Mini-Fit Jr. Terminals
FineAdjust Applicator
Specification Sheet
Part No. 63860-1000
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 large insulation OD’s.
Terminal
Series No.
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
Terminal Order No.
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
Wire Size
AWG
mm²
Insulation Diameter
mm
In.
Strip Length
mm
In.
5556
5558
30490
44476
44478
44485
45750
46012
46018
46083
46098
39-00-0419
39-00-0425
39-00-0428
18-24 0.80-0.20 2.15-3.10 .085-.122 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 2.15-3.10 .085-.122 3.00-3.50
40-13-0853
98-00-0174
18-24 0.80-0.20 2.15-3.10 .085-.122 3.00-3.50
18-20 0.80-0.50 2.15-3.10 .085-.122 3.00-3.50
18-20 0.80-0.50 2.15-3.10 .085-.122 3.00-3.50
44485-1411
18-24 0.80-0.20 2.15-3.10 .085-.122 3.00-3.50
18-20 0.80-0.50 2.05-2.95 .081-.116 3.00-3.50
18-20 0.80-0.50 2.05-2.95 .081-.116 3.00-3.50
18-20 0.80-0.50 2.05-2.95 .081-.116 3.00-3.50
46083-1121 46083-1211 46083-1221 18-20 0.80-0.50 2.05-2.95 .081-.116 3.00-3.50
18-20 0.80-0.50 2.05-2.95 .081-.116 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 O.D. 2.50-2.95mm (example UL1015).
Applicator 63860-1400 should be used for insulation O.D. 1.65-2.05mm (example UL1007).
.118-.138
.118-.138
.118-.138
.118-.138
.118-.138
.118-.138
.118-.138
.118-.138
.118-.138
.118-.138
.118-.138
Doc No. 63860-1000
Revision: D
Release Date: 03-20-06
Revision Date: 08-03-06
UNCONTROLLED COPY
Page 1 of 6
Mini-Fit Jr. Terminals
DEFINITION OF TERMS
BRUSH
BELL
MOUTH
INSULATION
CRIMP
CONDUCTOR
CRIMP
SEAM
BEND UP
ROLLING
STRIP
LENGTH
CUT-OFF
TAB
TWISTING
BEND
DOWN
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
Bend up
5
5
5
5
5
5
5
5
5
5
5
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
2
2
2
2
2
2
2
2
2
2
2
Twist
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
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
Terminal Series No.
5556
5558
30490
44476
44478
44485
45750
46012
46018
46083
46098
Degree
Degree
5
15
5
15
5
15
5
15
5
15
5
15
5
15
5
15
5
15
5
15
5
15
Punch Width (Ref)
Conductor
Insulation
mm In. mm In.
1.60 .063 3.20 .126
1.60 .063 3.20 .126
1.60 .063 3.20 .126
1.60 .063 3.20 .126
1.60 .063 3.20 .126
1.60 .063 3.20 .126
1.60 .063 3.20 .126
1.60 .063 3.20 .126
1.60 .063 3.20 .126
1.60 .063 3.20 .126
1.60 .063 3.20 .126
Seam
Seam shall not be open
And no wire allowed out
of the crimping area
Doc No. 63860-1000
Revision: D
Release Date: 03-20-06
Revision Date: 08-03-06
UNCONTROLLED COPY
Page 2 of 6
Mini-Fit Jr. Terminals
After crimping, the crimp profiles should measure the following:
Terminal Series No.
5556
5556
5556
5556
5558
5558
5558
5558
30490
30490
30490
30490
44476
44476
44478
44478
44485
44485
44485
44485
45750
45750
46012
46012
46018
46018
46083
46083
46098
46098
Wire Size
AWG
18
20
22
24
18
20
22
24
18
20
22
24
18
20
18
20
18
20
22
24
18
20
18
20
18
20
18
20
18
20
mm
0.80
0.50
0.35
0.20
0.80
0.50
0.35
0.20
0.80
0.50
0.35
0.20
0.80
0.50
0.80
0.50
0.80
0.50
0.35
0.20
0.80
0.50
0.80
0.50
0.80
0.50
0.80
0.50
0.80
0.50
2
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
0.97-1.07
0.95-1.04
0.85-0.94
0.79-0.87
0.97-1.07
0.95-1.04
0.85-0.94
0.79-0.87
0.97-1.07
0.95-1.04
0.97-1.07
0.95-1.04
0.97-1.07
0.95-1.04
0.85-0.94
0.79-0.87
0.97-1.07
0.84-0.94
0.97-1.07
0.84-0.94
0.97-1.07
0.84-0.94
0.97-1.07
0.84-0.94
0.97-1.07
0.84-0.94
.038-.042
.037-.041
.033-.037
.031-.034
.038-.042
.037-.041
.033-.037
.031-.034
.038-.042
.037-.041
.038-.042
.037-.041
.038-.042
.037-.041
.033-.037
.031-.034
.038-.042
.033-.037
.038-.042
.033-.037
.038-.042
.033-.037
.038-.042
.033-.037
.038-.042
.033-.037
1.68
1.66
1.65
1.63
1.68
1.66
1.65
1.63
1.68
1.66
1.68
1.66
1.68
1.66
1.65
1.63
1.68
1.66
1.68
1.66
1.68
1.66
1.68
1.66
1.68
1.66
.066
.065
.065
.064
.066
.065
.065
.064
.066
.065
.066
.065
.066
.065
.065
.064
.066
.065
.066
.065
.066
.065
.066
.065
.066
.065
Pull Force Min.
N
88.0
58.7
39.1
29.3
88.0
58.7
39.1
29.3
88.0
58.7
39.1
29.3
68.4
58.7
68.4
58.7
88.0
58.7
39.1
29.3
68.4
58.7
68.4
58.7
68.4
58.7
68.4
58.7
68.4
58.7
Lb.
19.8
13.2
8.8
6.6
19.8
13.2
8.8
6.6
19.8
13.2
8.8
6.6
15.4
13.2
15.4
13.2
19.8
13.2
8.8
6.6
15.4
13.2
15.4
13.2
15.4
13.2
15.4
13.2
15.4
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.
Doc No. 63860-1000
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 63860-1000
Item Order No Engineering No.
Description
Quantity
Perishable Tooling
63860-1070
63860-1070
Tool Kit (All “Y” Items)
REF
1
63444-1609
63444-1609
Conductor Punch
1Y
2
63445-1646
63445-1646
Conductor Anvil
1Y
3
63446-3208
63446-3208
Insulation Punch
1Y
4
63445-3211
63445-3211
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. 63860-1000
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
10
(2)
25
15
8
1
(2)
11
18
3
5
7
6
22
17
15
14
19
16
23
2
4
9
24
21
13
12
Figure 1
Doc No. 63860-1000
Revision: D
Release Date: 03-20-06
Revision Date: 08-03-06
UNCONTROLLED COPY
Page 5 of 6
