Air Feed Mylar Tape Applicator
Doc No. 63885-1900 Release Date: 12-08-04 UNCONTROLLED COPY Page 1 of 6
Revision: B Revision Date: 10-03-05
Mini-Mac Applicator
Application Tooling Specification
Air Feed-Mylar Tape
Order No. 63885-1900
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 Male FIQD Terminals14-22 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
Air Feed Mylar Tape Applicator
Doc No. 63885-1900 Release Date: 12-08-04 UNCONTROLLED COPY Page 2 of 6
Revision: B Revision Date: 10-03-05
Fully Insulated
Male and Female
Quick Disconnect
TAB
SIZE
FEMALE QD
MWID OR
MAX INSULATION
DIAMETER
STRIP LENGTH
MALE QD
REF
WIRE STOP
BRUSH
TAB
SIZE
Figure 3
MWID OR MAX
INSULATION
DIAMETER
STRIP
LENGTH
STUD SIZE
(REF)
Insulated
Terminal
Figure 1
BARREL
BRUSH
INSULATION
FERRULE
MWID OR MAX
INSULATION
DIAMETER
STRIP
LENGTH
STUD SIZE
(REF)
Un-
Insulated
Terminal
Figure 2
BARREL
BRUSH
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.
19001-0002 AA-5260T 22-18 0.35-0.80 3.56 .140 8.74 .344
19001-0005 AA-5266T 22-18 0.35-0.80 3.56 .140 8.74 .344
19001-0007 BB-5262T 16-14 1.30-2.00 4.32 .170 8.74 .344
19001-0009 BB-5268T 16-14 1.30-2.00 4.32 .170 8.74 .344
DEFINITION OF TERMS
The following illustrations are a generic terminal representation and not an exact image of any terminal listed in the scope.
Air Feed Mylar Tape Applicator
Doc No. 63885-1900 Release Date: 12-08-04 UNCONTROLLED COPY Page 3 of 6
Revision: B Revision Date: 10-03-05
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 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.
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
22 0.35 .105 2.67 .102 2.59 .109 2.77 8 35.6
20 0.50 .105 2.67 .102 2.59 .109 2.77 13 57.8
18 0.80 .105 2.67 .102 2.59 .109 2.77 20 90.0
16 1.30 .105 2.67 .102 2.59 .109 2.77 30 133.5
14 2.00 .105 2.67 .102 2.59 .109 2.77 50 222.4
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
C
RIMP DIE USE SOFT METAL
SLUG METHOD
E1
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
E2
Figure 2
Air Feed Mylar Tape Applicator
Doc No. 63885-1900 Release Date: 12-08-04 UNCONTROLLED COPY Page 4 of 6
Revision: B Revision Date: 10-03-05
PARTS LIST
Mini-Mac Applicator 63885-1900
Item Order No Engineering No. Description Quantity
Perishable Tooling
63885-1970 63885-1970 Tool Kit (All “Y” Items) REF
1 63465-0021 63465-0021 Conductor Punch 1 Y
2 63464-0020 63464-0020 Conductor Anvil 1 Y
3 63463-0020 63463-0020 Insulation Punch 1 Y
4 63462-0022 63462-0022 Insulation Anvil 1 Y
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-6.4mm Lg. 1
53 63890-0867 63890-0867 Collar-7.7mm 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 63885-1900 are equivalent to 19032-0200/MMT-AB-513, and 19288-0070/ATP-AB-513
(UL file number E79133).
Air Feed Mylar Tape Applicator
Doc No. 63885-1900 Release Date: 12-08-04 UNCONTROLLED COPY Page 5 of 6
Revision: B Revision Date: 10-03-05
Assembly Drawing
53
1
83
81
93
33
95
91
42
51
(2)
3
31
92
96
2
Figure 5
94
32
4
52
84
81
82
Air Feed Mylar Tape Applicator
Doc No. 63885-1900 Release Date: 12-08-04 UNCONTROLLED COPY Page 6 of 6
Revision: B Revision Date: 10-03-05
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
