Continuous Molded Strip Applicator
Mini-Mac Applicator
Application Tooling Specification
Mechanical Feed - Continuous Molded Strip
Order No. 63883-4100
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 cut-off tooling 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™ Quick Disconnect, (FIQD’s) Female Terminals, for 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 charts show the UL and government specifications (MIL-T-7928) for various wire sizes. The
tensile strength is shown in pounds. It 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: ATS-638834100
Revision: C
Release Date: 12-07-04
Revision Date: 12-05-08
UNCONTROLLED COPY
Page 1 of 6
Continuous Molded 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.
19003-0048
19003-0054
19003-0060
Terminal Eng. No.
BB-2206XC
BB-2207XC
BB-2208XC
Wire Size
AWG
16-14
16-14
16-14
mm²
1.30-2.00
1.30-2.00
1.30-2.00
Insulation Diameter
Maximum
mm
In.
6.60
.260
6.60
.260
6.60
.260
Strip Length
mm
6.35
6.35
6.35
In.
.250
.250
.250
DEFINITION OF TERMS
The following illustration is a generic terminal representation and not an exact image of any terminal listed in the
scope.
MWID OR MAX
INSULATION
DIAMETER
Fully Insulated
Female and Male
Quick Disconnect
STRIP
LENGTH
FEMALE QD
MALE QD
REF
CONTINUOUS
MOLDED STRIP
TAB SIZE
TAB SIZE
WIRE STOP
Figure 1
BRUSH
Doc No: ATS-638834100
Revision: C
Release Date: 12-07-04
Revision Date: 12-05-08
UNCONTROLLED COPY
Page 2 of 6
Continuous Molded Strip Applicator
Tool Calibration
To recalibrate this applicator, make sure the power is
completely shut off on the press.
CONDUCTOR
CRIMP DIE
E2
USE SOFT METAL
SLUG METHOD
1. The Mini-Mac applicator must be properly installed in the
press.
“X” CRIMP
2. Crimping dies must be properly installed in the Mini-Mac
HEIGHT
applicator.
E1
3. The recommended method of measuring the crimp height
CRIMP PROFILE
of the conductor dies is the soft metal slug method, (See
Use soft metal slug (solder) method to
Figure 2).
measure the “X” dimension. Verify tooling
4. The slug must have a diameter 0.51mm (.020”) larger
crimp height calibration by referring to the
than the “X” No Go dimension before crimping.
Go/No Go dimensions shown in the chart
5. Place the soft metal slug (solder) into the nest of the
below.
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”).
Figure 2
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
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 Minimum
Lbs
30
50
N
133.5
222.4
The above specifications are guidelines to an optimum crimp.
Doc No: ATS-638834100
Revision: C
Release Date: 12-07-04
Revision Date: 12-05-08
UNCONTROLLED COPY
Page 3 of 6
Continuous Molded Strip Applicator
PARTS LIST
Mini-Mac Applicator 63883-4100
Item Order No Engineering No.
Description
Quantity
Perishable Tooling
63883-4170
63883-4170
Tool Kit (All “Y” Items)
REF
1
63465-0004
63465-0004
Conductor Punch
1Y
2
63464-0004
63464-0004
Conductor Anvil
1Y
3
63469-0003
63469-0003
Cut-off Punch
1Y
4
63462-0044
63462-0044
Cut-off Anvil
1Y
Other Components (Ref. 30050)
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
63466-0931
63466-0931
Terminal Nose Support
1
10
63600-1290
63600-1290
Washer
1
11
63890-0866
63890-0866
Collar-6.4 Long
1
12
63890-0868
63890-0868
Collar-9.5 Long
1
Frame
13
63801-3201
63801-3201
Top
1
14
63801-3281
63801-3281
Base
1
15
63801-4450
63801-4450
Track
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 20 Long SHCS
1**
19
N/A
N/A
M4 by 45 Long SHCS
1**
20
N/A
N/A
M5 by 12 Long SHCS
1**
21
N/A
N/A
M8 by 30 Long BHCS
1**
22
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:
Crimp profiles used in 63883-4100 are equivalent to 19030-0035/MMC-BX-206, and 19030-
0036/MMC-BX-207 (UL file number E79133).
Doc No: ATS-638834100
Revision: C
Release Date: 12-07-04
Revision Date: 12-05-08
UNCONTROLLED COPY
Page 4 of 6
Continuous Molded Strip Applicator
Assembly Drawing
13
11
1
3
12
10
21
13
9
20
15
7
6
8
4
2
16
18
14
22
17
(2)
19
5
Figure 3
Doc No: ATS-638834100
Revision: C
Release Date: 12-07-04
Revision Date: 12-05-08
UNCONTROLLED COPY
Page 5 of 6
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