Mechanical Feed Metal Strip Applicator
Mini-Mac Applicator
Application Tooling Specification
Mechanical Feed-Metal Strip
Order No. 63881-0200
FEATURES
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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
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. 63881-0200
Revision: C
Release Date: 12-15-04
Revision Date: 09-30-05
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.
Terminal No.
19002-0030
19002-0033
19002-0041
19002-0061
Terminal Eng. No.
BB-5269Z
BB-5273Z
BB-5287Z
BB-5289Z
Wire Size
AWG
mm²
14-16 2.00-1.30
14-16 2.00-1.30
14-16 2.00-1.30
14-16 2.00-1.30
Insulation Diameter Max.
mm
In.
3.94
.155
3.94
.155
3.94
.155
3.94
.155
Strip Length
mm
In.
6.35 .250
6.35 .250
6.35 .250
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.
36
35
Figure 1
Wire Size
Insulation Diameter Max. Strip Length
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.
Terminal No.
Terminal Eng. No.
35
36
Figure 2
Doc No. 63881-0200
Revision: C
Release Date: 12-15-04
Revision Date: 09-30-05
UNCONTROLLED COPY
Page 2 of 7
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 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.
CONDUCTOR
CRIMP DIE
E2
USE SOFT METAL
SLUG METHOD
“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 3
CRIMP SPECIFICATIONS
“X” Dimension Conductor Crimp
Pull Force Min.
Mean
Go
No Go
AWG mm²
Lbs
N
In mm In mm In mm
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
Wire Size
Terminal Series No.
19002-00**
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. 63881-0200
Revision: C
Release Date: 12-15-04
Revision Date: 09-30-05
UNCONTROLLED COPY
Page 3 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
STRIP
LENGTH
Fully Insulated
Female
Quick Disconnect
TERMINAL
STRIP
MALE QD
TAPE OR
MOLDED REF
BRUSH
FEMALE QD
WIRE STOP
TAB
SIZE
TAB SIZE
Figure 4
CUT-OFF
TAB
Doc No. 63881-0200
Revision: C
Release Date: 12-15-04
Revision Date: 09-30-05
UNCONTROLLED COPY
Page 4 of 7
Mechanical Feed Metal Strip Applicator
PARTS LIST
Item
Mini-Mac Applicator 63881-0200
Order No
Engineering No.
Description
Quantity
Perishable Tooling
63881-0270 63881-0270
Tool Kit (All “Y” Items)
REF
63465-0008
63465-0008
Conductor Punch
1Y
63464-0008
63464-0008
Conductor Anvil
1Y
63463-0004
63463-0004
Insulation Punch
1Y
63462-0005
63462-0005
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 10250)
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
Spacer
1
63466-1075
63466-1075
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 40 Lg. SHCS
1**
N/A
N/A
M4 by 45 Lg. 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).
✴
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
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).
Doc No. 63881-0200
Revision: C
Release Date: 12-15-04
Revision Date: 09-30-05
UNCONTROLLED COPY
Page 5 of 7
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