Air Feed Mylar Tape Applicator
Mini-Mac Applicator
Air Feed- Mylar Tape
Application Tooling
Specification Sheet
Order No. 63885-7000
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™ Style, Male and Female, Fully Insulated Quick Disconnect, 18-22 AWG, Mylar Tap
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
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.
Doc No. ATS-638857000
Revision: D
Release Date: 12-08-04
Revision Date: 05-24-12
UNCONTROLLED COPY
Page 1 of 6
Air Feed Mylar Tape Applicator
Note:
To process the following terminals, use both conductor and insulation tooling
.
Terminal No.
19003-0003
19003-0007
19003-0013
19003-0020
19003-0026
19003-0032
19003-0074
19003-0075
19003-0127
19003-0130
19023-0051
19023-0060
19276-0003
Terminal Eng. No.
AA-2201T
AA-2201VNT
AA-2202T
AA-2203T
AA-2204T
AA-2205T
AA-2213T
AA-2214T
AA-2202VT
AA-2203VT
19023-0051
19023-0060
AA-2201T-LIF
Wire Size
AWG
mm²
22-18 0.35-0.80
22-18 0.35-0.80
22-18 0.35-0.80
22-18 0.35-0.80
22-18 0.35-0.80
22-18 0.35-0.80
22-18 0.35-0.80
22-18 0.35-0.80
22-18 0.35-0.80
22-18 0.35-0.80
22-18 0.35-0.80
22-18 0.35-0.80
22-18 0.35-0.80
Insulation Diameter Maximum
mm
In.
3.43
.135
3.43
.135
3.43
.135
3.43
.135
3.43
.135
3.43
.135
3.43
.135
3.43
.135
3.43
.135
3.43
.135
3.43
.135
3.43
.135
3.43
.135
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
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 #10) for
crimping expanded flare products. (See parts list and assembly drawing).
Terminal No.
Terminal Eng. No.
AA-2201XT
AA-2202XT
AA-2203XT
AA-2204XT
AA-2205XT
Wire Size
AWG
mm²
22-18 0.35-0.80
22-18
22-18
22-18
22-18
0.35-0.80
0.35-0.80
0.35-0.80
0.35-0.80
Insulation Diameter Maximum.
mm
In.
5.84
.230
5.84
5.84
5.84
5.84
.230
.230
.230
.230
Strip Length
mm
In.
6.35 .250
6.35
6.35
6.35
6.35
.250
.250
.250
.250
•
•
•
•
•
19003-0010
19003-0016
19003-0023
19003-0029
19003-0035
DEFINITION OF TERMS
Fully Insulated
Male and Female
Quick Disconnect
FEMALE QD
STRIP LENGTH
MWID OR
MAX INSULATION
DIAMETER
BRUSH
MALE QD
REF
TAB
SIZE
Figure 1
TAB SIZE
WIRE STOP
Doc No. ATS-638857000
Revision: D
Release Date: 12-08-04
Revision Date: 05-24-12
UNCONTROLLED COPY
Page 2 of 6
Air Feed Mylar Tape Applicator
The following illustrations are a generic terminal representation and not an exact image of any terminal listed in the
scope.
CRIMP SPECIFICATIONS
Wire Size
AWG
22
20
18
mm²
0.35
0.50
0.80
“X” Dimension Conductor Crimp
Mean
Go
No Go
In.
mm
In.
mm
In.
mm
.090 2.29 .088 2.24 .092 2.34
.094 2.38 .092 2.34 .096 2.44
.098 2.45 .095 2.41 .103 2.62
Pull Force Minimum
Lbs
8
13
20
N
35.6
57.8
90.0
Tool Qualification Notes:
1. Pull Force should be measured with no influence from the insulation crimp.
2. The above specifications are guidelines to an optimum crimp.
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.
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.
Doc No. ATS-638857000
Revision: D
Release Date: 12-08-04
Revision Date: 05-24-12
UNCONTROLLED COPY
Page 3 of 6
Air Feed Mylar Tape Applicator
PARTS LIST
Mini-Mac Applicator 63885-7000
Item Order No Engineering No.
Description
Quantity
Perishable Tooling
63885-7070
63885-7070
Tool Kit (All “Y” Items)
REF
1
63465-0002
63465-0002
Conductor Punch
1Y
2
63464-0002
63464-0002
Conductor Anvil
1Y
3
63463-0005
63463-0005
1Y
•
Insulation Punch
4
63462-0006
63462-0006
1Y
•
Insulation Anvil
Other Components
5
63443-0021
63443-0021
Lower Tooling Key
1
6
63466-0912
63466-0912
Anvil Mount
1
7
63466-0913
63466-0913
Terminal Support
1
8
63466-0921
63466-0921
Terminal Stripping Blade
1
9
63600-1290
63600-1290
Washer
1
1
10
63890-0866
63890-0866
•
Collar-6.4mm Long
11
63890-0867
63890-0867
Collar-7.7mm Long
1
Frame
12
63801-3301
63801-3301
Air Feed Applicator Frame Head
1
13
63801-3281
63801-3281
Base
1
14
63801-5850
63801-5850
Track Assembly
1
15
63801-3390
63801-3390
Air Kit
1
Hardware
16
N/A
N/A
M3 by 12 Long SHCS
1**
17
N/A
N/A
M4 by 10 Long SHCS
2**
18
N/A
N/A
M4 by 16 Long SHCS
1**
19
N/A
N/A
M4 by 45 Long SHCS
1**
20
N/A
N/A
M8 by 30 Long BHCS
1**
21
N/A
N/A
3mm by 6 Long 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 #10) for crimping expanded flare products. (See product list)
Note:
Crimp profiles used in 63885-7000 are equivalent to 19288-0049 / ATP-AA-575-CC and 19288-0233 /
ATP-M-675-CC (UL file number E79133).
Doc No. ATS-638857000
Revision: D
Release Date: 12-08-04
Revision Date: 05-24-12
UNCONTROLLED COPY
Page 4 of 6
Air Feed Mylar Tape Applicator
Assembly Drawing
12
1
•
11
10
12
•
9
20
3
8
17
(2)
7
15
2
6
14
•
18
4
16
13
21
19
5
Figure 3
•
Note:
Insulation tooling is NOT intended for “expanded flare” terminals. Remove the insulation punch
(Item #3), anvil (Item #4), and collar (Item #10) for crimping expanded flare products. (See product list)
Doc No. ATS-638857000
Revision: D
Release Date: 12-08-04
Revision Date: 05-24-12
UNCONTROLLED COPY
Page 5 of 6
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