Air Feed Mylar Tape Applicator
Mini-Mac Applicator
Specification Sheet
Air Feed-Mylar Tape
Order No. 63885-8400
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: Nylon Insulated Closed-End Connectors 10-16 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 specifications 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
RED
Blue
Blue
Yellow
Yellow
Wire Size (AWG)
18
16
14
12
10
*UL – 486 C
10
15
25
35
40
*UL - 486 C - Butt Splices, Parallel Splices, Closed End Connectors, and Wire Nuts
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 Order No.
19160-0083
Wire Size: 10 – 16 AWG 5.00 - 1.30 mm²
Wire Strip Length Insulation Diameter Maximum
Terminal Eng No. (REF)
In
mm
In
mm
NC-1610T
Varies
Varies
See Chart 1
See Chart 1
Doc No: ATS-638858400
Revision: A
Release Date: 4-22-09
Revision Date: 4-22-09
UNCONTROLLED COPY
Page 1 of 7
Air Feed Mylar Tape Applicator
OPERATION
Wire Preparation
Pre-twisted wire not required for OEM applications. For Solid Wire strip leads to 3/8 of an inch. Insert into
connector and crimp (OEM only).
3/8“
For stranded wire strip leads to approximately 3/4 of an inch.
Twist the wire combination even and tight. Trim stripped pre-
twisted area to 3/8 of an inch and insert into connector and
crimp. For more information follow the Quality Crimping
Handbook.
CHART 1
Wire Combinations for Nylon- Insulated Closed End Connectors
Order No. 19160-0083 (NC-1610T)
Wire Gauge (AWG)
Wire Type
Rating
12 14 16 17 18 20
Stranded or Solid
1
1
UL and CSA
Stranded or Solid
1
1
UL and CSA
Stranded or Solid
1
2
UL and CSA
Stranded or Solid
2
UL and CSA
Stranded or Solid
1 2
UL and CSA
Stranded or Solid
1 1
UL and CSA
Stranded or Solid
1 1
1
UL and CSA
Stranded or Solid
1
3
UL and CSA
Stranded or Solid
1
2
UL and CSA
Stranded or Solid
1
1
UL and CSA
Stranded or Solid
3
1
UL and CSA
Stranded or Solid
3
UL and CSA
Stranded or Solid
2
3
UL and CSA
Stranded or Solid
2
2
UL and CSA
Stranded or Solid
2
1
UL and CSA
Stranded or Solid
2
UL and CSA
Stranded or Solid
1
4
UL and CSA
Stranded or Solid
1
3
UL and CSA
Stranded or Solid
1
2
UL and CSA
Stranded or Solid
1
1
UL and CSA
Stranded or Solid
6
UL and CSA
Stranded or Solid
5
UL and CSA
Stranded or Solid
4
UL and CSA
Stranded or Solid
3
UL and CSA
Stranded only
2 1
UL
Stranded only
3 2
UL
Solid only
1
3
CSA
Doc No: ATS-638858400
Revision: A
Release Date: 4-22-09
Revision Date: 4-22-09
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.
Insulated
Terminal
MWID OR MAX
INSULATION
DIAMETER
BARREL
Un-Insulated
Terminal
MWID OR MAX
INSULATION
DIAMETER
BRUSH
STRIP
LENGTH
STUD SIZE
(REF)
STRIP
STUD SIZE
(REF)
BARREL
LENGTH
INSULATION
FERRULE
Figure 1
Figure 2
BRUSH
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: ATS-638858400
Revision: A
Release Date: 4-22-09
Revision Date: 4-22-09
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.
CONDUCTOR
CRIMP DIE
USE SOFT METAL
SLUG METHOD
1. The Mini-Mac applicator must be properly installed in the
E2
press.
2. Crimping dies must be properly installed in the Mini-Mac
applicator.
3. The recommended method of measuring the crimp height
“X” CRIMP
of the conductor dies is the soft metal slug method, (See
HEIGHT
Figure 4).
E1
4. The slug must have a diameter 0.51mm (.020”) larger than
CRIMP PROFILE
the “X” No Go dimension before crimping.
5. Place the soft metal slug (solder) into the nest of the
Use soft metal slug (solder) method to measure
the “X” dimension. Verify tooling crimp height
bottom die and crimp (by hand cycling the press) similar to
a terminal. The crimp height can be measured with a blade
calibration by referring to the Go/No Go dimensions
shown in the chart below.
type micrometer or dial caliper, (Dimension “X”).
6. Adjustment of the crimp height can be accomplished by
Figure 2
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 Range
AWG
10 - 16
mm²
5.00 - 1.30
“X” Dimension Conductor Crimp
Mean
Go
No Go
In
mm
In
mm
In
mm
.120 3.05 .116 2.95 .125 3.18
Crimp Inspection Marking
N/A
Doc No: ATS-638858400
Revision: A
Release Date: 4-22-09
Revision Date: 4-22-09
UNCONTROLLED COPY
Page 4 of 7
Air Feed Mylar Tape Applicator
PARTS LIST
Mini-Mac Applicator 63885-8400
Item Order No Engineering No.
Description
Quantity
Perishable Tooling
63885-8470
63885-8470
Tool Kit (All “Y” Items)
REF
1
63465-0066
63465-0066
Conductor Punch
1Y
2
63464-0057
63464-0057
Conductor Anvil
1Y
Other Components (Ref. 858450)
3
63443-0021
63443-0021
Lower Tooling Key
1
4
63466-0912
63466-0912
Anvil Mount
1
5
63466-0913
63466-0913
Terminal Support
1
6
63466-0921
63466-0921
Terminal Stripping Blade
1
7
63600-1290
63600-1290
Washer
1
8
63890-0866
63890-0866
Collar-6.4mm Long
1
Frame
9
63801-3301
63801-3301
Air Feed Applicator Frame Head
REF
10
63801-3281
63801-3281
Base
REF
11
63801-5850
63801-5850
Track Assembly
REF
12
63801-3390
63801-3390
Air Kit
REF
Hardware
13
N/A
N/A
M3 by 12 Long SHCS
1**
14
N/A
N/A
M4 by 10 Long SHCS
2**
15
N/A
N/A
M4 by 16 Long SHCS
1**
16
N/A
N/A
M4 by 45 Long SHCS
1**
17
N/A
N/A
M8 by 30 Long BHCS
1**
18
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 63885-8400 are equivalent to 19288-0236 / ATP-NC-1610 (UL file number E32244).
Doc No: ATS-638858400
Revision: A
Release Date: 4-22-09
Revision Date: 4-22-09
UNCONTROLLED COPY
Page 5 of 7
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