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C-Grid® SL™ FFC Termination Kit 

Doc. No: TM-638018550 

Release Date: 03-11-13 

UNCONTROLLED COPY

 

Page 1 of 23 

Revision: B 

Revision Date: 11-23-15 

 

 

 
 

 

 

 

 

 
 

 

 

 

 
 

 

 

 

 

 
 

 

 

 

 
 

 

 

 

 
 

 

 

 

 

 
 

 

 

 

 

C-Grid® SL™ FFC Termination Kit 

(For T2 and Terminator Crimp Module) 

Order No. 63801-8550 

Instruction Manual 

 

 

Description 

 

Operation 

 

Maintenance 

Summary of Contents for 63801-8550

Page 1: ... TM 638018550 Release Date 03 11 13 UNCONTROLLED COPY Page 1 of 23 Revision B Revision Date 11 23 15 C Grid SL FFC Termination Kit For T2 and Terminator Crimp Module Order No 63801 8550 Instruction Manual Description Operation Maintenance ...

Page 2: ...t Up and Operation 7 2 1 Crimp Module Preparation 7 2 2 Press Preparation 7 2 3 Shut Height 8 2 4 How to Manually Cycle the Press 8 2 5 FFC Termination Kit Installation in the Crimp Module 9 2 6 Crimp Module Installation and Removal 10 2 7 FFC Crimp Height Adjustment 11 2 8 Insulation Crimp Height Adjustment 12 2 9 Operation 12 Section 3 13 Troubleshooting 13 Section 4 14 Other Adjustments 14 4 1 ...

Page 3: ...if not avoided may result in minor or moderate injury CAUTION may also be used to alert against unsafe practices associated with events that could lead to personal injury WARNING WARNING Always wear proper eye protection when Operating or servicing this equipment Failure to wear eye protection could result in serious eye injury from flying debris Excessive noise levels Always wear proper ear prote...

Page 4: ...r modify alter or misuse the equipment Molex crimp specifications are valid only when used with Molex terminals applicators and tooling Failure to observe this precaution may result in injury and property damage Tooling Technical Assistance Molex offers tooling technical assistance for customers who may need some guidance for tooling adjustments This support can be obtained by calling either of th...

Page 5: ... 23 Revision B Revision Date 11 23 15 GUARD Figure 1 1 SLIDE INTERLOCK INSERTION NEST PUNCH CABLE CLAMP CABLE GUIDES CABLE STOP TOOLING LOCATOR CABLE ASSEMBLY TERMINATION NEST CABLE GUIDES EXTENSION LIMIT SWITCH CARRIER BREAK OFF LIP PRESS JUMPER Principal Mechanical Parts of the FFC Termination Kit ...

Page 6: ...ification Dimensions Lower Tooling Only Width 145mm 5 7 Depth 260mm 10 2 Height 44mm 1 7 Weight Termination Kit Only 3 8kg 8 5lbs Guarding The FFC Termination Kit is supplied with special guard panels that must be installed on the TM 3000 or TM 4000 press Do not operate the FFC Termination Kit without guard panels installed Product C Grid SL FFC Single Row Assembly Series 70430 and 70431 2 through...

Page 7: ...ion Kit to be installed in the Crimp Module the terminal feed mechanism and tooling clamps must be removed 1 Using a 4mm hex wrench remove the 2 M5 x 12mm long screws holding the feed mechanism to the module 2 Keep the M5 x 12mm long screws they will be used to mount a guard panel in this area 3 Remove the M6 BHCS and the left and right tooling clamps Leave the dowel pins in the base plate See Fig...

Page 8: ...nnect the power supply to the press 1 Open the guard door 2 Remove the applicator or Crimp Module from the press See Module Installation and Removal below for additional information Clean the bottom of the press ram and top of the quick change mounting plate 3 Place the shut height gauge onto the press quick change mounting plate Align the gauge to the ram as shown in Figure 2 4 4 Manually cycle t...

Page 9: ...in the Crimp Module 1 Remove the Crimp Module from the press 2 Remove the M4 screw holding the ram in the frame Pull the ram out of the frame 3 Install the FFC crimp punch and Tooling Locator in the ram See Figure 2 6 4 Move the FFC slide back by pulling out the slide lock plunger then pulling the slide back See Figure 2 7 5 Locate the base plate of the FFC tooling on the four dowel pins protrudin...

Page 10: ...rush do not use compressed air to clean the equipment The forces created by compressed air can force debris into the tool 3 To install the Crimp Module follow the procedure below a Using a 4mm hex wrench turn the M5 socket head cap screw clockwise until the locking clamp is fully opened b Slide the Module s ram adapter into the press ram yoke c Pull the Crimp Module s frame down until the Module s...

Page 11: ... power turn on the press and press the green MOTOR ON button Removal Remove the Crimp Module by reversing the previous steps When storing the Module always leave an un terminated FFC connector in the terminal nest to prevent damage to the FFC punch See Section 5 5 Storage 2 7 FFC Crimp Height Adjustment 1 Load FFC cable and an FFC connector in the tooling slide Push the slide into the press and cr...

Page 12: ...up in the terminal guides If terminating less than 20 circuits it is preferable to center the connector in the nest See Figure 2 13 2 Lower the cable stop onto the connector s 3 Place a cable between the guides and adjust the guides if necessary to center the cable over the connector but not so tight as to restrict cable handling Then slide the cable up to the cable stop NOTE It is important to pr...

Page 13: ...e housing 11 While holding the cable and connector back against the insertion bar slide the nest and slide assembly away 12 Push down on the connector to break the carrier strip off The cable will spring the connector back up See Figure 2 15 13 Remove the completed harness 14 Remove the carriers from the insertion bar by pushing the upper insertion bar forward This will expel the carrier strips fr...

Page 14: ...des assist the operator in alignment of the FFC to the connector terminals Use a 2 5mm hex wrench to loosen the screws holding the guide and adjust as necessary For narrower cables there is a guide extension that may be used See Figure 4 1 4 3 Slide Switch Adjustment If the slide switch is not properly adjusted the press may not cycle or it may cycle before the slide is fully pushed in Adjustment ...

Page 15: ...x recommends a soft brush do not use compressed air to clean the Crimp Module The forces created by compressed air can force debris into the tool or at the operator 1 Disconnect power from the press Open the guard door 2 Remove the Crimp Module from the press See Section 2 3 Crimp Module Installation and Removal 3 Use a 3mm hex wrench to remove the M4 socket head cap screw retaining the ram See Fi...

Page 16: ...ect power from the press Open the guard door 3 Use a grease gun on the Zerk fitting to grease the ram guides See Figure 5 1 4 For the ram use synthetic grease with Teflon or an equivalent The Crimp Module is shipped greased with Permatex No 82329 WARNING Never use penetrants such as WD40 for any lubrication on the Crimp Module Preventive Maintenance Chart An example of a maintenance chart is shown...

Page 17: ...Termination Kit parts list 5 4 Perishable Parts Perishable parts come in contact with the terminal or wire and tend to wear quickly or are fragile At least one perishable tool kit should be on hand to reduce production down time Recommended Perishable Parts are noted as PP in the Termination Kit parts list Tooling Replacement Schedule The following is offered as a general guideline for tooling rep...

Page 18: ...62200 6028 62200 6028 Spring Support 1 15 62200 7721 62200 7721 Cable Assembly With Limit Switch 1 16 62200 7729 62200 7729 Stop Block 1 17 62201 4201 62201 4201 Base Plate 1 18 62201 4206 62201 4206 Nest Locator Bar 1 19 62201 4211 62201 4211 Plate 1 20 62201 4214 62201 4214 Back Bar 1 21 62201 8704 62201 8704 Connector Nest 1 22 62201 8712 62201 8712 Insert Nest 1 23 62201 8713 62201 8713 Insert...

Page 19: ...ng BHCS 4 45 N A N A M4 by 12 Long SHCS 6 46 N A N A M4 by 20 Long FHCS 2 47 N A N A M5 by 10 Long FHCS 2 48 N A N A M5 by 16 Long SHCS 1 49 N A N A M6 by 8 Long SHCS 1 50 N A N A M6 by 16 Long SHCS 3 51 N A N A M6 by 20 Long SHCS 1 52 N A N A M6 by 10 Hex Nut 2 53 N A N A 3mm by 8 Long Dowel Pin 4 54 N A N A 4mm by 10 Long Dowel Pin 6 55 N A N A 4mm by 12 Long Dowel Pin 2 56 N A N A 4mm by 16 Lon...

Page 20: ...e 20 of 23 Revision B Revision Date 11 23 15 Figure 6 1 40 18 46 50 25 8 54 2 45 28 36 2 2 7 4 52 16 10 2 47 13 44 21 55 2 54 2 2 11 17 41 2 46 19 56 22 1 15 27 6 5 3 14 2 24 2 2 26 2 29 43 37 39 8 2 4 2 35 9 2 20 43 57 34 2 4 2 23 51 12 48 2 2 2 2 2 42 58 38 54 49 2 45 2 53 58 2 2 6 2 Assembly ...

Page 21: ...C Grid SL FFC Termination Kit Doc No TM 638018550 Release Date 03 11 13 UNCONTROLLED COPY Page 21 of 23 Revision B Revision Date 11 23 15 2 Figure 6 2 31 30 50 33 32 6 2 Guard Assembly ...

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