Air Feed Mylar Tape Applicator
Mini-Mac Applicator
Application Tooling Specification
Air Feed-Mylar Tape
Order No. 63885-4500
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: Krimptite / Versakrimp Ring, Spade and Butt splices Terminals 18-22 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
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. ATS-638854500
Revision: A
Release Date: 08-25-06
Revision Date: 10-02-06
UNCONTROLLED COPY
Page 1 of 8
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.
Wire Size: 18 – 22 AWG .80 – .35mm²
Wire Strip
Terminal
Terminal
Insul. Dia. Max.
Length
Number
Eng No. (REF) In mm
In
mm
19022-0010
AMCT-1T
.281 7.14 N/A
N/A
19033-0002
A-159T
.281 7.14 N/A
N/A
19033-0004
A-169T
.281 7.14 N/A
N/A
19044-0001
A-120-02T
.281 7.14 N/A
N/A
19044-0002
A-121-04T
.281 7.14 N/A
N/A
19044-0003
A-121-06T
.281 7.14 N/A
N/A
19044-0004
A-122-10T
.281 7.14 N/A
N/A
19044-0005
A-122-56T
.281 7.14 N/A
N/A
19044-0065
A-120-04T
.281 7.14 N/A
N/A
19044-0067
A-120-06T
.281 7.14 N/A
N/A
19044-0071
A-121-08T
.281 7.14 N/A
N/A
19044-0073
A-121-10T
.281 7.14 N/A
N/A
19044-0076
A-122-14T
.281 7.14 N/A
N/A
19056-0007
A-320-02T
.281 7.14 N/A
N/A
19056-0009
A-320-04T
.281 7.14 N/A
N/A
19056-0011
A-320-06T
.281 7.14 N/A
N/A
19056-0012
A-320-08T
.281 7.14 N/A
N/A
19056-0014
A-321-06T
.281 7.14 N/A
N/A
19056-0017
A-321-08T
.281 7.14 N/A
N/A
19056-0020
A-321-10T
.281 7.14 N/A
N/A
19056-0022
A-322-10T
.281 7.14 N/A
N/A
19056-0024
A-322-14T
.281 7.14 N/A
N/A
19056-0026
A-322-56T
.281 7.14 N/A
N/A
19056-0028
A-326-10T
.281 7.14 N/A
N/A
19056-0030
A-326-14T
.281 7.14 N/A
N/A
19056-0032
A-326-38T
.281 7.14 N/A
N/A
19056-0034
A-326-56T
.281 7.14 N/A
N/A
19056-0036
A-332-04T
.281 7.14 N/A
N/A
19056-0038
A-332-06T
.281 7.14 N/A
N/A
19056-0040
A-332-08T
.281 7.14 N/A
N/A
19056-0045
A-333-10T
.281 7.14 N/A
N/A
19079-0005 A-1006-MST .281 7.14 N/A
N/A
19086-0085
A-105-04T
.281 7.14 N/A
N/A
19086-0086
A-105-06T
.281 7.14 N/A
N/A
19086-0087
A-106-06T
.281 7.14 N/A
N/A
19086-0088
A-106-08T
.281 7.14 N/A
N/A
19086-0089
A-106-10T
.281 7.14 N/A
N/A
19086-0090
A-114-04T
.281 7.14 N/A
N/A
19086-0091
A-114-06T
.281 7.14 N/A
N/A
19086-0092
A-114-08T
.281 7.14 N/A
N/A
19086-0093
A-192-06T
.281 7.14 N/A
N/A
19086-0094
A-192-08T
.281 7.14 N/A
N/A
Doc No. ATS-638854500
Revision: A
Release Date: 08-25-06
Revision Date: 10-02-06
Wire Size: 18 – 22 AWG .80 – .35mm²
Terminal
Wire Strip
Terminal
Insul. Dia. Max.
Number
Length
Eng No. (REF) In mm
In
mm
19086-0095
A-192-10T
.281 7.14 N/A
N/A
19086-0096
A-195-06T
.281 7.14 N/A
N/A
19086-0097
A-195-08T
.281 7.14 N/A
N/A
19086-0098
A-195-10T
.281 7.14 N/A
N/A
19086-0099
A-198-04T
.281 7.14 N/A
N/A
19086-0100
A-198-06T
.281 7.14 N/A
N/A
19086-0101
A-198-08T
.281 7.14 N/A
N/A
19086-0102
A-198-10T
.281 7.14 N/A
N/A
19086-0111
A-L80-08T
.281 7.14 N/A
N/A
19086-0113
A-L81-06T
.281 7.14 N/A
N/A
19086-0115
A-L83-05T
.281 7.14 N/A
N/A
19088-0044
A-305-04T
.281 7.14 N/A
N/A
19088-0045
A-305-06T
.281 7.14 N/A
N/A
19088-0046
A-306-06T
.281 7.14 N/A
N/A
19088-0047
A-306-08T
.281 7.14 N/A
N/A
19088-0048
A-306-10T
.281 7.14 N/A
N/A
19088-0049
A-314-04T
.281 7.14 N/A
N/A
19088-0050
A-314-06T
.281 7.14 N/A
N/A
19088-0051
A-314-08T
.281 7.14 N/A
N/A
19088-0052
A-392-06T
.281 7.14 N/A
N/A
19088-0053
A-392-08T
.281 7.14 N/A
N/A
19088-0054
A-392-10T
.281 7.14 N/A
N/A
19088-0055
A-395-06T
.281 7.14 N/A
N/A
19088-0056
A-395-08T
.281 7.14 N/A
N/A
19088-0057
A-395-10T
.281 7.14 N/A
N/A
19088-0058
A-398-04T
.281 7.14 N/A
N/A
19088-0059
A-398-06T
.281 7.14 N/A
N/A
19088-0060
A-398-08T
.281 7.14 N/A
N/A
19088-0061
A-398-10T
.281 7.14 N/A
N/A
19117-0017
A-115-06T
.281 7.14 N/A
N/A
19117-0022
A-115-10T
.281 7.14 N/A
N/A
19117-0071
A-115-04T
.281 7.14 N/A
N/A
19117-0072
A-115-08T
.281 7.14 N/A
N/A
19117-0073
A-190-06T
.281 7.14 N/A
N/A
19117-0074
A-190-08T
.281 7.14 N/A
N/A
19117-0075
A-190-10T
.281 7.14 N/A
N/A
19117-0076
A-193-06T
.281 7.14 N/A
N/A
19117-0077
A-193-08T
.281 7.14 N/A
N/A
19117-0078
A-193-10T
.281 7.14 N/A
N/A
19117-0079
A-196-04T
.281 7.14 N/A
N/A
19117-0080
A-196-06T
.281 7.14 N/A
N/A
19117-0081
A-196-08T
.281 7.14 N/A
N/A
UNCONTROLLED COPY
Page 2 of 8
Air Feed Mylar Tape Applicator
Wire Size: 18 – 22 AWG .80 – .35mm²
Wire Strip
Terminal
Terminal
Insul. Dia. Max.
Length
Number
Eng No. (REF) In mm
In
mm
19123-0039
A-315-04T
.281 7.14 N/A
N/A
19123-0040
A-315-06T
.281 7.14 N/A
N/A
19123-0041
A-315-08T
.281 7.14 N/A
N/A
19123-0042
A-315-10T
.281 7.14 N/A
N/A
19123-0043
A-390-06T
.281 7.14 N/A
N/A
19123-0044
A-390-08T
.281 7.14 N/A
N/A
19123-0045
A-390-10T
.281 7.14 N/A
N/A
19123-0046
A-393-06T
.281 7.14 N/A
N/A
19123-0047
A-393-08T
.281 7.14 N/A
N/A
19123-0048
A-393-10T
.281 7.14 N/A
N/A
19123-0049
A-396-04T
.281 7.14 N/A
N/A
19123-0050
A-396-06T
.281 7.14 N/A
N/A
19123-0051
A-396-08T
.281 7.14 N/A
N/A
19140-0032
A-134-06T
.281 7.14 N/A
N/A
19140-0039
A-138-04T
.281 7.14 N/A
N/A
19140-0112
A-134-04T
.281 7.14 N/A
N/A
19140-0113
A-134-08T
.281 7.14 N/A
N/A
19140-0114
A-134-10T
.281 7.14 N/A
N/A
19140-0115
A-135-06T
.281 7.14 N/A
N/A
19140-0116
A-135-08T
.281 7.14 N/A
N/A
19140-0117
A-135-10T
.281 7.14 N/A
N/A
19140-0118
A-138-06T
.281 7.14 N/A
N/A
19140-0119
A-138-08T
.281 7.14 N/A
N/A
19140-0120
A-191-06T
.281 7.14 N/A
N/A
19140-0121
A-191-08T
.281 7.14 N/A
N/A
19140-0122
A-191-10T
.281 7.14 N/A
N/A
19140-0123
A-194-06T
.281 7.14 N/A
N/A
19140-0124
A-194-08T
.281 7.14 N/A
N/A
19140-0125
A-194-10T
.281 7.14 N/A
N/A
19140-0126
A-197-04T
.281 7.14 N/A
N/A
19140-0127
A-197-06T
.281 7.14 N/A
N/A
19140-0128
A-197-08T
.281 7.14 N/A
N/A
19146-0001
A-334-06T
.281 7.14 N/A
N/A
19146-0047
A-334-04T
.281 7.14 N/A
N/A
19146-0048
A-334-08T
.281 7.14 N/A
N/A
19146-0049
A-334-10T
.281 7.14 N/A
N/A
Doc No. ATS-638854500
Revision: A
Release Date: 08-25-06
Revision Date: 10-02-06
Wire Size: 18 – 22 AWG .80 – .35mm²
Terminal
Wire Strip
Terminal
Insul. Dia. Max.
Number
Length
Eng No. (REF) In mm
In
mm
19146-0050
A-335-06T
.281 7.14 N/A
N/A
19146-0051
A-335-08T
.281 7.14 N/A
N/A
19146-0052
A-335-10T
.281 7.14 N/A
N/A
19146-0053
A-338-04T
.281 7.14 N/A
N/A
19146-0054
A-338-06T
.281 7.14 N/A
N/A
19146-0055
A-338-08T
.281 7.14 N/A
N/A
19146-0056
A-391-06T
.281 7.14 N/A
N/A
19146-0057
A-391-08T
.281 7.14 N/A
N/A
19146-0058
A-391-10T
.281 7.14 N/A
N/A
19146-0059
A-394-06T
.281 7.14 N/A
N/A
19146-0060
A-394-08T
.281 7.14 N/A
N/A
19146-0061
A-394-10T
.281 7.14 N/A
N/A
19146-0062
A-397-04T
.281 7.14 N/A
N/A
19146-0063
A-397-06T
.281 7.14 N/A
N/A
19146-0064
A-397-08T
.281 7.14 N/A
N/A
19170-0002
A-110-06T
.281 7.14 N/A
N/A
19170-0004
A-110-08T
.281 7.14 N/A
N/A
19170-0006
A-110-10T
.281 7.14 N/A
N/A
19172-0002
A-310-06T
.281 7.14 N/A
N/A
19172-0004
A-310-08T
.281 7.14 N/A
N/A
19172-0006
A-310-10T
.281 7.14 N/A
N/A
19189-0004
A-145T
.234 5.95 N/A
N/A
19189-0006
A-L145T
.281 7.14 N/A
N/A
19203-0001 A-S-120-06T .281 7.14 N/A
N/A
19203-0002 A-S-121-08T .281 7.14 N/A
N/A
19203-0003 A-S-121-10T .281 7.14 N/A
N/A
19203-0004 A-S-122-10T .281 7.14 N/A
N/A
19203-0005 A-S-122-14T .281 7.14 N/A
N/A
19203-0006 A-S-122-56T .281 7.14 N/A
N/A
19203-0007 A-S-126-38T .281 7.14 N/A
N/A
19203-0011 A-S-132-06T .281 7.14 N/A
N/A
19203-0014 A-S-132-08T .281 7.14 N/A
N/A
19203-0016 A-S-133-10T .281 7.14 N/A
N/A
19215-0011
AS-345T
.281 7.14 N/A
N/A
UNCONTROLLED COPY
Page 3 of 8
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
Un-Insulated
Terminal
BARREL
BRUSH
MWID OR MAX
INSULATION
DIAMETER
STRIP
LENGTH
STUD SIZE
(REF)
STUD SIZE
(REF)
BARREL
STRIP
LENGTH
INSULATION
FERRULE
BRUSH
Figure 1
Figure 2
STRIP LENGTH
Fully Insulated
Male and Female
Quick Disconnect
FEMALE QD
MWID OR
MAX INSULATION
DIAMETER
BRUSH
MALE QD
REF
TAB
SIZE
Doc No. ATS-638854500
Revision: A
WIRE STOP
TAB
SIZE
Release Date: 08-25-06
Revision Date: 10-02-06
Figure 3
UNCONTROLLED COPY
Page 4 of 8
Air Feed Mylar Tape 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 4).
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.
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 4
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
22
20
18
mm²
0.35
0.50
0.80
“X” Dimension Conductor Crimp
Mean
Go
No Go
In
mm
In
mm
In
mm
.058 1.47 .056 1.42 .060 1.52
.064 1.63 .062 1.58 .066 1.68
.069 1.75 .066 1.67 .072 1.83
Pull Force Min.
Lbs
8.0
13.0
20.0
N
35.6
57.8
88.9
Pull Force should be measured with no influence from the insulation crimp. The above specifications are guidelines to an optimum
crimp.
Doc No. ATS-638854500
Revision: A
Release Date: 08-25-06
Revision Date: 10-02-06
UNCONTROLLED COPY
Page 5 of 8
Air Feed Mylar Tape Applicator
PARTS LIST
Mini-Mac Applicator 63885-4500
Item Order No Engineering No.
Description
Quantity
Perishable Tooling
63885-4570
63885-4570
Tool Kit (All “Y” Items)
REF
1
63465-0047
63465-0047
Conductor Punch
1Y
2
63464-0048
63464-0048
Conductor Anvil
1Y
3
N/A
N/A
Insulation Punch
N/A
4
N/A
N/A
Insulation Anvil
N/A
Other Components (Ref. 50050)
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
42 63466-0921
63466-0921
Terminal Stripping Blade
1
51 63600-1290
63600-1290
Washer
1
52 63890-0866
63890-0866
Collar-6.4mm Long
1
53 63890-0867
63890-0867
Collar-7.7mm Long
1
Frame
81 63801-3301
63801-3301
Air Feed Applicator Frame Head
1
82 63801-3281
63801-3281
Base
1
83 63801-5850
63801-5850
Track Assembly
1
84 63801-3390
63801-3390
Air Kit
1
Hardware
91
N/A
N/A
M3 by 12 Long SHCS
1**
92
N/A
N/A
M4 by 10 Long SHCS
2**
93
N/A
N/A
M4 by 12 Long SHCS
1**
94
N/A
N/A
M4 by 40 Long SHCS
1**
95
N/A
N/A
M8 by 30 Long BHCS
1**
96
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 63885-4500 are equivalent to 19027-0026/ATP-A-110 (UL file number E32244).
Doc No. ATS-638854500
Revision: A
Release Date: 08-25-06
Revision Date: 10-02-06
UNCONTROLLED COPY
Page 6 of 8
Air Feed Mylar Tape Applicator
Assembly Drawing
81
52
53
1
81
3
51
95
42
92
(2)
32
31
84
83
2
91
4
93
82
96
94
33
Figure 5
Doc No. ATS-638854500
Revision: A
Release Date: 08-25-06
Revision Date: 10-02-06
UNCONTROLLED COPY
Page 7 of 8
Air Feed Mylar Tape 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 processing 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.
Americas Headquarters
Far East North Headquarters
Far East South Headquarters
European Headquarters
Corporate Headquarters
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*-64"
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Visit our Web site at http://www.molex.com
Doc No. ATS-638854500
Revision: A
Release Date: 08-25-06
Revision Date: 10-02-06
UNCONTROLLED COPY
Page 8 of 8
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