Rear Feed Applicator for Flag Avikrimp™ Quick Disconnect Terminals
Mini-Mac Applicator
Rear Feed
Application Tooling
Specification Sheet
Order No. 63802-7300
FEATURES
Directly adapts to most automatic wire processing machines
Applicator designed to industry standard mounting and shut height 135.80mm (5.346")
Quick set-up time; plus the crimp height , track and feed adjustments can be set without removing the
applicator from the press
Fine adjustment allows users to achieve target with little effort by adjusting in increments of .015mm (.0006")
for conductor crimp height and .063mm (.0025") for insulation height
Independent adjustment rings allow users to quickly adjust the conductor or insulation crimp height without
affecting each other
SCOPE
Products: Flag Avikrimp™ Quick Disconnect Female Terminals, 18-22 AWG.
Terminal
Order No.
19006-0004
19006-0007
19006-0010
Terminal
Eng. No.
AA-5220Z
AA-5222Z
AA-5223Z
Wire Size
AWG
18-22
18-22
18-22
mm²
0.80-0.35
0.80-0.35
0.80-0.35
Tab Size
mm
6.35 by 0.81
4.75 by 0.51
4.75 by 0.81
In.
.250 by .032
.187 by .020
187 by .032
Insulation Diameter
Maximum
mm
In.
3.81
.150
3.81
.150
3.81
.150
Strip Length
mm
8.70
8.70
8.70
In.
.344
.344
.344
DEFINITION OF TERMS
CUT-OFF TAB
MAXIMUM
INSULATION
DIAMETER
WIRE
STRIP LENGTH
CONDUCTOR
CRIMP
Doc No: ATS-63802-7300
Revision: C
Release Date: 08-19-09
Revision Date: 09-08-11
UNCONTROLLED COPY
Page 1 of 5
Rear Feed Applicator for Flag Avikrimp™ Quick Disconnect Terminals
CRIMP SPECIFICATIONS
Terminal Order No.
Terminal Eng. No.
Wire Size
AWG
18
20
22
18
20
22
18
20
22
mm²
0.80
0.50
0.35
0.80
0.50
0.35
0.80
0.50
0.35
Conductor Crimp Height
Mean
Go
No Go
mm In. mm In. mm In.
1.98 .078 1.90 .075 2.05 .081
1.98 .078 1.90 .075 2.05 .081
1.98 .078 1.90 .075 2.05 .081
1.98 .078 1.90 .075 2.05 .081
1.98 .078 1.90 .075 2.05 .081
1.98 .078 1.90 .075 2.05 .081
1.98 .078 1.90 .075 2.05 .081
1.98 .078 1.90 .075 2.05 .081
1.98 .078 1.90 .075 2.05 .081
Pull Force
Minimum
N
Lb.
89.0 20.0
57.9 13.0
35.6 8.0
89.0 20.0
57.9 13.0
35.6 8.0
89.0 20.0
57.9 13.0
35.6 8.0
19006-0004
AA-5220Z
19006-0007
BB-5222Z
19006-0010
BB-5223Z
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.
CONDUCTOR
CRIMP DIE
E2
USE SOFT METAL
SLUG METHOD
1. The Applicator must be properly installed in the press.
2. Crimping dies must be properly installed in the
“X” CRIMP
Applicator.
HEIGHT
E1
3. The recommended method of measuring the crimp
height of the conductor dies is the soft metal slug
CRIMP PROFILE
method. See Figure 1.
4. The slug must have a diameter 0.51mm (.020”) larger
Use soft metal slug (solder) method to
than the “X” No Go dimension before crimping.
measure the “X” dimension. Verify tooling
5. Place the soft metal slug (solder) into the nest of the
crimp height calibration by referring to the
bottom die and crimp (by hand cycling the press) similar
Go/No Go dimensions shown in the chart
to a terminal. The crimp height can be measured with a
Figure 1
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.
Molex does not sell gauge pins contact your local industrial supplier.
Doc No: ATS-63802-7300
Revision: C
Release Date: 08-19-09
Revision Date: 09-08-11
UNCONTROLLED COPY
Page 2 of 5
Rear Feed Applicator for Flag Avikrimp™ Quick Disconnect Terminals
PARTS LIST
Rear Feed Mini-Mac Applicator 63802-7300
Item No. Order No. Engineering No.
Description
Quantity
Perishable Tooling
63802-7370
63802-7370
Tool Kit (All “Y” Items)
REF
1
63801-5515
63801-5515
Conductor Punch (E2 Die)
1Y
2
19803-5261
19803-5261
Conductor Anvil (E1 Die)
1Y
3
63801-5613
63801-5613
Insulation Punch (I 2 Die)
1Y
4
19803-5271
19803-5271
Insulation Anvil (I1 Die)
1Y
5
19229-0120
23650-43
Cutter Housing
1Y
6
19229-0121
23650-44
Cutter Plunger
1Y
Other Components
7
19229-0095
23650-45
Cutter Back Plate
1
8
19230-0038
24854-08
Feed Finger
1
9
19230-0063
24853
Shoulder Bushing
1
10
19230-0101
24854-09
Guide Rail
1
11
19230-0106
24854-25P
Guide and Hold Down
1
12
19250-0038
24855-23
Compression Spring
1
13
63801-2685
63801-2685
Terminal Drag Assembly
1
14
63801-7701
63801-7701
Cutter Striker
1
15
63803-5133
63803-5133
Conductor Bushing
1
Frame
16
19230-0084
24854-05
Slide (Terminal Track)
1
17
63801-2600
63801-2600
Rear Feed Frame
1
18
63801-2603
63801-2603
Base
1
Hardware
19
N/A
N/A
M3 by 10 Long SHCS
2**
20
N/A
N/A
M4 by 8 Long SHCS
6**
21
N/A
N/A
M4 by 8 Long BHCS
1**
22
N/A
N/A
M4 by 10 Long BHCS
1**
23
N/A
N/A
M4 by 12 Long SHCS
3**
24
N/A
N/A
M6 by 10 Long BHCS
6**
25
N/A
N/A
M8 by 20 Long BHCS
1**
26
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-63802-7300
Revision: C
Release Date: 08-19-09
Revision Date: 09-08-11
UNCONTROLLED COPY
Page 3 of 5
Rear Feed Applicator for Flag Avikrimp™ Quick Disconnect 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-63802-7300
Revision: C
Release Date: 08-19-09
Revision Date: 09-08-11
UNCONTROLLED COPY
Page 5 of 5
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