INSTRUCTION MANUAL NO. IS-0035E ISSUED 1989-03-07 REVISED 2005-02-15 REV. B SPLASH PROOF CONNECTOR CAP FITTING TOOL 57130-6000: For 52116 Housing 57131-6000: For 52117 Housing OPERATING MANUAL Molex Japan Co., Ltd. Molex Japan Co., Ltd. Title Rev. Contents of Update Instruction Manual No. Splash Proof Connector Cap Fitting Tool Issued 0 1989/03/07 New creation release. A 1989/03/16 Added the parts list. B 2005/02/15 Revised to a bilingual version. ECN-JM50015 Tool Number IS-0035E 57130-6000 57131-6000 Description Prepared by Checked by Approved by Y. Ishiwata T. Yoshida A. Horino A-1 <Safety Precautions> Please read the following before operating the tool. 1. Introduction Thank you for choosing our Splash Proof Connector Cap Fitting Tool. This document is prepared so that the tool is properly used. Please take the time to read this manual, making sure you understand the operating procedures described herein before attempting to operate the tool. 2. Dangerous operations 1) Don't insert a part of your body or other foreign materials in the splash proof connector cap fitting tool (hereinafter referred to as the "tool") while you're operating the handle of a tool, as injury my result. 2) Beware of a handle when it is opened. Releasing a ratchet may cause the handle to open abruptly, resulting in injury. 3) Only users who have received adequate training on usage and safety from their manager, and have appropriate knowledge and skills must use the tool. Use by unfamiliar users may cause injury. <Caution> 1) Unauthorized reproduction of this document in part or in whole is prohibited. 2) The contents of this document are subject to change without notice. 3) Molex Japan Co., Ltd. assumes no responsibility for losses resulting from use or misuse of this document. A-2 <Safety Precautions> Please read the following before operating the tool. 3. Careful handling 1) Carry out the cap fitting work with the acceptable connector after confirming the tool number. 2) Check the tool for any damage, and repair prior to use. There is fear that it causes a cap defective fitting. 3) Clean the tool regularly if used frequently. 4) Avoid storing the tool in extremes of temperature, or high-humidity environment. 5) Keep the tool in a place out of reach of children in order to prevent accidents. 4. Must not be carried out 1) Use the tool only for the cap fitting purpose. Don't use it in place of a hammer, pliers, or other tools. Don't remodel the tool. Parts damage may result in accident or injury. 2) Don't use a tool for unspecified connectors. Don't press fit an unspecified cap. Both may cause parts damage. 3) The ratchet mechanism of the tool is designed based on operation by the grip of the hand. Note that improper handling such as inserting it into other devices and opening the handle forcibly may decrease its capabilities and lifespan. Page 1 1. Description This tool is a hand tool, which is designed for the cap fitting to the housing of a splash proof connector of Molex. Please confirm the connector number on the hand tool before attempting to operate this tool, and carry out the cap fitting operation. 2. Tool Specification 1) Tool name: Splash Proof Connector Cap Fitting Tool 2) Tool number: (1) 57130-6000 (2) 57131-6000 3) Outer dimensions and weight: 230 (width) x 70 (depth) x 20 (thickness) mm, Approx. 500gf 4) Management method: The "shutting height size" between the housing holder and the lower jaw must be in the standard value when grips the handle enough to the operation end. 5) Applicable tool and housing: (2.5mm Pitch Splash Proof connector) Tool number Housing ASS'Y Circuits number Applicable terminal Applicable wire 57130-6000 52116 Plug housing 2-4 50038 AVS0.3 57131-6000 52117 Receptacle housing 2-4 50039 AVS0.3 6) Tool appearance and parts name Shutting height size Jaw Housing holder Ratchet part Handle Ratchet adjustment screw & Fixing nut Page 2 3. Operation Method 1) Grip the handle of a tool lightly to put it into the state of a preliminary that the "ratchet" is caught of 1-3 teeth. 2) Set a housing assembly to the tool so that the "cap (3)" may become parallel to the "lower jaw (4)." At this time, the "wire (2)" installed in the lower jaw is pushed into the interior of the "U ditch (5)." 3) Pull the "wire (2)" to the "arrow" direction so that any space should not open between the "cap (3)" and the "lower jaw (4)" and the wire doesn't move by one hand, and grasp the handle until the ratchet comes off by the other hand. 4) After work, confirm that the cap is surely locked to the housing, and there are neither damage nor transformations in the housing and the cap. "Note" The position in which the cap is locked to the housing by the size changes such as the housing, caps, and wires changes. Therefore, please adjust the ratchet of the tool used at a proper position before operation start. Housing (1) Cap (3) Arrow Wire (2) Lower jaw (4) U ditch (5) Wire (2) Lower jaw (4) Must not be space in this. Page 3 4. Daily Maintenance 4.1. Daily Maintenance 1) Management of tool Before a work start, please carry out the tool check in accordance with the "startup checklist" in this manual, and start work after checking that it satisfies a standard. * Please record each check result simultaneously. 2) Removal of foreign substances Since foreign substances such as dust and wire scrap adheres to a "connector holder", etc. during operation, please remove a foreign substance timely. * Neglect may become the cause that the cap pressing lock imperfection. 3) Cleaning of work end Please wipe with a dry cloth lightly after cleaning a tool with compression air every day at the time of a work end. There is an effect that prevents rusting. 4) Lubrication Please supply proper amount of the machine oil to the moveable points with the frequency of once a month. 5) Shutting height size The shutting height size between the housing holder and the lower jaw must be in the standard value when grips the handle enough to the operation end. (Please refer the figure on the next page) [Standard value of shutting height size] Tool of 57130-6000: 25.4+/-0.1 mm Tool of 57131-6000: 13.9+/-0.1 mm Page 4 4.2. Adjusting Method of Shutting Height Size 1) Loosen the "fixing nut (2)" by using the "spanner (1)" (back side) of the attachment. 2) Rotate the "adjustment screw (3)", and adjust the "Shutting height size (4)." Rotate to right: The jaw shuts a lot. Rotate to left: The jaw shuts a little. [Standard value of shutting height size] Tool of 57130-6000: 25.4+/-0.1 mm Tool of 57131-6000: 13.9+/-0.1 mm 3) Tighten the "fixing nut (2)" when a proper size is obtained. Shutting height size (4) Lower jaw (6) Connector holder (5) Fixing nut (2) (back side) Adjustment screw (3) "Spanner (1)" of the attachment Page 5 5. Parts List No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Parts number J4160 J4174 J4170 J4163 J4168 J4175 J4176 J4161 J4166 J4177 J4164 J4165 J4173 J4172 J4171 57128-1003 57128-1002 57130-1001 57131-1001 57128-1004 Parts Name Handle ASS'Y Outside Handle Inside Handle Torsion Spring Ratchet Spring Adjustment Screw Nut Pivot Pin Ratchet Pin Handle Pin Ratchet Plate Ratchet Spring Pin E-ring E-ring E-ring Rivet Link Insert Pivot Pin Upper Jaw Lower Jaw Housing Holder Housing Holder Cap Screw Shim Q'ty (1) 1 1 1 1 1 1 1 1 2 1 1 1 2 4 4 2 2 2 1 1 1 1 1 1 Remarks Phi3x10L 5mm 3mm 2.5mm M4x12L Page 6 6. Splash Proof Connector Cap Fitting Tool Startup Checklist [Applicable Tool] 57130-6000: Splash Proof Connector Cap Fitting Tool 57131-6000: Splash Proof Connector Cap Fitting Tool "Note" Please check the following matter before the commencement of work, and start operation after checking those without a problem. No. 1 Checkpoint Shutting height size Standard Method/equipment [Standard value] 57130-6000: 25.4+/-0.1 mm 57131-6000: 13.9+/-0.1 mm Measure with calipers. 2 Cap fitting The cap must surely be locked to the housing, and there must be neither Check by trial damage nor transformations in the operation. housing and the cap. 3 Crack of hosing There are no crack and deformations by the hand tool in a housing and a Check visually. cap. 4 Article and dust There are no article and dust in a Cleanup housing holder. Shutting height size (1) Lower jaw Connector holder (4) Fixing nut (back side) Adjustment screw Check result