0638858100

Air Feed Mylar Tape Applicator Mini-Mac Applicator Application Tooling Specification Air Feed-Mylar Tape Part No. 63885-8100 FEATURES Œ Œ Œ Œ 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/Versakrimp Ring, Spade, Rectangular, Hook Tongue Terminals, And Butt Splices 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 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. 63885-8100 Revision: A Release Date: 12-01-05 Revision Date: 12-01-05 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 No. Terminal Eng. No. Wire Size AWG mm² 19033-0006 B-179T 14-16 2.00-1.30 19033-0008 B-189T 14-16 2.00-1.30 19044-0015 B-118-10T 14-16 2.00-1.30 19044-0017 B-123-02T 14-16 2.00-1.30 19044-0018 B-125-56T 14-16 2.00-1.30 19044-0029 B-137-04T 14-16 2.00-1.30 19044-0034 B-139-04T 14-16 2.00-1.30 19044-0036 B-139-06T 14-16 2.00-1.30 19044-0038 B-139-08T 14-16 2.00-1.30 19044-0151 B-123-04T 14-16 2.00-1.30 19044-0153 B-123-06T 14-16 2.00-1.30 19044-0155 B-123-08T 14-16 2.00-1.30 19044-0157 B-125-10T 14-16 2.00-1.30 19044-0159 B-125-14T 14-16 2.00-1.30 19044-0175 B-137-06T 14-16 2.00-1.30 19044-0176 B-137-08T 14-16 2.00-1.30 19044-0177 B-137-10T 14-16 2.00-1.30 19044-0178 B-139-10T 14-16 2.00-1.30 19056-0054 B-318-10T 14-16 2.00-1.30 19056-0056 B-318-14T 14-16 2.00-1.30 19056-0058 B-318-38T 14-16 2.00-1.30 19056-0060 B-318-56T 14-16 2.00-1.30 19056-0062 B-323-02T 14-16 2.00-1.30 19056-0064 B-323-04T 14-16 2.00-1.30 19056-0067 B-323-06T 14-16 2.00-1.30 19056-0069 B-323-08T 14-16 2.00-1.30 19056-0071 B-325-10T 14-16 2.00-1.30 19056-0074 B-325-14T 14-16 2.00-1.30 19056-0076 B-325-56T 14-16 2.00-1.30 19079-0009 B-1006-MST 14-16 2.00-1.30 19086-0067 B-108-06T 14-16 2.00-1.30 19086-0119 B-108-04T 14-16 2.00-1.30 19086-0120 B-108-08T 14-16 2.00-1.30 19086-0121 B-109-06T 14-16 2.00-1.30 19086-0122 B-109-08T 14-16 2.00-1.30 19086-0123 B-109-10T 14-16 2.00-1.30 19086-0124 B-113-04T 14-16 2.00-1.30 19086-0125 B-113-06T 14-16 2.00-1.30 19086-0126 B-113-08T 14-16 2.00-1.30 19086-0127 B-182-06T 14-16 2.00-1.30 19086-0128 B-182-08T 14-16 2.00-1.30 19086-0129 B-182-10T 14-16 2.00-1.30 19086-0130 B-185-06T 14-16 2.00-1.30 19086-0131 B-185-08T 14-16 2.00-1.30 19086-0132 B-185-10T 14-16 2.00-1.30 19086-0133 B-188-04T 14-16 2.00-1.30 19086-0134 B-188-06T 14-16 2.00-1.30 19086-0135 B-188-08T 14-16 2.00-1.30 19086-0136 B-188-10T 14-16 2.00-1.30 19088-0062 B-308-04T 14-16 2.00-1.30 19088-0063 B-308-06T 14-16 2.00-1.30 19088-0064 B-309-06T 14-16 2.00-1.30 19088-0065 B-309-08T 14-16 2.00-1.30 19088-0066 B-309-10T 14-16 2.00-1.30 19088-0067 B-313-04T 14-16 2.00-1.30 Doc No. 63885-8100 Revision: A Insulation Strip Length Diameter Max. mm In. mm In. N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 Release Date: 12-01-05 Revision Date: 12-01-05 Terminal No. Terminal Eng. No. 19088-0068 19088-0069 19117-0049 19117-0051 19117-0067 19117-0082 19117-0085 19117-0088 19117-0089 19117-0090 19117-0091 19117-0092 19117-0093 19117-0094 19117-0095 19123-0052 19123-0053 19123-0054 19123-0055 19128-0015 19128-0017 19128-0018 19128-0019 19128-0020 19128-0022 19128-0024 19140-0092 19140-0094 19140-0110 19140-0111 19140-0129 19140-0130 19140-0131 19140-0132 19140-0133 19140-0134 19140-0135 19140-0139 19140-0140 19140-0141 19140-0142 19140-0143 19140-0144 19140-0145 19146-0020 19146-0065 19146-0066 19146-0067 19146-0068 19146-0069 19170-0008 19170-0010 19170-0013 19172-0008 19172-0010 B-313-06T B-313-08T B-116-06T B-116-08T B-183-10T B-116-04T B-116-10T B-180-06T B-180-08T B-180-10T B-183-06T B-183-08T B-186-04T B-186-06T B-186-08T B-316-04T B-316-06T B-316-08T B-316-10T B-1471-04T B-1471-06T B-1491-06T B-1491-08T B-1491-10T B-1781-06T B-1781-08T B-127-08T B-127-10T B-184-10T B-187-06T B-107-04T B-107-06T B-107-08T B-124-04T B-124-06T B-124-08T B-127-06T B-181-06T B-181-08T B-181-10T B-184-06T B-184-08T B-187-04T B-187-08T B-324-06T B-307-04T B-307-06T B-307-08T B-324-04T B-324-08T B-119-06T B-119-08T B-119-10T B-319-06T B-319-08T Wire Size AWG 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 UNCONTROLLED COPY 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 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 Insulation Strip Length Diameter Max. mm In. mm In. N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 Page 2 of 8 Air Feed Mylar Tape Applicator Terminal No. Terminal Eng. No. 19172-0012 19189-0010 19022-0026 19056-0103 19056-0105 19056-0108 19056-0111 19056-0113 19056-0115 19056-0117 19056-0119 19088-0070 19088-0071 19088-0072 19088-0073 19088-0074 19088-0075 19088-0076 19088-0077 19088-0078 19088-0079 19123-0059 19123-0060 19123-0061 19123-0062 19123-0063 B-319-10T B-131T MCT-1T B-337-04T B-337-06T B-337-08T B-337-10T B-339-04T B-339-06T B-339-08T B-339-10T B-382-06T B-382-08T B-382-10T B-385-06T B-385-08T B-385-10T B-388-04T B-388-06T B-388-08T B-388-10T B-380-06T B-380-08T B-380-10T B-383-06T B-383-08T Doc No. 63885-8100 Revision: A Wire Size AWG 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 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 Insulation Strip Length Diameter Max. mm In. mm In. N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 Release Date: 12-01-05 Revision Date: 12-01-05 Terminal No. Terminal Eng. No. 19123-0064 19123-0065 19123-0066 19123-0067 19146-0070 19146-0071 19146-0072 19146-0076 19146-0078 19146-0079 19146-0080 19146-0081 19146-0082 19146-0083 19146-0084 19146-0085 19189-0013 19203-0043 19203-0045 19203-0046 19203-0048 19203-0050 19203-0052 19215-0017 19215-0115 B-383-10T B-386-04T B-386-06T B-386-08T B-327-06T B-327-08T B-327-10T B-381-06T B-381-08T B-381-10T B-384-06T B-384-08T B-384-10T B-387-04T B-387-06T B-387-08T B-L131T B-S-123-06T B-S-125-14T B-S-125-56T B-S-137-06T B-S-137-08T B-S-137-10T BA-331T BS-331T Wire Size AWG 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 14-16 UNCONTROLLED COPY 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 Insulation Strip Length Diameter Max. mm In. mm In. N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 N/A N/A 7.14 .281 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. Insulated Terminal MWID OR MAX INSULATION DIAMETER Un-Insulated Terminal BARREL BRUSH MWID OR MAX INSULATION DIAMETER STRIP LENGTH STUD SIZE (REF) STUD SIZE (REF) BARREL STRIP LENGTH INSULATION FERRULE BRUSH Figure 1 Figure 2 STRIP LENGTH Fully Insulated Male and Female Quick Disconnect FEMALE QD MWID OR MAX INSULATION DIAMETER BRUSH MALE QD REF TAB SIZE Doc No. 63885-8100 Revision: A Release Date: 12-01-05 Revision Date: 12-01-05 WIRE STOP TAB SIZE Figure 3 UNCONTROLLED COPY Page 4 of 8 Air Feed Mylar Tape 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 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. 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 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. 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 .085 2.16 .082 2.08 .092 2.33 .085 2.16 .082 2.08 .092 2.33 Pull Force Min. Lbs N 30.0 50.0 133.5 222.6 Pull Force should be measured with no influence from the insulation crimp. The above specifications are guidelines to an optimum crimp. Doc No. 63885-8100 Revision: A Release Date: 12-01-05 Revision Date: 12-01-05 UNCONTROLLED COPY Page 5 of 8 Air Feed Mylar Tape Applicator PARTS LIST Mini-Mac Applicator 63885-8100 Item Order No Engineering No. Description Quantity Perishable Tooling 63885-8170 63885-8170 Tool Kit (All “Y” Items) REF 1 63465-0036 63465-0036 Conductor Punch 1Y 2 63464-0037 63464-0037 Conductor Anvil 1Y Other Components (Ref. 50050) 31 63466-0912 63466-0912 Anvil Mount 1 32 63466-0913 63466-0913 Terminal Support 1 33 63443-0021 63443-0021 Lower Tooling Key 1 42 63466-0921 63466-0921 Terminal Stripping Blade 1 51 63600-1290 63600-1290 Washer 1 52 63890-0866 63890-0866 Collar-6.35 Lg. 1 53 63890-0867 63890-0867 Collar-7.7 Lg. 1 Frame 81 63801-3301 63801-3301 Air Feed Applicator Frame Head REF 82 63801-3281 63801-3281 Base REF 83 63801-5850 63801-5850 Track Assembly REF 84 63801-3390 63801-3390 Air Kit REF Hardware 91 N/A N/A M3 by 12 Lg SHCS 1** 92 N/A N/A M4 by 10 Lg SHCS 2** 93 N/A N/A M4 by 16 Lg. SHCS 1** 94 N/A N/A M4 by 45 Lg. SHCS 1** 95 N/A N/A M8 by 30 Lg. BHCS 1** 96 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 63885-8100 are equivalent to 19027-0055/ATP-B-120 (UL file number E32244). Doc No. 63885-8100 Revision: A Release Date: 12-01-05 Revision Date: 12-01-05 UNCONTROLLED COPY Page 6 of 8 Air Feed Mylar Tape Applicator Assembly Drawing 81 1 52 51 81 53 95 42 92 (2) 32 84 83 31 2 91 93 82 96 94 33 Figure 5 Doc No. 63885-8100 Revision: A Release Date: 12-01-05 Revision Date: 12-01-05 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 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. 63885-8100 Revision: A Release Date: 12-01-05 Revision Date: 12-01-05 UNCONTROLLED COPY Page 8 of 8