Continuous Molded Strip Applicator
Mini-Mac Applicator
Application Tooling Specification
Mechanical Feed - Continuous Molded Strip
Order No. 63883-2600
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 Male and Female Couplers 14-22 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 and 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
*UL – 486 C
*UL – 310
3
5
8
13
20
30
50
70
80
90
100
N/A
N/A
8
10
10
15
25
35
40
45
50
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. 63883-2600
Revision: B
Release Date: 12-07-04
Revision Date: 10-03-05
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.
Terminal Eng. No.
19005-0003
19005-0008
AA-2261C
BB-2263C
Wire Size
AWG
mm²
22-18 0.35-0.80
16-14 1.30-2.00
Insulation Diameter Max.
mm
In.
4.19
.165
4.19
.165
Strip Length
mm
In.
7.92 .312
7.92 .312
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
CONTINUOUS
MOLDED STRIP
MALE QD
REF
TAB SIZE
BRUSH
TAB SIZE
Figure 1
Doc No. 63883-2600
Revision: B
Release Date: 12-07-04
Revision Date: 10-03-05
WIRE STOP
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.
1. The Mini-Mac applicator must be properly installed in the press.
2. Crimping dies must be properly installed in the Mini-Mac applicator.
3. The recommended method of measuring the crimp height of the
conductor dies is the soft metal slug method, (See Figure 2).
4. The slug must have a diameter 0.51mm (.020”) larger than the “X”
No Go dimension before crimping.
5. Place the soft metal slug (solder) into the nest of the 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”).
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.
CONDUCTOR
CRIMP DIE
USE SOFT METAL
SLUG METHOD
E2
“X” CRIMP
HEIGHT
E1
CRIMP PROFILE
Use soft metal slug (solder) method to measure
the “X” dimension. Verify tooling crimp height
calibration by referring to the Go/No Go
dimensions shown in the chart below.
Figure 2
CRIMP SPECIFICATIONS
Wire Size
AWG
mm²
22
20
18
16
14
0.35
0.50
0.80
1.30
2.00
“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
.100 2.54 .097 2.46 .104 2.64
.100 2.54 .097 2.46 .104 2.64
Pull Force Min.
Lbs
N
8
13
20
30
50
35.6
57.8
90.0
133.5
222.4
The above specifications are guidelines to an optimum crimp.
Doc No. 63883-2600
Revision: B
Release Date: 12-07-04
Revision Date: 10-03-05
UNCONTROLLED COPY
Page 3 of 6
Continuous Molded Strip Applicator
PARTS LIST
Mini-Mac Applicator 63883-2600
Item Order No Engineering No.
Description
Quantity
Perishable Tooling
63883-2670
63883-2670
Tool Kit (All “Y” Items)
REF
1
63465-0018
63465-0018
Conductor Punch
1Y
2
63464-0018
63464-0018
Conductor Anvil
1Y
3
63469-0005
63469-0005
Cut-off Punch
1Y
4
63462-0008
63462-0008
Cut-off Anvil
1Y
Other Components (Ref. 30050)
31 63466-0912
63466-0912
Anvil Mount
1
32 63466-0913
63466-0913
Terminal Support
1
33 63443-0021
63443-0021
Lower Tooling Key
1
41 63466-0931
63466-0931
Terminal Nose Support
1
42 63466-0921
63466-0921
Terminal Stripping Blade
1
51 63600-1290
63600-1290
Washer
1
52 63890-0866
63890-0866
Collar-6.4 Lg.
1
53 63890-0868
63890-0868
Collar-9.5 Lg.
1
Frame
81 63801-3201
63801-3201
Mechanical Feed Applicator Frame Head
REF
82 63801-3281
63801-3281
Base
REF
83 63801-4450
63801-4450
Track Assembly
REF
Hardware
91
N/A
N/A
M3 by 12 Lg. SHCS
1**
92
N/A
N/A
M4 by 10 Lg. SHCS
2**
93
N/A
N/A
M4 by 20 Lg. SHCS
1**
94
N/A
N/A
M4 by 45 Lg. SHCS
1**
95
N/A
N/A
M5 by 12 Lg. SHCS
1**
96
N/A
N/A
M8 by 30 Lg. BHCS
1**
97
N/A
N/A
3mm by 6 Lg. Roll Pin
1**
** Available from an industrial supply company such as MSC (1-800-645-7270).
Note: Crimp profiles used in 63883-2600 are equivalent to 19030-0062/MMC-AB-263 (UL file number E79133).
Doc No. 63883-2600
Revision: B
Release Date: 12-07-04
Revision Date: 10-03-05
UNCONTROLLED COPY
Page 4 of 6
Continuous Molded Strip Applicator
Assembly Drawing
81
52
1
53
3
51
96
81
41
95
83
32
31
42
2
4
92
(2)
91
93
82
97
94
Doc No. 63883-2600
Revision: B
Figure 3
33
Release Date: 12-07-04
Revision Date: 10-03-05
UNCONTROLLED COPY
Page 5 of 6
Continuous Molded Strip Applicator
NOTES
1. Molex recommends an extra perishable tooling kit be maintained at your facility.
2. Verify tooling alignment by manually cycling the press with 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 Applicator Manual (Document no. 63880-0000).
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 process manufacturer’s instruction manual.
CAUTION: Molex crimp specifications are valid only when used with Molex terminals, applicators and tooling.
Contact Information
For more information on Molex application tooling please contact Molex at 1-800-786-6539.
Molex Application Tooling Group
1150 E. Diehl Road
Naperville, IL 60563
Tel: (630) 969-4550
Fax: (630) 505-0049
Visit our Web site at http://www.molex.com
Doc No. 63883-2600
Revision: B
Release Date: 12-07-04
Revision Date: 10-03-05
UNCONTROLLED COPY
Page 6 of 6
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