Modular Plug Bench Top Terminator MODULAR PLUG BENCH TOP TERMINATOR Instruction Manual Order No. 62300-1400 For Shielded Modular Plug 95043 Series Description Operation Maintenance Order No ATS-623001400 Revision: C Release Date: 06-05-98 Revision Date: 01-05-09 UNCONTROLLED COPY Page 1 of 17 Modular Plug Bench Top Terminator WARNING NEVER USE THIS MACHINE WITHOUT THE GUARDS OR SAFETY DEVICES THAT ARE INTENDED TO PREVENT HANDS FROM REMAINING IN THE TERMINATION OR FEED AREAS. RUNNING THIS MACHINE WITHOUT GUARDS, UNDER ANY CIRCUMSTANCES, CAN CAUSE SERIOUS INJURY. NEVER OPERATE, SERVICE, OR ADJUST THIS MACHINE WITHOUT PROPER INSTRUCTION AND WITHOUT FIRST READING AND UNDERSTANDING THE INSTRUCTIONS IN THIS MANUAL. NEVER ADJUST OR SERVICE THIS MACHINE WHILE IT IS CONNECTED TO ANY ELECTRICAL POWER SOURCE. DISCONNECT POWER BY UNPLUGGING THE MACHINE FROM ITS POWER SOURCE. WORK SAFELY AT ALL TIMES For Service, Contact Your Local Molex Sales Office Molex Application Tooling Group 2200 Wellington Court Lisle, Illinois 60532 Tel: 630-969-4550 Fax: 630-505-0049 Order No ATS-623001400 Revision: C Release Date: 06-05-98 Revision Date: 01-05-09 UNCONTROLLED COPY Page 2 of 17 Modular Plug Bench Top Terminator Table of Contents SECTION 1. General Description 2. Setting Up and Operation 3. Maintenance and Troubleshooting 4. Parts Lists, Assembly Drawings, and Schematics Order No ATS-623001400 Revision: C Release Date: 06-05-98 Revision Date: 01-05-09 UNCONTROLLED COPY Page 3 of 17 Modular Plug Bench Top Terminator Section 1 General Description 1.1. Description 1.2. Features 1.3. Technical Specifications 1.4. Delivery Check 1.5. Tools 1.6. Products Order No ATS-623001400 Revision: C Release Date: 06-05-98 Revision Date: 01-05-09 UNCONTROLLED COPY Page 4 of 17 Modular Plug Bench Top Terminator General Description Figure 1-1 1.1 Description The 62300-1400 Modular Plug Bench Top Terminator is designed to terminate prestripped, prepared cable to the 8 circuit Shielded Modular Plug (95043 series). The operator prepares the cable, slides on a ferrule, inserts the end into the plug, then inserts this assembly into the terminator. When the plug is in position, pressing the foot switch will activate the ram, pressing the wires into the terminals, and setting the strain relief. 1.3 Technical Specifications Dimensions Width Depth Height 150mm (5.91 in) 305mm (12.0 in) 150mm (5.91 in) Unpacked weight 10.5 kg (23.2lbs) Power Requirements Voltage: 110V AC 50/60Hz, 7A 1.2 Features Simple design for low maintenance. All electrical, no shop air required. Small and light weight for easy relocation. Quiet operation. Order No ATS-623001400 Revision: C Release Date: 06-05-98 Revision Date: 01-05-09 UNCONTROLLED COPY Page 5 of 17 Modular Plug Bench Top Terminator Rate This machine terminates up to 600 per hour, depending on operator skill and connector size. 1.5 Tools The following tools are recommended for setup and adjustments to the this tool. 1.4 Delivery Check Carefully remove the terminator from its shipping container. Check to see that following items are included in this package: Decription: Metric Hex Wrench Set Needle nose pliers Eye Loupe - 5X Quantity 62300-1400 Terminator 69002-5715 Foot Switch Assembly ATS-623001400 Instruction Manual 1 1 1 1.6 Products: Shielded Modular Plug, 8 position for Round Cable. 95043-1881 95043-2800 95043-2801 95043-2802 95043-2803 95043-2804 95043-2805 Order No ATS-623001400 Revision: C 95043 Series Number 95043-2806 95043-2895 95043-5893 95043-2807 95043-2896 95043-5894 95043-2881 95043-3981 95043-5895 95043-2891 95043-4881 95043-5896 95043-2892 95043-5881 95043-6891 95043-2893 95043-5891 95043-7880 95043-2894 95043-5892 95043-7881 Release Date: 06-05-98 Revision Date: 01-05-09 95043-7882 95043-7883 95043-7884 95043-7885 95043-7886 95043-7887 95043-7897 UNCONTROLLED COPY Page 6 of 17 Modular Plug Bench Top Terminator Section 2 Setting Up And Operation 2.1. Installation 2.2. Setup 2.3. Operation Order No ATS-623001400 Revision: C Release Date: 06-05-98 Revision Date: 01-05-09 UNCONTROLLED COPY Page 7 of 17 Modular Plug Bench Top Terminator 2.1 Installation (See Figure 1-1) 1. Set the terminator on a firm work surface. Be sure there is adequate room around the terminator to handle the harnesses. 2. Plug the power cord into a suitable power source. 3. Make sure there is adequate lighting. WARNING: When servicing this machine, always disconnect the power cord. 2.2 Setup Termination Depth Adjustment (See Figure 1-1) The termination depth can be adjusted using the following steps. 1. Remove the four (4) socket head cap screws, two on each side, that hold the plastic guard plate in place and remove the guard plate. 2. Locate the two (2) tool holder screws in the center of the ram and loosen them. 3. There are three (3) SHCS; one has a lock nut on the top of the ram. This is the tooling adjusting screw. Loosen the lock nut and turn the adjusting screw (CW) clockwise to increase termination depth or (CCW) counterclockwise to decrease the depth. 4. Make sure tool holder is firmly up against the adjusting screw and tighten the two (2) holding screws. 5. Double check the termination depth and repeat steps 2, 3 and 4 as necessary. When satisfied that the wires are seated correctly, replace the guard. Brake Adjustment 1. Remove the two (2) screws that hold the rear motor cover. 2. Carefully remove the rear cover and slide it around on the wire out of the way. 3. Locate the three (3) brake shoe springs loading nuts. See Figure 2-1. Order No ATS-623001400 Revision: C Release Date: 06-05-98 Revision Date: 01-05-09 Figure 2-1 4. Increase the compression on the brake shoe springs by turning the loading nuts (CW) clockwise. NOTE: Nuts should all be adjusted to the same distance from the plate. 5. Replace the rear cover but do not replace the screws at this time. 6. Turn the power on. If the ram still actuates, repeat step 2 through 5 until ram operates normally. 7. Replace the two (2) rear cover screws. 2.3 OPERATION Terminator Panel Buttons (See Figure 1-1) 1. "ON-OFF" This button turns on or off the power to the terminator. 2. "AUTO-STEP" This button sets the mode of operation - "AUTO" (Automatic) or "STEP" (Jog). 3. Power Light indicates power is on to the terminator. Operation 1. Slide a shield onto a length of pre-stripped cable then insert the cable into a modular connector. See Figure 2-2. 2. Slide the shield onto the connector. UNCONTROLLED COPY Page 8 of 17 Modular Plug Bench Top Terminator 3. Insert the connector assembly into the opening in the guard guiding it into the termination nest and up to the stop. See Figure 2-2. 4. When the connector is correctly seated in the nest, press the foot switch to terminate the connector and ferrule onto the cable. NOTE: Depress the foot switch to cycle the press. If the foot switch is held down, the press will continue to cycle. 5. Push down on the cable and remove the harness. Repeat steps 1 through 4 for the other end if required. Figure 2-2 Order No ATS-623001400 Revision: C Release Date: 06-05-98 Revision Date: 01-05-09 UNCONTROLLED COPY Page 9 of 17 Modular Plug Bench Top Terminator Section 3 Maintenance 3.1. Cleaning 3.2. Lubrication 3.3. Perishable Parts 3.4. Spare Parts 3.5. Troubleshooting Order No ATS-623001400 Revision: C Release Date: 06-05-98 Revision Date: 01-05-09 UNCONTROLLED COPY Page 10 of 17 Modular Plug Bench Top Terminator 3.1 Cleaning WARNING: Always disconnect the power cord from the power source during all maintenance operations. For efficient operation, this Semiautomatic Modular Plug Terminator Machine should be cleaned daily with a soft bristle brush to remove any carrier strip debris and terminal plating dust from the tooling area. For continuous operation this may have to be done several times throughout the day. See Chart 3.1 for recommended Preventive Maintenance Schedule. When it is necessary to change tooling, care should be taken to remove any debris from tapped holes or mounting surfaces. Debris can prevent tooling from being properly locked into position. CAUTION: Using compressed air to clean tooling is not recommended. Chips can wedge in the tooling and/or fly at an operator. 3.2 Lubrication There is a covered port on the top of the ram. 3 - 4 drops of SAE 10W motor oil, or equivalent, should be put in this port approximately once a month. See Figure 1-1. WARNING: Never use penetrates such as WD40 for any lubrication on the Termination machine. An example of a maintenance chart is shown below. Copy and use this chart to track the maintenance of your Press or use this as a template to create your own schedule or use your company's standard chart, if applicable. Preventive Maintenance Chart Daily: Clean. See Section 3.1. Monthly: Lubricate ram, See Section 3.2. CHECK SHEET MONTH _________YEAR _________ Week Monthly 1 2 3 4 Lubricate Yes Daily Clean Cleaning Yes Inspect all tooling for wear Yes Order No ATS-623001400 Revision: C MON TUE Release Date: 06-05-98 Revision Date: 01-05-09 Days of the Week WED THU FRI SAT SUN Solution SAE 10 non-detergent oil Soft Brush Industrial Degreaser Replace if signs of wear. UNCONTROLLED COPY Page 11 of 17 Modular Plug Bench Top Terminator Schedule should be adjusted up or down depending on usage. Molex recommends that a log of preventive maintenance be kept with the press. 3.3 Perishable Parts Customers are responsible for maintaining the Modular Plug Terminator Machine. Perishable parts are those parts that come in contact with the product and will wear out over time. Molex recommends that all customers keep at least one set of the perishable tool kit in stock at all times. This will reduce the amount of production down time. These parts are identified in the parts list in Section 4. 3.4. Spare Parts Customers are responsible for maintaining the Modular Plug Terminator Machine. Spare parts are moving and functioning parts that can be damaged or wear out over time and will require replacement. Molex recommends that the customer keep some or all of them in stock to reduce production down time. These parts are identified in the parts list in Section 4. 3.5 Troubleshooting Symptom Power cord properly plugged in but power will not come on Termination not deep enough and ferrule not adequately crimped Ram actuates when power is turned on Cause Solution Damage to power cord. Repair or replace cord. Fuse blown. Replace blown fuse with proper size fuse. Ram runs in "Step" but not in "Auto" Order No ATS-623001400 Revision: C Readjust the termination depth. Termination depth not set correctly. See Section 2.1.SETUP, Termination Depth Adjustment. Faulty foot switch. Repair or replace as required. Reset the brake. Brake out of adjustment. See Section 2.1.SETUP, Brake Adjustment. Make sure when moving the ram Ram not stopped at full up position. in "Step" mode that the ram is stopped at the top of its stroke. On the back of the motor mounting block is a miniature limit switch that Ram position switch faulty indicates the position or the ram. If faulty, replace it. Release Date: 06-05-98 Revision Date: 01-05-09 UNCONTROLLED COPY Page 12 of 17 Modular Plug Bench Top Terminator Section 4 4.1 Parts List and Assembly Drawings 4.2 Schematic Drawings Order No ATS-623001400 Revision: C Release Date: 06-05-98 Revision Date: 01-05-09 UNCONTROLLED COPY Page 13 of 17 Modular Plug Bench Top Terminator 4.1 Parts List 62300-1400 Modular Plug Terminator Description RSP / PP Parts / Notes Quantity Guard, Front 1 Mount, Guard 1 Base, Nest 1 Nest PP 1 Switch, Toggle 1 Switch, Toggle 1 Light, Red Indicator 1 Die, Upper PP 1 Ram 1 Plate, Ram Top 1 Block, Cam Bearing 1 Pin, Cam 1 Cam 1 Box, Gear 1 Motor 1 Shaft, Rear Motor 1 Pin, Locking 1 Coupling, Brake 1 Plate, Front Brake 1 Pad, Brake 1 Disk, Clutch 1 Spring, Brake 3 Ring, Brake 1 Nut, Fixed 3 Base, Ring 1 Nut, Fixed 3 Assembly, Brake Electrical Control 1 Nut, Brake Spring Adjusting 3 Switch, Miniature 1 Switch, Miniature With Lever 1 Base, Machine 1 Plate, Base 1 Assembly, Foot Switch 1 Timer (Not Shown) 1 Warning Label (Not Shown) 1 Molex Logo (Not Shown) 1 RSP - Part is a Molex Recommended Spare Part. PP - Part is a Perishable Part. ** Available from an industrial supply company such as MSC (1-800-645-7270). Item 1 2 3 4 5 6 7 8 9 10 11 12 13 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Americas Headquarters Lisle, Illinois 60532 U.S.A. 1-800-78MOLEX amerinfo@molex.com Order No 62300-1401 62300-1402 62300-1403 62300-1404 62300-1405 62300-1406 62300-1407 62300-1408 62300-1409 62300-1410 62300-1411 62300-1412 62300-1413 62300-1414 62300-1415 62300-1416 62300-1417 62300-1418 62300-1419 62300-1420 62300-1421 62300-1422 62300-1423 62300-1424 62300-1425 62300-1426 62300-1427 62300-1428 62300-1429 62300-1430 62300-1431 62300-1432 69002-5717 62300-1450 62300-1498 11-41-0264 Far East North Headquarters Yamato, Kanagawa, Japan 81-462-65-2324 feninfo@molex.com Far East South Headquarters Jurong, Singapore 65-6-268-6868 fesinfo@molex.com European Headquarters Munich, Germany 49-89-413092-0 eurinfo@molex.com Corporate Headquarters 2222 Wellington Ct. Lisle, IL 60532 U.S.A. 630-969-4550 Fax: 630-969-1352 Visit our Web site at http://www.molex.com Order No ATS-623001400 Revision: C Release Date: 06-05-98 Revision Date: 01-05-09 UNCONTROLLED COPY Page 14 of 17 Modular Plug Bench Top Terminator 4.1 Assembly Drawings Order No ATS-623001400 Revision: C Release Date: 06-05-98 Revision Date: 01-05-09 UNCONTROLLED COPY Page 15 of 17 Modular Plug Bench Top Terminator 4.1 Assembly Drawings Order No ATS-623001400 Revision: C Release Date: 06-05-98 Revision Date: 01-05-09 UNCONTROLLED COPY Page 16 of 17 Modular Plug Bench Top Terminator 4.2 Electrical Drawings Order No ATS-623001400 Revision: C Release Date: 06-05-98 Revision Date: 01-05-09 UNCONTROLLED COPY Page 17 of 17