Air Feed Mylar Tape Applicator
Mini-Mac Applicator
Application Tooling Specification
Air Feed-Mylar Tape
Order No. 63885-4200
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: Insulkrimp Male and Female Standard and Expanded Flare 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
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. 63885-4200
Revision: B
Release Date: 12-08-04
Revision Date: 10-04-05
UNCONTROLLED COPY
Page 1 of 7
Air Feed Mylar Tape 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.
Note:
To process the following terminals, use both conductor and insulation tooling.
Terminal No.
19003-0042
19003-0052
19003-0058
19003-0077
19003-0078
19003-0080
19003-0133
19003-0136
19023-0054
19023-0063
Terminal Eng. No.
BB-2206T
BB-2207T
BB-2208T
BB-2215T
BB-2216T
BB-2206VBT
BB-2207VT
BB-2208VT
19023-0054
19023-0063
Wire Size
AWG
mm²
16-14 1.30-2.00
16-14 1.30-2.00
16-14 1.30-2.00
16-14 1.30-2.00
16-14 1.30-2.00
16-14 1.30-2.00
16-14 1.30-2.00
16-14 1.30-2.00
16-14 1.30-2.00
16-14 1.30-2.00
Insulation Diameter Max.
mm
In.
4.06
.160
4.06
.160
4.06
.160
4.06
.160
4.06
.160
4.06
.160
4.06
.160
4.06
.160
4.06
.160
4.06
.160
Strip Length
mm
In.
6.35 .250
6.35 .250
6.35 .250
6.35 .250
6.35 .250
6.35 .250
6.35 .250
6.35 .250
6.35 .250
6.35 .250
*Note:
To process the following terminals, use conductor tooling only. Insulation tooling is NOT intended for “expanded flare”
terminals. Remove the insulation punch (Item #3), anvil (Item #4), and collar (Item #53) for crimping expanded flare
products. (See parts list and assembly drawing)
Terminal No.
✴
✴
✴
Terminal Eng. No.
BB-2206XT
BB-2207XT
BB-2208XT
19003-0049
19003-0055
19003-0061
Wire Size
AWG
mm²
16-14 1.30-2.00
16-14 1.30-2.00
16-14 1.30-2.00
Insulation Diameter Max.
mm
In.
6.60
.260
6.60
.260
6.60
.260
Strip Length
mm
In.
6.35 .250
6.35 .250
6.35 .250
Doc No. 63885-4200
Revision: B
Release Date: 12-08-04
Revision Date: 10-04-05
UNCONTROLLED COPY
Page 2 of 7
Air Feed Mylar Tape 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
BARREL
MWID OR MAX
INSULATION
DIAMETER
Insulated
Terminal
Un-Insulated
Terminal
STRIP
LENGTH
STUD SIZE
(REF)
STRIP
LENGTH
INSULATION
FERRULE
BRUSH
STUD SIZE
(REF)
BARREL
Figure 1
BRUSH
Figure 2
Fully Insulated
Male and Female
Quick Disconnect
STRIP LENGTH
FEMALE QD
MWID OR
MAX INSULATION
DIAMETER
BRUSH
MALE QD
REF
TAB
SIZE
WIRE STOP
TAB
SIZE
Figure 3
Doc No. 63885-4200
Revision: B
Release Date: 12-08-04
Revision Date: 10-04-05
UNCONTROLLED COPY
Page 3 of 7
Air Feed Mylar Tape 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 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.
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 2
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
AWG
16
14
mm²
1.30
2.00
“X” Dimension Conductor Crimp
Mean
Go
No Go
In mm
In mm
In mm
.098 2.45 .095 2.41 .103 2.62
.098 2.45 .095 2.41 .103 2.62
Pull Force Min.
Lbs
30
50
N
133.5
222.4
Pull Force should be measured with no influence from the insulation crimp. The above specifications are guidelines to an optimum
crimp.
Doc No. 63885-4200
Revision: B
Release Date: 12-08-04
Revision Date: 10-04-05
UNCONTROLLED COPY
Page 4 of 7
Air Feed Mylar Tape Applicator
PARTS LIST
Mini-Mac Applicator 63885-4200
Item Order No Engineering No.
Description
Quantity
Perishable Tooling
63885-4270
63885-4270
Tool Kit (All “Y” Items)
REF
1
63465-0004
63465-0004
Conductor Punch
1Y
2
63464-0004
63464-0004
Conductor Anvil
1Y
3
63463-0007
63463-0007
Insulation Punch
1Y
4
63462-0009
63462-0009
Insulation Anvil
1Y
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:
Insulation tooling is NOT intended for “expanded flare” terminals. Remove the insulation punch (Item #3), anvil
(Item #4), and collar (Item #53) for crimping expanded flare products. (See product list)
Note:
Crimp profiles used in 63885-4200 are equivalent to 19032-0220/MMT-BB-275 and 19288-0104/ATP-BB-275
(UL file number E79133).
Doc No. 63885-4200
Revision: B
Release Date: 12-08-04
Revision Date: 10-04-05
UNCONTROLLED COPY
Page 5 of 7
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