Air Feed Mylar Tape Applicator
Mini-Mac Applicator
Application Tooling Specification
Air Feed-Mylar Tape
Order No. 63885-2500
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™ Piggyback FIQD Terminals 10-12 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 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
Wire Size (AWG)
12
10
*UL - 486 A
70
80
*UL – 486 C
35
40
*UL – 310
70
80
*Military Class 2
110
150
*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.
Terminal No.
19013-0016
19013-0034
Terminal Eng. No.
C-2319T
19013-0034
Wire Size
AWG
mm²
10-12 5.25-3.30
10-12 5.25-3.30
Insulation Diameter Maximum
mm
In
7.11
.280
7.11
.280
Strip Length
mm
In
7.92 .312
7.92 .312
Doc No. ATS-638852500
Revision: C
Release Date: 12-08-04
Revision Date: 05-24-07
UNCONTROLLED COPY
Page 1 of 6
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.
MWID OR MAX
INSULATION
DIAMETER
BARREL
STRIP
LENGTH
STUD SIZE
(REF)
STRIP
LENGTH
INSULATION
FERRULE
Figure 1
BARREL
MWID OR MAX
INSULATION
DIAMETER
Insulated
Terminal
Un-Insulated
Terminal
BRUSH
STUD SIZE
(REF)
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-638852500
Revision: C
Release Date: 12-08-04
Revision Date: 05-24-07
UNCONTROLLED COPY
Page 2 of 6
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
E2
USE SOFT METAL
I ns ul ated
Termi nal
M W D OR M AX
I
N
I SULA TI ON
DI AM ETER
BA RRE L
M W I O RM AX
D
I NSU LATI ON
DI AM ETE R
U n-I sul ated
n
Te rmi al
n
STR I
P
LENG TH
STUD SI ZE
( REF)
STR I
P
LENG TH
N
I SULA TI N
O
FER RU LE
BRU SH
STU D SI E
Z
( RE F)
BA RRE L
Fi gur e1
B RUS H
Fi gur e2
ST RI LE NGT H
P
The Mini-Mac applicator must be properly installed in
the press.
“X” CRIMP
Crimping dies must be properly installed in the Mini-
HEIGHT
Mac applicator.
E1
The recommended method of measuring the crimp
CRIMP PROFILE
height of the conductor dies is the soft metal slug
Use soft metal slug (solder) method to measure
method. See Figure 4.
the “X” dimension. Verify tooling crimp height
The slug must have a diameter 0.51mm (.020”) larger
calibration by referring to the Go/No Go
than the “X” No Go dimension before crimping.
dimensions shown in the chart below.
Place the soft metal slug (solder) into the nest of the
bottom die and crimp (by hand cycling the press) similar
Figure 4
to a terminal. The crimp height can be measured with a
blade type micrometer or dial caliper, (Dimension “X”).
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
12
10
mm²
3.30
5.25
“X” Dimension Conductor Crimp
Mean
Go
No Go
In
mm
In
mm
In
mm
.134 3.40 .131 3.33 .137 3.48
.134 3.40 .131 3.33 .137 3.48
Pull Force Minimum
Lbs
70.0
80.0
N
311.4
355.9
Pull Force should be measured with no influence from the insulation crimp. The above specifications are
guidelines to an optimum crimp.
Doc No. ATS-638852500
Revision: C
Release Date: 12-08-04
Revision Date: 05-24-07
UNCONTROLLED COPY
Page 3 of 6
Air Feed Mylar Tape Applicator
PARTS LIST
Mini-Mac Applicator 63885-2500
Item Order No Engineering No.
Description
Quantity
Perishable Tooling
63885-2570
63885-2570
Tool Kit (All “Y” Items)
REF
1
63465-0011
63465-0011
Conductor Punch
1Y
2
63464-0011
63464-0011
Conductor Anvil
1Y
3
63463-0008
63463-0008
Insulation Punch
1Y
4
63462-0011
63462-0011
Insulation Anvil
1Y
Other Components (REF 850050)
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 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:
Crimp profiles used in 63885-2500 are equivalent to 19032-0270.
Doc No. ATS-638852500
Revision: C
Release Date: 12-08-04
Revision Date: 05-24-07
UNCONTROLLED COPY
Page 4 of 6
Air Feed Mylar Tape Applicator
Assembly Drawing
12
10
1
3
11
12
9
20
8
17
(2)
7
15
2
4
18
6
14
16
13
21
19
5
Figure 5
Doc No. ATS-638852500
Revision: C
Release Date: 12-08-04
Revision Date: 05-24-07
UNCONTROLLED COPY
Page 5 of 6
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