0638810200 - Molex Inc.

Mechanical Feed Metal Strip Applicator

Doc No. 63881-0200 Release Date: 12-15-04 UNCONTROLLED COPY Page 1 of 7

Revision: C Revision Date: 09-30-05

Mini-Mac Applicator

Application Tooling Specification

Mechanical Feed-Metal Strip

Order No. 63881-0200

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.250, .205, and .187 Tab FIQD 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 26 3 N/A N/A 7

Yellow 24 5 N/A N/A 10

Red 22 8 8 8 15

Red 20 13 10 13 19

Red 18 20 10 20 38

Blue 16 30 15 30 50

Blue 14 50 25 50 70

Yellow 12 70 35 70 110

Yellow 10 80 40 80 150

Red 8 90 45 N/A 225

Blue 6 100 50 N/A 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

Mechanical Feed Metal Strip Applicator

Doc No. 63881-0200 Release Date: 12-15-04 UNCONTROLLED COPY Page 2 of 7

Revision: C Revision Date: 09-30-05

Figure 1

Figure 2

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 Max. Strip Length

Terminal No. Terminal Eng. No. AWG mm² mm In. mm In.

19002-0030 BB-5269Z 14-16 2.00-1.30 3.94 .155 6.35 .250

19002-0033 BB-5273Z 14-16 2.00-1.30 3.94 .155 6.35 .250

19002-0041 BB-5287Z 14-16 2.00-1.30 3.94 .155 6.35 .250

19002-0061 BB-5289Z 14-16 2.00-1.30 3.94 .155 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.

Wire Size Insulation Diameter Max. Strip Length

Terminal No. Terminal Eng. No. AWG mm² mm In. mm In.

19002-0027 BB-5263Z 14-16 2.00-1.30 3.94 .155 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.

Mechanical Feed Metal Strip Applicator

Doc No. 63881-0200 Release Date: 12-15-04 UNCONTROLLED COPY Page 3 of 7

Revision: C Revision Date: 09-30-05

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.

CRIMP SPECIFICATIONS

Wire Size “X” Dimension Conductor Crimp Pull Force Min.

Mean Go No Go

AWG mm² In mm In mm In mm Lbs N

16 1.30 .116 2.95 .113 2.87 .120 3.05 30.0 133.5

14 2.00 .116 2.95 .113 2.87 .120 3.05 50.0 222.6

Cut-off Tab Max.

Terminal Series No. mm In.

19002-00** 0.38 .015

Pull Force should be measured with no influence from the insulation crimp. The above specifications are guidelines to an optimum

crimp.

“X” CRIMP

HEIGHT

CONDUCTOR

RIMP DIE USE SOFT METAL

SLUG METHOD

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.

CRIMP PROFILE

Figure 3

Mechanical Feed Metal Strip Applicator

Doc No. 63881-0200 Release Date: 12-15-04 UNCONTROLLED COPY Page 4 of 7

Revision: C Revision Date: 09-30-05

MALE QD

TAPE OR

MOLDED REF

Fully Insulated

Female

Quick Disconnect

TAB

SIZE CUT-OFF

TAB

TERMINAL

STRIP

MWID OR MAX

INSULATION

DIAMETER

STRIP

LENGTH

WIRE STOP

BRUSH

TAB SIZE

Figure 4

FEMALE QD

DEFINITION OF TERMS

The following illustrations are a generic terminal representation and not an exact image of any terminal listed in the scope.

Mechanical Feed Metal Strip Applicator

Doc No. 63881-0200 Release Date: 12-15-04 UNCONTROLLED COPY Page 5 of 7

Revision: C Revision Date: 09-30-05

PARTS LIST

Mini-Mac Applicator 63881-0200

Item Order No Engineering No. Description Quantity

Perishable Tooling

63881-0270 63881-0270 Tool Kit (All “Y” Items) REF

1 63465-0008 63465-0008 Conductor Punch 1 Y

2 63464-0008 63464-0008 Conductor Anvil 1 Y

3 63463-0004 63463-0004 Insulation Punch 1 Y

4 63462-0005 63462-0005 Insulation Anvil 1 Y

12 63466-0201 63466-0201 Cut-off Plunger Rear 1 Y

14 63466-0301 63466-0301 Rear Plunger Retainer 1 Y

16 63466-0002 63466-0002 Cut-Off Blade 1 Y

Other Components (REF 10250)

22 63466-0403 63466-0403 Cut-off Plunger Striker (Rear) 1

24 63466-0101 63466-0101 Scrap Chute 1

25 63700-0539 63700-0539 Cut-Off Plunger Spring 1

33 63443-0021 63443-0021 Lower Tooling Key 1

✴ 35 63466-1054 63466-1054 Spacer 1

✴ 36 63466-1075 63466-1075 Spacer 1

42 63466-0921 63466-0921 Terminal Stripping Blade 1

51 63600-1290 63600-1290 Washer 1

52 63890-0866 63890-0866 Collar-6.40 Lg. 1

53 63890-0867 63890-0867 Collar-7.70 Lg. 1

72 63801-4510 63801-4510 Terminal Guide Front 1

96 63600-0110 63600-0110 M4 Washer, 3mm Thick 1

Frame

81 63801-3201 63801-3201 Mechanical Feed Applicator Frame Head REF

82 63801-3281 63801-3281 Base REF

83 63801-4550 63801-4550 Track Assembly REF

Hardware

91 N/A N/A M4 by 10 Lg SHCS 2**

92 N/A N/A M4 by 12 Lg SHCS 1**

93 N/A N/A M4 by 20 Lg SHCS 4**

94 N/A N/A M4 by 40 Lg. SHCS 1**

95 N/A N/A M4 by 45 Lg. SHCS 1**

97 N/A N/A M8 by 30 Lg. BHCS 1**

98 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 63881-0200 are equivalent to, 19292-0003/MMZ-BB-522, 19807-2001, 19287-

0063/ASP-BB-5221087, and 19287-0068/ASP-BB-522250 (UL file number E79133).

Mechanical Feed Metal Strip Applicator

Doc No. 63881-0200 Release Date: 12-15-04 UNCONTROLLED COPY Page 6 of 7

Revision: C Revision Date: 09-30-05

(2)

Figure 5

(2)

✴

Assembly Drawing

✴ See spacer assembly notes on page 2.

Mechanical Feed Metal Strip Applicator

Doc No. 63881-0200 Release Date: 12-15-04 UNCONTROLLED COPY Page 7 of 7

Revision: C Revision Date: 09-30-05

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