Mini-Fit Jr. Terminals
Doc No. 63860-1400 Release Date: 03-20-06 UNCONTROLLED COPY Page 1 of 6
Revision: D Revision Date: 08-03-06
FineAdjust Applicator
Specification Sheet
Part No. 63860-1400
FEATURES
Quick punch removal with the push of a button for fast and easy tooling change
Applicator designed to industry standard mounting and shut height 135.80mm (5.346")
Quick set-up time; plus the crimp height, track and feed adjustments can be set without removing the applicator from the press
Fine adjustment allows users to achieve target with little effort by adjusting in increments of 0.15mm (.0006") for conductor crimp
height and .063mm (.0025") for insulation height
Independent adjustment rings allow users to quickly adjust the conductor or insulation crimp height without affecting each other
Directly adapts to most automatic wire processing machines
SCOPE
Products: Mini-Fit Jr.™ Crimp Terminal 18-24 AWG with smaller insulation OD’s.
Wire Size
Æ
Insulation Diameter Strip Length Terminal
Series No. Terminal Order No. AWG mm² mm In. mm In.
39-00-0038 39-00-0153 39-00-0200 39-00-0419
39-00-0055 39-00-0163 39-00-0207 39-00-0425
39-00-0059 39-00-0169 39-00-0213 39-00-0428
39-00-0073 39-00-0175 39-00-0405 39-00-0436
39-00-0108 39-00-0181 39-00-0407 39-00-0440
5556
39-00-0114 39-00-0194 39-00-0410 40-13-0851
18-24 0.80-0.20 1.30-2.15 .051-.085 3.00-3.50 .118-.138
39-00-0040 39-00-0120 39-00-0420 39-00-0437
39-00-0053 39-00-0126 39-00-0426 40-01-0853
39-00-0061 39-00-0219 39-00-0427 40-13-0853
5558
39-00-0075 39-00-0411 39-00-0430 98-00-0174
18-24 0.80-0.20 1.30-2.15 .051-.085 3.00-3.50 .118-.138
30490 30490-0002 30490-1002 30490-2002 18-24 0.80-0.20 1.30-2.15 .051-.085 3.00-3.50 .118-.138
44476 44476-1111 44476-1211 18-20 0.80-0.50 1.30-2.15 .051-.085 3.00-3.50 .118-.138
44478 44478-1111 44478-1211 18-20 0.80-0.50 1.30-2.15 .051-.085 3.00-3.50 .118-.138
44485 44485-1211 44485-1311 44485-1411 18-24 0.80-0.20 1.30-2.15 .051-.085 3.00-3.50 .118-.138
45750 45750-1111 45750-1211 18-20 0.80-0.50 1.65-2.05 .065-.081 3.00-3.50 .118-.138
46012 46012-1111 46012-1211 18-20 0.80-0.50 1.65-2.05 .065-.081 3.00-3.50 .118-.138
46018 46018-1541 18-20 0.80-0.50 1.65-2.05 .065-.081 3.00-3.50 .118-.138
46083 46083-1111 46083-1121 46083-1211 46083-1221 18-20 0.80-0.50 1.65-2.05 .065-.081 3.00-3.50 .118-.138
46098 46098-1541 18-20 0.80-0.50 1.65-2.05 .065-.081 3.00-3.50 .118-.138
Æ
This Applicator will crimp the above terminals and wires.
However it provides optimum A-620 Class 2 crimps for 18-20 AWG wire
with insulation OD 1.65-2.05mm (example UL1007).
Applicator 63860-1000 should be used for insulation OD 2.05-2.95mm (example UL1015).
Mini-Fit Jr. Terminals
Doc No. 63860-1400 Release Date: 03-20-06 UNCONTROLLED COPY Page 2 of 6
Revision: D Revision Date: 08-03-06
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
BELL
MOUTH
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
CUT-OFF
TAB
SEAM
DEFINITION OF TERMS
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the scope.
CRIMP SPECIFICATION
Bell mouth Cut-off Tab Max. Conductor Brush
Terminal Series No. mm In. mm In. mm In.
5556 0.20-0.50 .008-.020 0.30 .012 0.00-1.00 .000-.039
5558 0.20-0.50 .008-.020 0.30 .012 0.00-1.00 .000-.039
30490 0.20-0.50 .008-.020 0.30 .012 0.00-1.00 .000-.039
44476 0.20-0.50 .008-.020 0.30 .012 0.00-1.00 .000-.039
44478 0.20-0.50 .008-.020 0.30 .012 0.00-1.00 .000-.039
44485 0.20-0.50 .008-.020 0.30 .012 0.00-1.00 .000-.039
45750 0.20-0.50 .008-.020 0.30 .012 0.00-1.00 .000-.039
46012 0.20-0.50 .008-.020 0.30 .012 0.00-1.00 .000-.039
46018 0.20-0.50 .008-.020 0.30 .012 0.00-1.00 .000-.039
46083 0.20-0.50 .008-.020 0.30 .012 0.00-1.00 .000-.039
46098 0.20-0.50 .008-.020 0.30 .012 0.00-1.00 .000-.039
Punch Width (Ref)
Bend up Bend down Twist Roll Conductor Insulation
Terminal Series No.
Degree Degree mm In. mm In.
5556 5 2 5 15 1.60 .063 2.00 .079
5558 5 2 5 15 1.60 .063 2.00 .079
30490 5 2 5 15 1.60 .063 2.00 .079
44476 5 2 5 15 1.60 .063 2.00 .079
44478 5 2 5 15 1.60 .063 2.00 .079
44485 5 2 5 15 1.60 .063 2.00 .079
45750 5 2 5 15 1.60 .063 2.00 .079
46012 5 2 5 15 1.60 .063 2.00 .079
46018 5 2 5 15 1.60 .063 2.00 .079
46083 5 2 5 15 1.60 .063 2.00 .079
46098 5 2 5 15 1.60 .063 2.00 .079
Seam
Seam shall not be open
And no wire allowed out
of the crimping area
Mini-Fit Jr. Terminals
Doc No. 63860-1400 Release Date: 03-20-06 UNCONTROLLED COPY Page 3 of 6
Revision: D Revision Date: 08-03-06
After crimping, the crimp profiles should measure the following:
Conductor
Wire Size Crimp Height Crimp Width (Ref) Pull Force Min.
Terminal Series No.
AWG mm2 mm In. mm In. N Lb.
5556 18 0.80 0.97-1.07 .038-.042 1.68 .066 88.0 19.8
5556 20 0.50 0.95-1.04 .037-.041 1.66 .065 58.7 13.2
5556 22 0.35 0.85-0.94 .033-.037 1.65 .065 39.1 8.8
5556 24 0.20 0.79-0.87 .031-.034 1.63 .064 29.3 6.6
5558 18 0.80 0.97-1.07 .038-.042 1.68 .066 88.0 19.8
5558 20 0.50 0.95-1.04 .037-.041 1.66 .065 58.7 13.2
5558 22 0.35 0.85-0.94 .033-.037 1.65 .065 39.1 8.8
5558 24 0.20 0.79-0.87 .031-.034 1.63 .064 29.3 6.6
30490 18 0.80 0.97-1.07 .038-.042 1.68 .066 88.0 19.8
30490 20 0.50 0.95-1.04 .037-.041 1.66 .065 58.7 13.2
30490 22 0.35 0.85-0.94 .033-.037 1.65 .065 39.1 8.8
30490 24 0.20 0.79-0.87 .031-.034 1.63 .064 29.3 6.6
44476 18 0.80 0.97-1.07 .038-.042 1.68 .066 68.4 15.4
44476 20 0.50 0.95-1.04 .037-.041 1.66 .065 58.7 13.2
44478 18 0.80 0.97-1.07 .038-.042 1.68 .066 68.4 15.4
44478 20 0.50 0.95-1.04 .037-.041 1.66 .065 58.7 13.2
44485 18 0.80 0.97-1.07 .038-.042 1.68 .066 88.0 19.8
44485 20 0.50 0.95-1.04 .037-.041 1.66 .065 58.7 13.2
44485 22 0.35 0.85-0.94 .033-.037 1.65 .065 39.1 8.8
44485 24 0.20 0.79-0.87 .031-.034 1.63 .064 29.3 6.6
45750 18 0.80 0.97-1.07 .038-.042 1.68 .066 68.4 15.4
45750 20 0.50 0.84-0.94 .033-.037 1.66 .065 58.7 13.2
46012 18 0.80 0.97-1.07 .038-.042 1.68 .066 68.4 15.4
46012 20 0.50 0.84-0.94 .033-.037 1.66 .065 58.7 13.2
46018 18 0.80 0.97-1.07 .038-.042 1.68 .066 68.4 15.4
46018 20 0.50 0.84-0.94 .033-.037 1.66 .065 58.7 13.2
46083 18 0.80 0.97-1.07 .038-.042 1.68 .066 68.4 15.4
46083 20 0.50 0.84-0.94 .033-.037 1.66 .065 58.7 13.2
46098 18 0.80 0.97-1.07 .038-.042 1.68 .066 68.4 15.4
46098 20 0.50 0.84-0.94 .033-.037 1.66 .065 58.7 13.2
Æ
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.
Mini-Fit Jr. Terminals
Doc No. 63860-1400 Release Date: 03-20-06 UNCONTROLLED COPY Page 4 of 6
Revision: D Revision Date: 08-03-06
PARTS LIST
FineAdjust Applicator 63860-1400
Item Order No Engineering No. Description Quantity
Perishable Tooling
63860-1470 63860-1470 Tool Kit (All “Y” Items) REF
1 63444-1609 63444-1609 Conductor Punch 1 Y
2 63445-1646 63445-1646 Conductor Anvil 1 Y
3 63446-2001 63446-2001 Insulation Punch 1 Y
4 63445-2005 63445-2005 Insulation Anvil 1 Y
5 63443-0002 63443-0002 Cut-Off Plunger Front 1 Y
6 63443-0012 63443-0012 Plunger Retainer Front 1 Y
Other Components
7 11-24-1067 4996-4 Cut-off Plunger Spring 1
8 11-40-4039 8302-5 Plunger Striker Front 1
9 63443-0021 63443-0021 Lower Tooling Key 1
10 63443-6003 63443-6003 Rear Cover 1
11 11-18-4083 60707-8 Front Cover 1
12 63443-2408 63443-2408 Anvil Mount 1
13 63443-4018 63443-4018 Wire Stop 1
14 63443-0009 63443-0009 Scrap Chute Front 1
Frame
15 63800-4901 63800-4901 Top 1
16 63801-3281 63801-3281 Base 1
17 63801-4650 63801-4650 Track 1
Hardware
18 N/A N/A M3 by 6Lg. SHCS 2**
19 N/A N/A M4 by 6Lg. SHCS 1**
20 N/A N/A M4 by 12Lg. BHCS 2**
21 N/A N/A M4 by 16Lg SHCS 1**
22 N/A N/A M4 by 20Lg. SHCS 1**
23 N/A N/A M4 by 50Lg. SHCS 1**
24 N/A N/A 3MM by 6Lg. Roll Pin 1**
25 N/A N/A #10-32 by 1/4”Lg. BHCS 1**
** Available from an industrial supply company such as MSC (1-800-645-7270).
Mini-Fit Jr. Terminals
Doc No. 63860-1400 Release Date: 03-20-06 UNCONTROLLED COPY Page 5 of 6
Revision: D Revision Date: 08-03-06
Figure 1
25
20
10
15
1
3
15
18
11
5
7
6
22
23
14
19
21
13
12
9
24
2
4
(2)
(2)
8
16
17
Assembly Drawing
Mini-Fit Jr. Terminals
Doc No. 63860-1400 Release Date: 03-20-06 UNCONTROLLED COPY Page 6 of 6
Revision: D Revision Date: 08-03-06
NOTES
1. Molex recommends an extra perishable tooling kit be maintained at your facility.
2. Verify tooling alignment by manually cycling the press and 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 FineAdjust Manual.
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.
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