Mini-Fit Jr. Terminals 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.TM Crimp Terminal 18-24 AWG with smaller insulation OD's. Terminal Series No. 5556 5558 30490 44476 44478 44485 45750 46012 46018 46083 46098 Terminal Order No. AEInsulation Diameter Strip Length mm In. mm In. 39-00-0419 39-00-0425 39-00-0428 18-24 0.80-0.20 1.30-2.15 .051-.085 3.00-3.50 39-00-0436 39-00-0440 40-13-0851 39-00-0437 40-01-0853 18-24 0.80-0.20 1.30-2.15 .051-.085 3.00-3.50 40-13-0853 98-00-0174 18-24 0.80-0.20 1.30-2.15 .051-.085 3.00-3.50 18-20 0.80-0.50 1.30-2.15 .051-.085 3.00-3.50 18-20 0.80-0.50 1.30-2.15 .051-.085 3.00-3.50 44485-1411 18-24 0.80-0.20 1.30-2.15 .051-.085 3.00-3.50 18-20 0.80-0.50 1.65-2.05 .065-.081 3.00-3.50 18-20 0.80-0.50 1.65-2.05 .065-.081 3.00-3.50 18-20 0.80-0.50 1.65-2.05 .065-.081 3.00-3.50 46083-1121 46083-1211 46083-1221 18-20 0.80-0.50 1.65-2.05 .065-.081 3.00-3.50 18-20 0.80-0.50 1.65-2.05 .065-.081 3.00-3.50 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). 39-00-0038 39-00-0055 39-00-0059 39-00-0073 39-00-0108 39-00-0114 39-00-0040 39-00-0053 39-00-0061 39-00-0075 30490-0002 44476-1111 44478-1111 44485-1211 45750-1111 46012-1111 46018-1541 46083-1111 46098-1541 Doc No. 63860-1400 Revision: D Wire Size AWG mm 39-00-0153 39-00-0163 39-00-0169 39-00-0175 39-00-0181 39-00-0194 39-00-0120 39-00-0126 39-00-0219 39-00-0411 30490-1002 44476-1211 44478-1211 44485-1311 45750-1211 46012-1211 39-00-0200 39-00-0207 39-00-0213 39-00-0405 39-00-0407 39-00-0410 39-00-0420 39-00-0426 39-00-0427 39-00-0430 30490-2002 AE Release Date: 03-20-06 Revision Date: 08-03-06 UNCONTROLLED COPY .118-.138 .118-.138 .118-.138 .118-.138 .118-.138 .118-.138 .118-.138 .118-.138 .118-.138 .118-.138 .118-.138 Page 1 of 6 Mini-Fit Jr. Terminals DEFINITION OF TERMS BEND UP BELL MOUTH BRUSH CONDUCTOR CRIMP ROLLING SEAM INSULATION CRIMP TWISTING STRIP LENGTH BEND DOWN CUT-OFF TAB CRIMP HEIGHT The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the scope. CRIMP SPECIFICATION Terminal Series No. 5556 5558 30490 44476 44478 44485 45750 46012 46018 46083 46098 Terminal Series No. Bend up Bell mouth mm In. 0.20-0.50 .008-.020 0.20-0.50 .008-.020 0.20-0.50 .008-.020 0.20-0.50 .008-.020 0.20-0.50 .008-.020 0.20-0.50 .008-.020 0.20-0.50 .008-.020 0.20-0.50 .008-.020 0.20-0.50 .008-.020 0.20-0.50 .008-.020 0.20-0.50 .008-.020 Bend down Twist Degree 5556 5558 30490 44476 44478 44485 45750 46012 46018 46083 46098 Doc No. 63860-1400 Revision: D 5 5 5 5 5 5 5 5 5 5 5 Release Date: 03-20-06 Revision Date: 08-03-06 2 2 2 2 2 2 2 2 2 2 2 5 5 5 5 5 5 5 5 5 5 5 Cut-off Tab Max. mm In. 0.30 .012 0.30 .012 0.30 .012 0.30 .012 0.30 .012 0.30 .012 0.30 .012 0.30 .012 0.30 .012 0.30 .012 0.30 .012 Roll Degree 15 15 15 15 15 15 15 15 15 15 15 Conductor Brush mm In. 0.00-1.00 .000-.039 0.00-1.00 .000-.039 0.00-1.00 .000-.039 0.00-1.00 .000-.039 0.00-1.00 .000-.039 0.00-1.00 .000-.039 0.00-1.00 .000-.039 0.00-1.00 .000-.039 0.00-1.00 .000-.039 0.00-1.00 .000-.039 0.00-1.00 .000-.039 Punch Width (Ref) Conductor Insulation mm In. mm In. 1.60 .063 2.00 .079 1.60 .063 2.00 .079 1.60 .063 2.00 .079 1.60 .063 2.00 .079 1.60 .063 2.00 .079 1.60 .063 2.00 .079 1.60 .063 2.00 .079 1.60 .063 2.00 .079 1.60 .063 2.00 .079 1.60 .063 2.00 .079 1.60 .063 2.00 .079 UNCONTROLLED COPY Seam Seam shall not be open And no wire allowed out of the crimping area Page 2 of 6 Mini-Fit Jr. Terminals After crimping, the crimp profiles should measure the following: 5556 5556 5556 5556 AWG 18 20 22 24 mm 0.80 0.50 0.35 0.20 Conductor Crimp Height Crimp Width (Ref) mm In. mm In. 0.97-1.07 .038-.042 1.68 .066 0.95-1.04 .037-.041 1.66 .065 0.85-0.94 .033-.037 1.65 .065 0.79-0.87 .031-.034 1.63 .064 5558 5558 5558 5558 18 20 22 24 0.80 0.50 0.35 0.20 0.97-1.07 0.95-1.04 0.85-0.94 0.79-0.87 .038-.042 .037-.041 .033-.037 .031-.034 1.68 1.66 1.65 1.63 30490 30490 30490 30490 18 20 22 24 0.80 0.50 0.35 0.20 0.97-1.07 0.95-1.04 0.85-0.94 0.79-0.87 .038-.042 .037-.041 .033-.037 .031-.034 44476 44476 18 20 0.80 0.50 0.97-1.07 0.95-1.04 44478 44478 18 20 0.80 0.50 44485 44485 44485 44485 18 20 22 24 45750 45750 Terminal Series No. Wire Size 2 Pull Force Min. N 88.0 58.7 39.1 29.3 Lb. 19.8 13.2 8.8 6.6 .066 .065 .065 .064 88.0 58.7 39.1 29.3 19.8 13.2 8.8 6.6 1.68 1.66 1.65 1.63 .066 .065 .065 .064 88.0 58.7 39.1 29.3 19.8 13.2 8.8 6.6 .038-.042 .037-.041 1.68 1.66 .066 .065 68.4 58.7 15.4 13.2 0.97-1.07 0.95-1.04 .038-.042 .037-.041 1.68 1.66 .066 .065 68.4 58.7 15.4 13.2 0.80 0.50 0.35 0.20 0.97-1.07 0.95-1.04 0.85-0.94 0.79-0.87 .038-.042 .037-.041 .033-.037 .031-.034 1.68 1.66 1.65 1.63 .066 .065 .065 .064 88.0 58.7 39.1 29.3 19.8 13.2 8.8 6.6 18 20 0.80 0.50 0.97-1.07 0.84-0.94 .038-.042 .033-.037 1.68 1.66 .066 .065 68.4 58.7 15.4 13.2 46012 46012 18 20 0.80 0.50 0.97-1.07 0.84-0.94 .038-.042 .033-.037 1.68 1.66 .066 .065 68.4 58.7 15.4 13.2 46018 46018 18 20 0.80 0.50 0.97-1.07 0.84-0.94 .038-.042 .033-.037 1.68 1.66 .066 .065 68.4 58.7 15.4 13.2 46083 46083 18 20 0.80 0.50 0.97-1.07 0.84-0.94 .038-.042 .033-.037 1.68 1.66 .066 .065 68.4 58.7 15.4 13.2 46098 46098 18 20 0.80 0.50 0.97-1.07 0.84-0.94 .038-.042 .033-.037 1.68 1.66 .066 .065 68.4 58.7 15.4 13.2 AE 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. Doc No. 63860-1400 Revision: D Release Date: 03-20-06 Revision Date: 08-03-06 UNCONTROLLED COPY Page 3 of 6 Mini-Fit Jr. Terminals 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 1Y 2 63445-1646 63445-1646 Conductor Anvil 1Y 3 63446-2001 63446-2001 Insulation Punch 1Y 4 63445-2005 63445-2005 Insulation Anvil 1Y 5 63443-0002 63443-0002 Cut-Off Plunger Front 1Y 6 63443-0012 63443-0012 Plunger Retainer Front 1Y 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). Doc No. 63860-1400 Revision: D Release Date: 03-20-06 Revision Date: 08-03-06 UNCONTROLLED COPY Page 4 of 6 Mini-Fit Jr. Terminals Assembly Drawing 20 25 (2) 15 10 8 (2) 1 18 3 11 5 17 7 15 6 14 22 19 16 21 23 13 2 4 9 12 Figure 1 24 Doc No. 63860-1400 Revision: D Release Date: 03-20-06 Revision Date: 08-03-06 UNCONTROLLED COPY Page 5 of 6 Mini-Fit Jr. Terminals NOTES 1. 2. 3. 4. 5. Molex recommends an extra perishable tooling kit be maintained at your facility. Verify tooling alignment by manually cycling the press and Applicator before crimping under power. Check that all screws are tight. Slugs, Terminals, Dirt and Oil should be kept clear of work area. Wear safety glasses at all times. 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. Americas Headquarters Far East North Headquarters Far East South Headquarters European Headquarters Corporate Headquarters -JTMF *MMJOPJT64" :BNBUP ,BOBHBXB +BQBO +VSPOH 4JOHBQPSF .VOJDI (FSNBOZ 8FMMJOHUPO$U .0-&9 -JTMF *-64" BNFSJOGP!NPMFYDPN GFOJOGP!NPMFYDPN GFTJOGP!NPMFYDPN FVSJOGP!NPMFYDPN 'BY Visit our Web site at http://www.molex.com Doc No. 63860-1400 Revision: D Release Date: 03-20-06 Revision Date: 08-03-06 UNCONTROLLED COPY Page 6 of 6