Rear Feed Applicator for Flag Krimptite™ Quick Disconnect Female Terminals Rear Feed Mini-Mac Applicator Application Tooling Specification Sheet Order No. 63802-7600 FEATURES Quick set-up time; plus the crimp height, track and feed adjustments can be preset in applicator Conductor and insulation rings allow quick adjustment for conductor and insulation diameter change Applicator designed to industry standard mounting and shut height 135.80mm (5.346") Directly adapts to most automatic wire processing machines SCOPE Products: Flag Krimptite™ Quick Disconnect Female Terminals, 14-16 AWG. Terminal Order No. 19008-0028 19008-0029 19008-0031 Terminal Eng. No. BBZ-1148 BBZ-1148-032 BBZ-1159 Wire Size AWG mm² 16-14 1.30-2.00 16-14 1.30-2.00 16-14 1.30-2.00 DEFINITION OF TERMS Tab Size mm In. 4.75 by 0.51 .187 by .020 4.75 by 0.81 .187 by .032 6.35 by 0.51 .250 by .020 Insulation Diameter mm In. N/A N/A N/A N/A N/A N/A Strip Length mm In. 7.94 .313 7.94 .313 7.94 .313 MAXIMUM INSULATION DIAMETER STRIP LENGTH WIRE CONDUCTOR CRIMP CUT-OFF TAB The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the scope. Doc No: ATS-638027600 Revision: B Release Date: 08-20-09 Revision Date: 01-13-11 UNCONTROLLED COPY Page 1 of 5 Rear Feed Applicator for Flag Krimptite™ Quick Disconnect Female Terminals CRIMP SPECIFICATIONS Terminal Order No. Terminal Eng. No. 19008-0028 19008-0029 19008-0031 Wire Size AWG 14 16 14 16 14 16 Conductor Crimp Height Mean Go No Go mm In. mm In. mm In. mm² 2.00 BBZ-1148 1.55 .061 1.42 .056 1.68 1.30 2.00 BBZ-1148-032 1.55 .061 1.42 .056 1.68 1.30 2.00 BBZ-1159 1.55 .061 1.42 .056 1.68 1.30 Seam Seam shall not be open and no wire allowed out of the crimping .066 .066 .066 Pull Force Minimum N Lb. 222.4 50.0 133.4 30.0 222.4 50.0 133.4 30.0 222.4 50.0 133.4 30.0 Pull Force should be measured with no influence from the insulation crimp. The above specifications are guidelines to an optimum crimp. Tool Calibration CONDUCTOR CRIMP DIE To recalibrate this applicator, make sure the power is completely shut off on the press. 1. The Applicator must be properly installed in the press. 2. Crimping dies must be properly installed in the Applicator. 3. The recommended method of measuring the crimp height of the conductor dies is the soft metal slug method. See Figure 1. 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. Figure 1 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. Molex does not sell gauge pins contact your local industrial supplier. Doc No: ATS-638027600 Revision: B Release Date: 08-20-09 Revision Date: 01-13-11 UNCONTROLLED COPY Page 2 of 5 Rear Feed Applicator for Flag Krimptite™ Quick Disconnect Female Terminals PARTS LIST Rear Feed Applicator 63802-7600 Item Order No Engineering No. Description Quantity Perishable Tooling 63802-7670 63802-7670 Tool Kit (All “Y” Items) REF 1 63801-5519 63801-5519 Conductor Punch (Upper Die) 1Y 2 19230-0086 24854-23 Conductor Anvil (Indenter Die) 1Y 3 19229-0120 23650-43 Cutter Housing 1Y 4 19229-0121 23650-44 Cutter Plunger 1Y Other Components 5 19229-0095 23650-45 Cutter Back Plate 1 6 19230-0038 24854-08 Feed Finger 1 7 19230-0101 24854-09 Guide Rail 1 8 19230-0106 24854-25P Guide and Hold Down 1 9 19250-0038 24855-23 Compression Spring 1 10 63801-7160 63801-7160 Terminal Drag Assembly 1 11 63801-7701 63801-7701 Cutter Striker 1 12 63803-5134 63803-5134 Conductor Bushing 1 Frame 13 19230-0084 24854-05 Slide (Terminal Track) 1 14 63801-2600 63801-2600 Rear Feed Frame 1 15 63801-2603 63801-2603 Base 1 Hardware 16 N/A N/A M3 by 10 Long SHCS 2** 17 N/A N/A M4 by 8 Long SHCS 6** 18 N/A N/A M4 by 8 Long BHCS 2** 19 N/A N/A M4 by 12 Long SHCS 2** 20 N/A N/A M6 by 10 Long BHCS 6** 21 N/A N/A M8 by 20 Long BHCS 1** 22 N/A N/A M8 Flat Hard Washer 1** 23 N/A N/A 6mm by 10 Long Dowel Pin 4** ** Available from an industrial supply company such as MSC (1-800-645-7270). Doc No: ATS-638027600 Revision: B Release Date: 08-20-09 Revision Date: 01-13-11 UNCONTROLLED COPY Page 3 of 5 Rear Feed Applicator for Flag Krimptite™ Quick Disconnect Female Terminals Assembly Drawing 19 6 15 19 (2) 17 11 (2) 12 1 7 14 22 REF 21 17 (2) 14 10 8 15 13 (2) 4 20 9 23 (2) 18 (2) (2) 23 17 (2) 20 (4) 2 3 Figure 2 5 16 Doc No: ATS-638027600 Revision: B (2) Release Date: 08-20-09 Revision Date: 01-13-11 UNCONTROLLED COPY Page 4 of 5 Rear Feed Applicator for Flag Krimptite™ Quick Disconnect Female Terminals NOTES 1. Molex recommends an extra perishable tooling kit be maintained at your facility. 2. Verify tooling alignment by manually cycling the press and 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 Manual. 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. Wear Safety Glasses At All Times. http://www.molex.com Doc No: ATS-638027600 Revision: B Release Date: 08-20-09 Revision Date: 01-13-11 UNCONTROLLED COPY Page 5 of 5