0011219507

Manual Press with SEMCONN™ Ferrule Adapter Kit Manual Press with SEMCONN™ Ferrule Adapter Kit Instruction Manual Order No. 11-21-9507 71310 and 71313 series
Description
Operation
Maintenance Order No: ATS-011219507 Revision: A Release Date: 08-24-99 Revision Date: 01-22-09 UNCONTROLLED COPY Page 1 of 17 Manual Press with SEMCONN™ Ferrule Adapter Kit WARNING NEVER OPERATE, SERVICE, OR ADJUST THIS PRESS OR INSTALL DIES WITHOUT PROPER INSTRUCTION AND WITHOUT FIRST READING AND UNDERSTANDING THE INSTRUCTIONS IN THIS MANUAL. 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-011219507 Revision: A Release Date: 08-24-99 Revision Date: 01-22-09 UNCONTROLLED COPY Page 2 of 17 Manual Press with SEMCONN™ Ferrule Adapter Kit Table of Contents SECTION 1 General Description 2 Setup - Operation 3 Maintenance and Troubleshooting 4 Parts List, Assembly Drawings Order No: ATS-011219507 Revision: A Release Date: 08-24-99 Revision Date: 01-22-09 UNCONTROLLED COPY Page 3 of 17 Manual Press with SEMCONN™ Ferrule Adapter Kit 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-011219507 Revision: A Release Date: 08-24-99 Revision Date: 01-22-09 UNCONTROLLED COPY Page 4 of 17 Manual Press with SEMCONN™ Ferrule Adapter Kit Principal Mechanical Parts of the 11-21-9507 Press RAM HANDLE ASSEMBLY STANDARD ASEMBLY PRESS 11-31-6356 RATCHET REASE LEVER TOOLING HOLDER UPPER TOOLING (SOLD SEPERATLY) BASE PLATE CABLE CLAMP Figure 1-1 Order No: ATS-011219507 Revision: A Release Date: 08-24-99 Revision Date: 01-22-09 NEST LOWER TOOLING (SOLD SEPERATLY) UNCONTROLLED COPY Page 5 of 17 Manual Press with SEMCONN™ Ferrule Adapter Kit Instruction Manual Instruction Manual Specification Sheet General Description 1.1 Description The 11-21-9507 is the 11-31-6356 Manual Press with the 11-31-7559 SEMCONN™ Ferrule Adaptor Kit. 1.5 1.2 Features



1.3 Full cycle ratchet assures complete crimp. Handle is easily changed to suit right or left handed operators. Modular tooling is quickly installed into the Molex Standard Assembly Press 11-31-6356 (AM60026-50). Manually operated, no shop air or electricity required. Technical Specifications Dimensions Height Press with tooling 533.0mm (21.00”) Width Depth Unpacked weight 152mm (6.00“) 267mm (10.50“) 25kg (55 lbs) 1.4  Inch hex wrench set  Small standard screwdriver  Adjustable wrench 1.6 Products SEMCONN™ Shielded Plug Assembly kit for Shielded Round Cable, series 71310 and SEMCONN™ Shielded Plug Assembly, series 71313. ORDERING INFORMATION The Table below lists the part numbers for the various ways to order tooling for this press. SEMCONN™ Ferrule Crimping Die Sets must always be ordered separately. Order No. Engineering No. 11-21-9507 AM-60098 11-31-7559 AM-60063 11-31-6383 AM-60041-6 11-31-6384 AM-60041-8 The following items are included in this package : Decription: 11-31-6385 AM-60041-4 Description Complete Manual Press with Adaptor Kit Installed Adaptor Kit Ferrule Crimping Die Set for 4-Circuit Ferrule Crimping Die Set for 6-Circuit Ferrule Crimping Die Set for 8-Circuit Ferrule Crimping Die Set for 16-Circuit Quantity Molex Standard Assembly Press 11-31-6356 (AM60026-50) Terminator Tool Kit 11-31-7559 Order No: ATS-011219507 Revision: A Tools 11-31-6382 AM-60041-4 Delivery Check 1 1 1 The following tools are recommended for setup and adjustments to the this tool. It is designed to terminate round cable into a connector assembly, 71310, and 71313 series. It will accommodate 4 to 16 circuit connectors. The operator loads a connector and cable assembly, with the ferrule in position on the cable, into the nest pushing it to the right against the stop rail. Then the press is cycled by pulling the press crimping lever forward and down, then returning it to the full up position. The ferrule is now crimped to the cable. This tooling is ideally suited for low to medium volume production. See Section 2.4 for tool listing. ATS-011316356 ATS-011219507 ATS-011317559 See Section 3 for detailed parts lists of the press. 1 1 Release Date: 08-24-99 Revision Date: 01-22-09 UNCONTROLLED COPY Page 6 of 17 Manual Press with SEMCONN™ Ferrule Adapter Kit Section 2 Installation 2.1. Instaltion 2.2. Set-Up 2.3. Operation 2.4. Products Order No: ATS-011219507 Revision: A Release Date: 08-24-99 Revision Date: 01-22-09 UNCONTROLLED COPY Page 7 of 17 Manual Press with SEMCONN™ Ferrule Adapter Kit 3. Slide the upper tooling holder with upper tooling, upward over the ram adjusting screw, until it comes to a stop. See Figure 2-2. 2.1 Installation To secure the press, use a bench capable of supporting at least 150 pounds, with adequate lighting for easy operation. There are two (2) holes for 5/16” screws provided in the press base for fastening the press to the workbench. Be sure there is adequate room around the press to operate easily. RAM ADJUSTING SCREW LATCH TOOLING HOLDER RAM UPPER TOOLING Figure 2-2 TOOLING SLOT LOCKING #1/4-20 SET-SCREW UPPER CRIMP DIE Figure 2-1 The 11-21-9507 Manual Press comes with adaptor kit already installed. See Figure 1-1. The adapter will have to be removed from the Press when installing the upper and lower crimp dies (sold separately), follow the steps below: 4. Push the latch backward (away from the operator). The upper tooling will now slide up onto the ram an additional approximately 4.0mm (0.16”). 5. Release the latch, the upper tooling will stay in place. SPRING LOADED SCREW (2) LOWER CRIMP DIE Upper Tooling 1. Loosen the locking #1/4-20 set-screw on the side of the upper tooling holder until it clears the middle slot in the tool holder. 2. Install the upper crimp die into the tooling holder. The crimping area of the crimp die should be facing the back of the press when installed. See Figure 2-1. NOTE: Lowering the press ram slightly may assist in installing the upper tooling. Order No: ATS-011219507 Revision: A Release Date: 08-24-99 Revision Date: 01-22-09 Figure 2-3 #1/4-20 LOCKING SET SCREW UNCONTROLLED COPY TOOLING PLATE Page 8 of 17 Manual Press with SEMCONN™ Ferrule Adapter Kit Lower Tooling 1. Loosen the two (2) spring loaded screws on the base plate of the Molex Standard Manual Press and remove the lower tooling. 2. Install the lower crimp die in the lower tooling plate. The actual crimp area of the die should be facing the back of the press. See Figure 2-3. 3. Tighten the locking #1/4-20 set screw on the left side of the tooling plate to lock in the lower crimping die. 4. With the press ram in the up position, mount the lower tooling in the press. 5. Slide the tooling plate under the screws. See Figure 2-3. Make sure the two (2) spring loaded screws in the press base plate are up high enough for the tooling plate to slide under the washers. 6. Lower the two (2) spring loaded screws but do not tighten. 7. Slowly lower the press ram by pulling the press lever forward and down. 8. Move the lower tooling in position lining up the lower die with the upper die. 9. Tighten the two spring loaded screws. 10. Return the press ram to the full up position. insert and tighten the two #10 socket head cap screws. 12. Install the cable clamp assembly as shown in Figure 2-4. Do not tighten the two (2) #8-32 SHCS mounting screws at this time as this clamp assembly can be slid back and forth to suit the cable and connector assembly. 2.2 Set Up The setup operations required for this tooling are adjusting the cable clamp mount, adjusting the press ram stroke, and adjusting the connector nest. Cable Clamp The cable clamp is adjusted as follows: 1. Loosen the two (2) #10-32 SHCS on the clamp mount. See Figure 2-4. 2. Slide the clamp mount forward or back to the desired position aligning the cable to the ferrule crimp dies. 3. Tighten the two (2) #10-32 SHCS. It may be necessary to adjust the press ram to insure a proper crimping of the ferrule. The stroke is adjusted as follows: 1. Install a cable and connector assembly with a ferrule into the fixture. 2. Crimp the ferrule. See Section 2.3 Operation for details. 3. Inspect the crimp per product specifications drawing no.PS-71310 and adjust the ram stroke below. #10-32 SHCS (2) Ram Stroke Adjustment #8-32 SHCS (2) CABLE CLAMP ASSEMBLY Figure 2-4 MOUNTING CLAMP 11. Install the cable mounting clamp bracket by positioning the bracket over the two mounting holes. See Figure 2-4. Then Order No: ATS-011219507 Revision: A Release Date: 08-24-99 Revision Date: 01-22-09 1. Loosen the #8-32 set screw in the Ram which locks the Ram Adjusting Screw into place. See Figure 2-5. 2. There is an indicator engraved on the ram just above the Ram Adjusting Screw. Turn the Ram Adjusting Screw clockwise (CW) toward the “+” sign to increase the ram stroke. To decrease the stroke, turn the Ram Adjusting Screw counterclockwise (CCW) toward the “-” sign. Stroke adjustment controls the shut height of the connector assembly. Ram stroke is set so that the connector measures a specific shut height UNCONTROLLED COPY Page 9 of 17 Manual Press with SEMCONN™ Ferrule Adapter Kit when terminated. See Product Specifications for proper shut height dimensions and related information. 3. Once the correct stroke is set, tighten the #8-32 set screw. 2.3 Operation Press Operation Once the tooling is set up in (Section 2.2) see product specifications drawing no.PS-71310 for cable preparation. Follow the steps below: ADJUSTING KNOB #8-32 SHSS LOWER RAISE 1. Push down on the upper wire clamp and hold the front end to open it. 2. Install the cable and the connector assembly, with the ferrule, in position in the nest. Make sure the connector is pushed against the connector nest. 3. Position the cable into the notch of the lower wire clamp. 4. Release the upper wire clamp. CONNECTOR AGAINST CONNECTOR NEST FERRULE 5.26mm ADJUSTMENT RANGE MAXIMUM DEPTH Figure 2-5 Connector Nest The connector nest is located just to the right of the lower crimp die. See Figure 1-1. It is adjusted as follows: CABLE 1. Loosen the two (2) #8-32 SHCS that lock the nest in position. 2. Slide the nest to the left or right for proper position, making sure that the crimp portion of the ferrule is located directly over the lower crimping die when the connector is pushed up against the connector nest. 3. Tighten the two (2) #8-32 SHCS. Order No: ATS-011219507 Revision: A Release Date: 08-24-99 Revision Date: 01-22-09 Figure 2-6 5. Cycle the press by pulling the press crimp lever forward and down. 6. Return the press lever to the full up position. 7. Open the cable clamp. 8. Remove the terminated assembly. UNCONTROLLED COPY Page 10 of 17 Manual Press with SEMCONN™ Ferrule Adapter Kit PRESS HANDLE RATCHET RELEASE LEVER Warning: Once the press ram handle has started to descend, it cannot be returned to the up position until the full stroke of the press has been completed. In case of a jam or some other problem, should the press ram ever need to be returned to the up position before completing the full stroke, pull up on the ratchet release lever and raise the press ram handle. The ratchet release lever is located on the upper left side of the press frame. See Figure 2-7. Figure 2-7 Order No: ATS-011219507 Revision: A Release Date: 08-24-99 Revision Date: 01-22-09 UNCONTROLLED COPY Page 11 of 17 Manual Press with SEMCONN™ Ferrule Adapter Kit Section 3 Maintenance 3.1. Cleaning 3.2. Lubrication 3.3. Perishable Parts 3.4. Spare Parts 3.5. Troubleshooting 3.6. Glossary of Terms Order No: ATS-011219507 Revision: A Release Date: 08-24-99 Revision Date: 01-22-09 UNCONTROLLED COPY Page 12 of 17 Manual Press with SEMCONN™ Ferrule Adapter Kit 3.1 Cleaning This press should be cleaned daily. Use a soft bristle brush to remove debris from critical areas such as the housing nest. See the Chart on next page for recommended Preventive Maintenance Schedule. NOTE: Using compressed air to clean tooling is not recommended. Chips can wedge in the tooling and/or fly at an operator. 3.2 Lubrication 1. 2. 3. Grease the ram including the cam follower groove. Oil all moving parts of the press. Lubricate with multipurpose synthetic lubricant with Teflon or an equivalent. Molex ships its presses pre-greased with Permatex multi-purpose synthetic grease with Teflon No. 82329. A SAE 30WT non-detergent oil or light spindle oil or 3-in-1 oil should be used on pivot points. WARNING: Never use penetrants such as WD40 for any lubrication on the press. 4. Lubricate all points shown in Figures 3-1 with the specified oil and grease (or equivalent). GREASE OIL OIL OIL ROLLERS and BEARINGS (2) OIL ROLLERS and BEARINGS (2) GREASE Figure 3-1 Order No: ATS-011219507 Revision: A Release Date: 08-24-99 Revision Date: 01-22-09 UNCONTROLLED COPY Page 13 of 17 Manual Press with SEMCONN™ Ferrule Adapter Kit 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 you own schedule or use your company’s standard chart, if applicable. Preventive Maintenance Chart Daily: Clean. See Section 3.1. As Required: Lubricate. See Section 3.2. CHECK SHEET MONTH _________YEAR _________ Week Daily Clean Days of the Week MON TUE WED THU FRI SAT SUN Solution 1 2 3 4 Cleaning Reapply greasing Reapply oil Inspect all tooling for wear Yes Soft Brush Industrial Degreaser Yes Replace if signs of wear. 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 Complete Manual Press and with the Adaptor Kit Assembly. 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. For the proper perishable tool kit information, refer to the Specification Sheet supplied with the Press. 3.4 Spare Parts Customers are responsible for maintaining the Complete Manual Press and with the Adaptor Kit Assembly. Spare parts are available. Moving and functioning parts 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. See Section 4. Order No: ATS-011219507 Revision: A Release Date: 08-24-99 Revision Date: 01-22-09 UNCONTROLLED COPY Page 14 of 17 Manual Press with SEMCONN™ Ferrule Adapter Kit 3.5 Troubleshooting Symptom Ram goes down but will not go back up Full stroke ratchet mechanism not engaging
Cause
Sticking ratchet pawl or debris in mechanism Solution Clean and lubricate pivot points. Release ram with release lever and adjust ram stroke. See Section 2.2, Ram Stroke Adjustment.
Ram set too low
Sticking ratchet pawl or debris in mechanism
Broken ratchet pawl spring or damaged pawl
Worn anti-backup sprocket.
Damaged upper and/or lower crimp die Clean and lubricate pivot points Repair or Replace. Replace. Replace die(s). Connector nest not positioned correctly. Crimp section of
Ferrule not positioned correctly over die See Section 2.2, Connector Nest. ferrule damaged. Read Section 2.1, Upper Tooling and
Upper and lower dies not properly aligned Lower Tooling, to realign the dies. Ferrule not Adjust the press stroke. See Section 2.2.
Press ram stroke too short fully crimped Ram Stroke Adjustment Consult Press Manual order number ATS-011316356 for any press problems. Order No: ATS-011219507 Revision: A Release Date: 08-24-99 Revision Date: 01-22-09 UNCONTROLLED COPY Page 15 of 17 Manual Press with SEMCONN™ Ferrule Adapter Kit Section 4 4.1 Parts List 4.2 Assembly Drawings Order No: ATS-011219507 Revision: A Release Date: 08-24-99 Revision Date: 01-22-09 UNCONTROLLED COPY Page 16 of 17 Manual Press with SEMCONN™ Ferrule Adapter Kit 4.1 Parts List Item 1 2 4.2 Manual Press with SEMCONN™ Ferrule Adapter Kit 11-21-9507 Order No. Engineering No. Description 11-21-9507 AM60098 SEMCONN™ Ferrule Adapter Kit 11-31-6356 AM60026-50 Molex Standard Manual Press Quantity 1 1 Assembly 2 1 Americas Headquarters Lisle, Illinois 60532 U.S.A. 1-800-78MOLEX amerinfo@molex.com 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-011219507 Revision: A Release Date: 08-24-99 Revision Date: 01-22-09 UNCONTROLLED COPY Page 17 of 17