-10T 10-12 5.00-3.30 19147-0093 C-341-06T 10-12 5.00-3.30 19147-0095 C-341-08T 10-12 5.00-3.30 19147-0098 C-341-10T 10-12 5.00-3.30 19178-0015 C-111-06T 10-12 5.00-3.30 19178-0017 C-111-08T 10-12 5.00-3.30 19178-0019 C-111-10T 10-12 5.00-3.30 19178-0023 C-199-14T 10-12 5.00-3.30 19180-0014 C-311-06T 10-12 5.00-3.30 19180-0016 C-311-08T 10-12 5.00-3.30 UNCONTROLLED COPY Insulation Diameter Maximum mm In 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 Strip Length mm 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.94 7.94 7.94 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 In .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .313 .313 .313 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 Page 2 of 8 Air Feed Mylar Tape Applicator Terminal Order No. Terminal Eng. No. 19180-0018 19180-0020 19180-0021 19189-0017 19189-0019 19193-0102 19193-0105 19193-0108 19193-0111 19193-0113 19193-0115 19193-0118 19193-0122 19193-0127 19193-0129 19193-0131 19193-0133 19193-0135 19193-0139 19193-0142 19203-0009 19203-0092 C-311-10T C-399-14T C-399-556 C-146T C-L146T C-328-04T C-328-06T C-328-08T C-328-10T C-328-209T C-330-10T C-330-14T C-330-56T C-336-04T C-336-06T C-336-08T C-340-10T C-340-14T C-340-38T C-340-56T C-S-140-38T C-S-128-06T Wire Size AWG 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 Doc No. ATS-638851000 Revision: E mm² 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 Insulation Diameter Maximum mm In 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 Strip Length mm 7.14 7.14 7.14 5.95 9.13 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 In .281 .281 .281 .234 .359 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 .281 Release Date: 12-23-04 Revision Date: 11-04-10 Terminal Order No. Terminal Eng. No. 19203-0094 19203-0095 19203-0096 19203-0097 19203-0098 19203-0100 19203-0101 19203-0102 19203-0103 19203-0104 19203-0111 19203-0112 19203-0114 19203-0115 192030116 19203-0117 19203-0278 19211-0002 19215-0024 19215-0027 19215-0030 C-S-128-10T C-S-130-14T C-S-130-56T C-T-328-06T C-T-328-08T C-T-328-10T C-T-330-14T C-T-330-56T C-T-340-38T C-T-346T C-U-128-06T C-U-128-08T C-U-128-10T C-U-130-14T C-U-130-56T C-U-140-38T C-S-128-08T WP-1210T CB-346-OPT CB-346T CS-346T Wire Size AWG 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 mm² 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 5.00-3.30 UNCONTROLLED COPY Insulation Diameter Maximum mm In 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 3.40 .136 6.35 .250 6.35 .250 6.35 .250 Strip Length mm 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 9.13 7.14 7.14 7.14 7.14 7.14 7.14 7.14 7.14 9.13 9.13 9.13 In .281 .281 .281 .281 .281 .281 .281 .281 .281 .359 .281 .281 .281 .281 .281 .281 .281 .281 .359 .359 .359 Page 3 of 8 Air Feed Mylar Tape 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 Terminal Un-Insulated Terminal MWID OR MAX INSULATION DIAMETER BARREL BRUSH STRIP LENGTH STUD SIZE (REF) STUD SIZE (REF) BARREL STRIP LENGTH INSULATION FERRULE Figure 2 BRUSH Figure 1 Fully Insulated Male and Female Quick Disconnect STRIP LENGTH FEMALE QD MWID OR MAX INSULATION DIAMETER BRUSH MALE QD REF TAB SIZE Doc No. ATS-638851000 Revision: E WIRE STOP TAB SIZE Release Date: 12-23-04 Revision Date: 11-04-10 Figure 3 UNCONTROLLED COPY Page 4 of 8 Air Feed Mylar Tape Applicator CONDUCTOR CRIMP DIE 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 4). 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. 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 2 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. CRIMP SPECIFICATIONS Wire Size AWG mm² 16 14 12 10 1.30 2.00 3.30 5.25 “X” Dimension Conductor Crimp Mean Go No Go In mm In mm In mm .119 3.02 .116 2.95 .123 3.12 .119 3.02 .116 2.95 .123 3.12 .119 3.02 .116 2.95 .123 3.12 .119 3.02 .116 2.95 .123 3.12 Pull Force Minimum Lbs N 30.0 50.0 70.0 80.0 133.5 222.6 311.4 355.9
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-638851000 Revision: E Release Date: 12-23-04 Revision Date: 11-04-10 UNCONTROLLED COPY Page 5 of 8 Air Feed Mylar Tape Applicator PARTS LIST Mini-Mac Applicator 63885-1000 Item Order No Engineering No. Description Quantity Perishable Tooling 63885-1070 63885-1070 Tool Kit (All “Y” Items) REF 1 63465-0003 63465-0003 Conductor Punch 1Y 2 63464-0003 63464-0003 Conductor Anvil 1Y Other Components 3 63443-0021 63443-0021 Lower Tooling Key 1 4 63466-0912 63466-0912 Anvil Mount 1 5 63466-0913 63466-0913 Terminal Support 1 6 63466-0921 63466-0921 Terminal Stripping Blade 1 7 63600-1290 63600-1290 Washer 1 8 63890-0866 63890-0866 Collar-6.4mm Long 1 9 63890-0867 63890-0867 Collar-7.7mm Long 1 Frame 10 63801-3301 63801-3301 Air Feed Applicator Frame Head 1 11 63801-3281 63801-3281 Base 1 12 63801-5850 63801-5850 Track Assembly 1 13 63801-3390 63801-3390 Air Kit 1 Hardware 14 N/A N/A M3 by 12 Long SHCS 1** 15 N/A N/A M4 by 10 Long SHCS 2** 16 N/A N/A M4 by 16 Long SHCS 1** 17 N/A N/A M4 by 45 Long SHCS 1** 18 N/A N/A M8 by 30 Long BHCS 1** 19 N/A N/A 3mm by 6 Long Roll Pin 1** ** Available from an industrial supply company such as MSC (1-800-645-7270). Note: Crimp profiles used in 63885-1000 are equivalent to 19027-0088/ATP-C-130 (UL file number E32244). Doc No. ATS-638851000 Revision: E Release Date: 12-23-04 Revision Date: 11-04-10 UNCONTROLLED COPY Page 6 of 8 Air Feed Mylar Tape Applicator Assembly Drawing 10 8 1 7 10 9 18 6 15 (2) 5 13 12 4 2 14 11 16 19 Figure 5 17 3 Doc No. ATS-638851000 Revision: E Release Date: 12-23-04 Revision Date: 11-04-10 UNCONTROLLED COPY Page 7 of 8 Air Feed Mylar Tape 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. http://www.molex.com Doc No. ATS-638851000 Revision: E Release Date: 12-23-04 Revision Date: 11-04-10 UNCONTROLLED COPY Page 8 of 8