Mechanical Feed Metal Strip Applicator
Mini-Mac Applicator
Application Tooling Specification
Mechanical Feed-Metal Strip
Order No. 63881-2100
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 Metal strip fed low profile FIQD Terminals 10-12 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
3
5
8
13
20
30
50
70
80
90
100
*UL – 486 C
N/A
N/A
8
10
10
15
25
35
40
45
50
*UL – 310
N/A
N/A
8
13
20
30
50
70
80
N/A
N/A
*Military
Class 2
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. 63881-2100
Revision: C
Release Date: 12-15-04
Revision Date: 09-30-05
UNCONTROLLED COPY
Page 1 of 6
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.
19606-0004
Terminal Eng. No.
19606-0004
Wire Size
AWG
mm²
10-12 3.30-5.00
Insulation Diameter Max.
mm
In.
5.84
.230
Strip Length
mm
In.
.344 8.73
DEFINITION OF TERMS
The following illustrations are a generic terminal representation and not an exact image of any terminal listed in the scope.
Fully Insulated
Female
Quick Disconnect
TERMINAL
STRIP
MALE QD
TAPE OR
MOLDED REF
MWID OR MAX
INSULATION
DIAMETER
STRIP
LENGTH
BRUSH
FEMALE QD
WIRE STOP
TAB
SIZE
TAB SIZE
Figure 1
CUT-OFF
TAB
Doc No. 63881-2100
Revision: C
Release Date: 12-15-04
Revision Date: 09-30-05
UNCONTROLLED COPY
Page 2 of 6
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 2).
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
E1
CRIMP PROFILE
“X” CRIMP
HEIGHT
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
CRIMP SPECIFICATIONS
“X” Dimension Conductor Crimp
Pull Force Min.
Mean
Go
No Go
AWG mm²
Lbs
N
In mm In mm In mm
10
5.25 .114 2.90 .111 2.82 .117 2.97 80.0 355.9
12
3.30 .114 2.90 .111 2.82 .117 2.97 70.0 311.4
Wire Size
Terminal Series No.
19606-0004
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. 63881-2100
Revision: C
Release Date: 12-15-04
Revision Date: 09-30-05
UNCONTROLLED COPY
Page 3 of 6
Mechanical Feed Metal Strip Applicator
PARTS LIST
Item
Mini-Mac Applicator 63881-2100
Order No Engineering No.
Description
Quantity
Perishable Tooling
63881-2170
63881-2170
Tool Kit (All “Y” Items)
REF
63465-0023
63465-0023
Conductor Punch
1Y
63464-0022
63464-0022
Conductor Anvil
1Y
63463-0022
63463-0022
Insulation Punch
1Y
63462-0024
63462-0024
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. 12150)
63466-0404
63466-0404
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
63466-1040
63466-1089
Spacer
1
63466-1089
63466-1040
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 45 Lg. SHCS
1**
N/A
N/A
M4 by 50Lg. 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
Note:
Crimp profiles used in 63881-2100 are equivalent to 19031-0041and 19031-0042.
Doc No. 63881-2100
Revision: C
Release Date: 12-15-04
Revision Date: 09-30-05
UNCONTROLLED COPY
Page 4 of 6
Mechanical Feed Metal Strip Applicator
Assembly Drawing
81
52
1
3
53
22
93 (2)
51
97
81
93 (2)
72
12
83
14
35
4
94
2
16
25
42
36
96
91 (2)
24
92
98
82
95
33
Figure 3
Doc No. 63881-2100
Revision: C
Release Date: 12-15-04
Revision Date: 09-30-05
UNCONTROLLED COPY
Page 5 of 6
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