Air Feed Mylar Tape Applicator
Mini-Mac Applicator
Air Feed- Mylar Tape
Application Tooling
Specification Sheet
Order No. 63885-2000
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: Avikrimp™ Fully Insulated Quick Disconnect, Female, for 18-22 AWG Wire, Mylar Tape.
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. 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-638852000
Revision: D
Release Date: 12-08-04
Revision Date: 05-23-12
UNCONTROLLED COPY
Page 1 of 6
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.
Terminal No.
19002-0002
19002-0006
19002-0007
19002-0010
19002-0014
19002-0017
19002-0020
19002-0022
19277-0003
Terminal Eng. No.
AA-5261T
AA-5261BT
AA-5267T
AA-5271T
AA-5275T
AA-5279T
AA-5293T
AA-5285T
AA-5261T-LIF
Wire Size
AWG
mm²
18-22 0.80-0.35
18-22 0.80-0.35
18-22 0.80-0.35
18-22 0.80-0.35
18-22 0.80-0.35
18-22 0.80-0.35
18-22 0.80-0.35
18-22 0.80-0.35
18-22 0.80-0.35
Insulation Diameter Maximum
mm
In.
3.18
.125
3.18
.125
3.18
.125
3.18
.125
3.18
.125
3.18
.125
3.18
.125
3.18
.125
3.18
.125
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
DEFINITION OF TERMS
The following illustrations are a generic terminal representation and not an exact image of any terminal listed in
the scope.
Fully Insulated Female
Quick Disconnect
STRIP
LENGTH
TERMINAL
STRIP
MALE QD TAPE OR
MOLDED REF
MWID OR MAX
INSULATION
DIAMETER
BRUSH
FEMALE QD
WIRE STOP
TAB
SIZE
TAB SIZE
Figure 1
CUT-OFF
TAB
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
.100 2.54 .097 2.46 .104 2.64
.100 2.54 .097 2.46 .104 2.64
.100 2.54 .097 2.46 .104 2.64
Pull Force Minimum
Lbs
8.0
13.0
20.0
N
35.6
57.8
90.0
Doc No: ATS-638852000
Revision: D
Release Date: 12-08-04
Revision Date: 05-23-12
UNCONTROLLED COPY
Page 2 of 6
Air Feed Mylar Tape Applicator
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 Mini-Mac applicator must be properly installed in the press.
2. Crimping dies must be properly installed in the Mini-Mac
“X” CRIMP
applicator.
HEIGHT
E1
3. The recommended method of measuring the crimp height of the
conductor dies is the soft metal slug method, (See Figure 2).
CRIMP PROFILE
4. The slug must have a diameter 0.51mm (.020”) larger than the
Use soft metal slug (solder) method to
“X” No Go dimension before crimping.
measure the “X” dimension. Verify
5. Place the soft metal slug (solder) into the nest of the bottom die
tooling crimp height calibration by
and crimp (by hand cycling the press) similar to a terminal. The
referring to the Go/No Go dimensions
crimp height can be measured with a blade type micrometer or
shown in the chart below.
dial caliper, (Dimension “X”).
6. Adjustment of the crimp height can be accomplished by indexing
Figure 2
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.
Doc No: ATS-638852000
Revision: D
Release Date: 12-08-04
Revision Date: 05-23-12
UNCONTROLLED COPY
Page 3 of 6
Air Feed Mylar Tape Applicator
PARTS LIST
Mini-Mac Applicator 63885-2000
Item Order No Engineering No.
Description
Quantity
Perishable Tooling
63885-2070
63885-2070
Tool Kit (All “Y” Items)
REF
1
63465-0005
63465-0005
Conductor Punch
1Y
2
63464-0005
63464-0005
Conductor Anvil
1Y
3
63463-0002
63463-0002
Insulation Punch
1Y
4
63462-0003
63462-0003
Insulation Anvil
1Y
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
10
63890-0866
63890-0866
Collar-6.4mm Long
1
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 LongSHCS
1**
17
N/A
N/A
M4 by 10 LongSHCS
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:
Crimp profiles used in 63885-2000 are equivalent to 19032-0045 / MMT-AA-512 and 19288-0028 /
ATP-AA-512 (UL file number E79133).
Doc No: ATS-638852000
Revision: D
Release Date: 12-08-04
Revision Date: 05-23-12
UNCONTROLLED COPY
Page 4 of 6
Air Feed Mylar Tape Applicator
Assembly Drawing
12
11
1
3
10
12
9
20
8
17
(2)
7
15
2
4
18
6
14
16
13
21
19
5
Figure 3
Doc No: ATS-638852000
Revision: D
Release Date: 12-08-04
Revision Date: 05-23-12
UNCONTROLLED COPY
Page 5 of 6
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