Stick Insertion Tool
Terminal Stick Insertion Tool
Operation Manual
Order No. 62200-1700
For LFH™ Series 71624 and 70984
Description
Operation
Maintenance
Order No TM-622001700
Revision: B
Release Date: 06-28--13
Revision Date: 10-28-14
UNCONTROLLED COPY
Page 1 of 20
Stick Insertion Tool
Table of Contents
Contents
Terminal Stick Insertion Tool ............................................................................................................................................. 1
Safety Warnings and Information ...................................................................................................................................... 3
Tooling Technical Assistance ............................................................................................................................................ 4
Section 1 ........................................................................................................................................................................... 5
General Description ...................................................................................................................................................... 5
1.1 Description......................................................................................................................................................... 6
1.2 Features ............................................................................................................................................................ 6
1.3 Technical Specifications .................................................................................................................................... 6
1.4 Delivery Check .................................................................................................................................................. 6
1.5 Tools.................................................................................................................................................................. 6
1.6 Installation ......................................................................................................................................................... 6
1.7 Products ............................................................................................................................................................ 6
Section 2 ........................................................................................................................................................................... 7
Setting Up And Operation ............................................................................................................................................. 7
Principal Mechanical Parts of the Terminal Stick Insertion Tool ................................................................................... 8
2.1 Adjustments ....................................................................................................................................................... 9
2.2 Operation ......................................................................................................................................................... 10
Section 3 ......................................................................................................................................................................... 12
Maintenance ............................................................................................................................................................... 12
3.1 Cleaning .......................................................................................................................................................... 13
3.2 Lubrication ....................................................................................................................................................... 13
3.3 Perishable Parts .............................................................................................................................................. 14
3.4 Preventive Maintenance Chart ........................................................................................................................ 14
3.4 Troubleshooting ............................................................................................................................................... 14
Section 4 ......................................................................................................................................................................... 15
4.1 Main Parts List and Assembly ......................................................................................................................... 16
4.2 Parts List Insertion Fixture ............................................................................................................................... 17
4.3 Parts List Tool Kit ............................................................................................................................................ 19
Order No TM-622001700
Revision: B
Release Date: 06-28--13
Revision Date: 10-28-14
UNCONTROLLED COPY
Page 2 of 20
Stick Insertion Tool
Safety Warnings and Information
Read and understand all of the instructions and safety information in this
manual before operating or servicing this tool.
Keep this manual available when using this tool.
Replacement manuals are available for download at www.molex.com.
SAFETY ALERT SYMBOL
This symbol is used to call your attention to hazards or unsafe practices which could result in an injury
or property damage. The signal word, defined below, indicates the severity of the hazard. The message
after the signal word provides information for preventing or avoiding the hazard.
DANGER:
DANGER
Indicates an imminently hazardous situation which, if not avoided, could result in death or serious injury.
WARNING:
WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION:
CAUTION
Indicates a potentially hazardous situation which, 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
Never Operate, service, or adjust this machine,
or install termination tooling, without proper
instruction and without first reading and
understanding the instructions in this manual.
Always wear proper eye protection when
Operating or servicing this tool.
Failure to wear eye protection could result
In serious eye injury from flying debris.
WARNING
Do not use compressed air to clean this equipment.
The forces created by compressed air can force debris into the tool.
Failure to observe these precautions may result in injury or property damage..
CAUTION
Never perform any service or maintenance other than as described in this manual.
Never modify, alter or misuse the equipment
Failure to observe this precaution may result in injury and property damage.
Order No TM-622001700
Revision: B
Release Date: 06-28--13
Revision Date: 10-28-14
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Page 3 of 20
Stick Insertion Tool
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 the two numbers listed below and asking for the Molex Tooling
Group.
Call Toll Free 1-800-786-6539 (US) 1-630-969-4550 (Global).
This assistance is limited to the operation and set-up of a customer’s Molex Stick Insertion Tool. Questions with
regard to Molex connector products or how to identify the proper tooling and/ or tooling documentation should be
directed to your local Molex personnel or Customer Service Representative.
When calling for service on this tool it is recommended to have the following: a copy of the Operation Manual, the
Specific Application Tooling Specification Sheet and a person familiar with the tools should be present. The
following information is also recommended to supply:
1.
2.
3.
4.
5.
6.
7.
8.
Customer name
Customer address
Person to contact such as (name, title, e-mail, and telephone number)
Tools order number (Lease number also if applicable)
Serial number (Lease number also if applicable)
Molex Connector product order number
Urgency of request
Nature of problem
Molex Application Tooling Group
2200 Wellington Court
Lisle, IL 60532, USA
Tel: +1 (630) 969-4550
Fax:+1 (630) 505-0049
Visit our Web site at http://www.molex.com
Order No TM-622001700
Revision: B
Release Date: 06-28--13
Revision Date: 10-28-14
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Page 4 of 20
Stick Insertion Tool
Section 1
General Description
1.1.
Description
1.2.
Features
1.3.
Technical Specifications
1.4.
Delivery Check
1.5.
Tools
1.6.
Installation
1.7.
Products
Order No TM-622001700
Revision: B
Release Date: 06-28--13
Revision Date: 10-28-14
UNCONTROLLED COPY
Page 5 of 20
Stick Insertion Tool
General Description
1.5 Tools
1.1 Description
The Molex 62200-1700 Stick Insertion Fixture is used
to load four LFH™ contact terminal sticks into a
shielded housing. The four LFH™ terminal sticks are
loaded into a drawer and the shielded housing is
placed into a sliding nest. Then the cable is secured
under the cable clamp. Insertion occurs when the
lever is pulled.
1.2 Features
Four LFH™ terminal sticks are inserted into the
shielded housing simultaneously.
The terminal stick holding drawer includes a feature
to prevent loading the LFH™ terminal sticks, and the
shielded housing upside-down.
The insertion lever has a positive stop for consistent
insertions, ensuring no damage to the shield or
terminal sticks.
The insertion lever can be positioned for either a
right handed or left handed operator.
The stick drawer has 1/4 turn screws on the drawer
cover making it easier to load and unload the LFH™
terminal sticks and shielded housing.
1.3 Technical Specifications
Dimensions
Height
Width
Depth
Weight
130mm (4.70”)
400mm (15.70”)
225mm (8.90”)
11.8kgf (26.0lbs.)
Production Rate:
This insertion tool loads up to 25 shield assemblies
per hour depending on the operator’s skill.
Metric Hex Wrench Set
6 inch Adjustable Wrench
1.6 Installation
Before attempting to operate the Terminal Stick
Insertion Tool, be sure it is securely fastened to a
clean, study work bench or table in a well-lighted
area. Fasten the base with four M8 screws, of
sufficient length for the table top. (Not supplied). See
Figure 1-1.
STICK
INSERTION
TOOL
M8
SCREWS
(4)
WORK
BENCH
Figure 1-1
Damage to the shield assembly and/or injury to the
operator could result were the tool to move during
insertion. Be sure there is ample room around the
tool to allow easy loading and operation.
1.7
Products
Order No.
1.4 Delivery Check
Carefully remove the Terminal Stick Insertion Tool
from its shipping container. Check to see that
following items are included in this package:
Decription:
Quantity
62200-1700 Terminal Stick Insertion Tool
1
TM-6220017000 Instruction Manual
1
62200-0734
Plug Removal Tool 1
Order No TM-622001700
Revision: B
The following tools are recommended for setup and
adjustments to the this tool.
Release Date: 06-28--13
Revision Date: 10-28-14
Description
1.27mm (.050") Pitch
70984-4009 70984-4010
LFH™ Matrix 50
I/O Shield Cable Kit,
70984-4011
Terminal Stick, 40 Circuits
1.27mm (.050") Pitch
LFH™ Matrix 50
71624-3000 71624-3001
I/O Shield Cable Kit,
Subassembly, 160 Circuits
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Stick Insertion Tool
Section 2
Setting Up And Operation
2.1.
Adjustments
2.2.
Operation
Order No TM-622001700
Revision: B
Release Date: 06-28--13
Revision Date: 10-28-14
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Page 7 of 20
Stick Insertion Tool
Principal Mechanical Parts of the Terminal Stick Insertion Tool
REVOLVING
HANDLE
PLUG REMOVAL
TOOL
INSERTION
LEVER
PLUG NEST
SLIDE STOP
PLUG NEST
160 CKT MALE
PLUG NEST SLIDE
STOP SCREW
STICK GUIDE RIGHT
QUARTER TURN
SCREW (2)
DRAWER
COVER
STICK DRAWER
SLIDE
SLIDE
BASE
SLIDE
GIB (2)
LEVER PIVOT
BLOCK
PLUG NEST
SLIDE
STICK GUIDE
LEFT
STICK DRAWER
STOP
STICK DRAWER
SLIDE STOP SCREW
STICK DRAWER
PUSHER BLADE
HOLDER
Figure 2-1
Order No TM-622001700
Revision: B
Release Date: 06-28--13
Revision Date: 10-28-14
STICK DRAWER
SLIDE STOP
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Stick Insertion Tool
Set Up
Slide Gib
The Terminal Stick Insertion Tool has been factory set
and should not need any adjustments. However, over
time if there are some adjustments needed follow the
steps below.
If either slide has excessive side clearance, faulty
insertions may result. There are two slide gibs to
guide both slides.
2.1 Adjustments
Plug Nest Slide Stop
Loosen the screws on one of the gibs and move
the gib until the side clearance is minimized but the
slide can still move freely.
Left or Right Handed Operation
The forward (insertion) position of the plug nest is
controlled by a plug nest slide stop screw. To
adjust the plug nest:
1. Loosen the lock nut on the plug nest slide and
turn the slide stop screw counterclockwise
several turns. See Figure 2-1.
2. Make a sample assembly and check alignment.
The insertion lever can be installed on either the
left side or the right side of the insertion tool
depending on the operator’s preference. To adjust
the lever:
LEVER
Note: Care must be taken when inserting the
terminal sticks. There is no stop only the
pusher blades.
3. Leave the plug nest in the inserted position.
Keep the shield assembly in the nest and
adjust the slide stop screw clockwise until the
stop screw just starts to move the plug nest
back.
4. Tighten the lock nut.
5. The back (retracted) position of the plug nest is
controlled by the pin travel in the slot on the
insertion lever. No adjustment is needed.
Stick Drawer Slide
The forward (loading) position of the stick drawer is
controlled by a stick drawer slide stop screw. See
Figure 2-1.
The screw is adjusted until the bottom of the
narrow groove (that the pusher blade travels
through) just barely touches the back of the pusher
blades.
This will keep the pusher blades from being
damaged if the stick drawer is pushed into them.
The stick drawer stop will prevent the stick drawer
slide from leaving the tool.
LEVER
PIVOT
M6 SET
SCREW
M6 SCREW (2)
Figure 2-2A
SLIDE GIB
1. Remove the two M6 screws from the lever
pivot mounted to the side gib. See Figure 22A.
M6 SHCS (2)
PIN IN PLUG
NEST SLIDE
SLIDE GIB
LEVER
Figure 2-2B
Order No TM-622001700
Revision: B
Release Date: 06-28--13
Revision Date: 10-28-14
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Page 9 of 20
Stick Insertion Tool
2. Lift up the entire lever and rotate the handle
with the mounting block to the opposite side of
the tool.
3. Place the lever over the pin in the plug nest
slide.
4. Tighten the two M6 screws. See Figure 2.2B.
3. Make sure that the stick drawer is pushed
forward until it stops.
4. Remove the drawer cover by turning the two
quarter-turn screws 90° so that the head of
the screw can be inserted into the slot on the
cover and the cover can be pulled up. See
Figure 2-5.
DRAWER COVER
2.2 Operation
1. Load the shielded housing into the plug nest.
The plug nest can be loaded only one way.
See Figure 2-3. The long side of the "D"
shell is towards the top of the nest.
QUARTER-TURN
SCRWS (2)
SHIELD ASSEMBLY
PLUG NEST
BALL
LOCATOR
BALL
LOCATOR
Figure 2-3
PLUG NEST
Figure 2-5
5. Place the bottom row LFH™ stick assembly
into the drawer. The stick drawer has small
slots and grooves in it which it accepts the
stick latches to avoid loading a stick upside
down. See figure 2-6.
GROOVES
SHIELD ASSEMBLY
SLOTS
BALL
LOCATOR
Figure 2-6
TERMINAL STICKS
Figure 2-4
Note: Make sure that the back of the shield
faces the stick drawer (the mating end of the
shield faces away from the stick drawer).
2. The screw holes in the shield should also
"pop" into the ball locators in the nest. See
Figure 2-4.
Order No TM-622001700
Revision: B
Release Date: 06-28--13
Revision Date: 10-28-14
6. Repeat step 5 for the remaining LFH™ terminal
sticks in the connector. The groove orientation
on the terminal sticks must be the same for all
the sticks; if it is not, the sticks will not stack
properly. See Figure 2-7.
Note: Even if the sticks have no wires
terminated to them, they still must be loaded
in the drawer. The tooling is designed to
accept (4) sticks only.
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Stick Insertion Tool
specification document no. AS-71624-001 for
housing assembly dimensional requirements.
12. In the fully inserted position, lift the drawer
cover up by turning the two quarter-turn screws
90°. See Figure 2-8.
DRAW COVER
REMOVED
LEVER IN FULLY
INSERTED POSITION
TERMINAL
STICKS
PUSHER
BLADES (5)
QUARTER-TURN
SCRWS (2)
REMOVAL
TOOL
Figure 2-7
7. Insert the cover over the two quarter-turn
screws and rotate the head of the screws 90°to
lock. The cover should hold sticks in place for
insertion and is not meant to clamp stacked
terminal sticks.
8. If the cover does not snap into position, one or
more of the LFH™ terminal sticks in the drawer
were loaded upside - down.
9. Remove the LFH™ terminal sticks and restack
them, then close the cover. See Figure 2-7.
10. Slowly pull the handle on the insertion lever
towards the LFH™ terminal sticks. When the
terminal sticks have started into the shield
housing, quickly follow through with the handle
motion, until it stops. It is important to "feel"
the start of the terminal sticks into the shield; if
a lot of resistance is felt, move the insertion
lever back to check for misalignment or
obstructions.
11. It is very important to quickly snap the terminal
sticks into the housing. Due to the shear
properties of the LFH™ terminal sticks over
mold material, a slowly loaded assembly will
probably have sheared latches, resulting in low
terminal retention force. If they are quickly
snapped into the housing, the latches will not
have time to shear, and retention forces will be
much higher. Refer to the application
Order No TM-622001700
Revision: B
Release Date: 06-28--13
Revision Date: 10-28-14
Figure 2-8
INSERTED
ASSEMBLY
13. Using the plug removal tool, Order No. 622000734, lift the finished assembly out of the shield
nest.
14. There is a cleared - out area in the center of
the shield nest for the plug removal tool to
enter. Remove the inserted assembly from the
cable clamp. See Figure 2-9.
15. Return the nests back to their starting
positions.
REMOVAL TOOL
INSERTED ASSEMBLY
PLUG NEST
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Figure 2-9
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Stick Insertion Tool
Section 3
Maintenance
3.1.
Cleaning
3.2.
Lubrication
3.3.
Perishable Parts
3.4.
Troubleshooting
Order No TM-622001700
Revision: B
Release Date: 06-28--13
Revision Date: 10-28-14
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Page 12 of 20
Stick Insertion Tool
3.1
Cleaning
For efficient operation, this tool should be cleaned daily with a soft bristle brush to remove any debris and
plating dust from the slide area and the two nests. For continuous operation this may have to be done
several times throughout the day.
See Section 3.4 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.
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. Oil all moving parts of this tool.
2. Sparingly lubricate the sliding parts approximately every month with SAE 10W motor oil or equivalent.
3. Lubricate with multipurpose synthetic lubricant with Teflon or an equivalent. Molex ships its presses pregreased with Permatex multi-purpose synthetic grease with Teflon No. 82329. SAE 10 non-detergent oil or
light spindle oil or 3-in-1 oil should be used on pivot points.
WARNING: Never use a penetrant such as WD40 for any lubrication on this tool.
4. Lubricate all points shown in Figures 3-1 with the specified oil and grease (or equivalent).
Figure 3-1
Order No TM-622001700
Revision: B
Release Date: 06-28--13
Revision Date: 10-28-14
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Stick Insertion Tool
3.3
3.4
Perishable Parts
Customers are responsible for maintaining this tool. 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.
Preventive Maintenance Chart
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.
Daily: Clean. See Section 3.1.
Monthly: Clean as necessary, See Section 3.1.
Lubricate sliding parts, See Section 3.2.
CHECK SHEET
MONTH _________YEAR _________
Days of the Week
Daily Clean
MON TUE WED THU FRI SAT SUN
Week
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.
3.4
Troubleshooting
Symptom
Poor terminal
retention
Cause
Terminal sticks not
fully inserted
Insertion lever slowly
inserted
Terminal stick to
shield misaligned
Shield not located in nest
Terminal stick to shield
misalignment
Shield or terminal
damaged
Shield not located in nest.
Terminal stick(s) loaded
upside down
Order No TM-622001700
Revision: B
Solution
Check forward position of plug nest slide. Adjust if necessary.
See Adjustments Section 2.1.
After the contacts have started into the shield, the insertion
lever must be "snapped" in to position to avoid shearing the
terminal stick latches.
Make sure that there is not excessive side clearance in the slides.
If there is, adjust one slide gib. See Adjustments Section 2.1.
Make sure that the shield has snapped into the nest and is
located by the spring loaded balls. Section 2.2.
Make sure that there is not excessive side clearance in the slides.
If there is, adjust one slide gib. See Adjustments Section 2.1.
Make sure that the shield has snapped into the nest and is
located by the spring loaded balls. Section 2.2.
All four terminal sticks must be in the proper orientation, otherwise
shield damage will result. See Section 2.2.
Release Date: 06-28--13
Revision Date: 10-28-14
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Stick Insertion Tool
Section 4
4.1
Main Parts List and Assembly Drawing
4.2
Insertion Fixture Parts List and Assembly Drawing
4.3
Tool Kit Parts List and Assembly Drawing
Order No TM-622001700
Revision: B
Release Date: 06-28--13
Revision Date: 10-28-14
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Page 15 of 20
Stick Insertion Tool
4.1
Main Parts List and Assembly
62200-1700 Terminal Stick Insertion Tool Figure 4-1
Item Order No Engineering No.
Description
Notes
Quantity
1
62200-0700
62200-0700
Terminal Stick Insertion Fixture
Figure 4-3
1
2
62200-1000
62200-1000
Terminal Stick Insertion Slide 160 Circuit Tool Kit Figure 4-2
1
1
2
Figure 4-1
Order No TM-622001700
Revision: B
Release Date: 06-28--13
Revision Date: 10-28-14
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Stick Insertion Tool
4.2
Parts List Insertion Fixture
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
62200-0700 Terminal Stick Insertion Fixture Figure 4-2
Order No Engineering No.
Description
PP Quantity
62200-0723
62200-0723
Slide Base
1
62200-0724
62200-0724
Slide Gib
2
62200-0725
62200-0725
Stick Drawer Slide
1
62200-0726
62200-0726
Plug Nest Slide
1
62200-0727
62200-0727
Lever Pivot Block
1
62200-0728
62200-0728
Insertion Lever
1
62200-0730
62200-0730
Lever Pivot Pin
1
62200-0731
62200-0731
Plug Nest Slide Stop
1
62200-0732
62200-0732
Stick Drawer Slide Stop
1
62200-0734
62200-0734
Plug Removal Tool
1
63600-0135
63600-0135
Handle Revolving M8
1
Hardware
N/A
69809-1620
M6 by 20 Long Dowel
1**
N/A
69901-1416
M4 by 16 Long SHCS
2**
N/A
69901-1616
M6 by 16 Long SHCS
2**
N/A
69901-1630
M6 by 30 Long SHCS
12**
N/A
69901-1635
M6 by 35 Long SHCS
2**
N/A
69904-3612
M6 by12 Long Set Screw Cup
1**
N/A
69907-1600
M6 Hex Nut
2**
PP - Part is a Perishable Part.
** Available from an industrial supply company such as MSC (1-800-645-7270).
Order No TM-622001700
Revision: B
Release Date: 06-28--13
Revision Date: 10-28-14
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Stick Insertion Tool
Assembly Insertion Fixture
7
6
16
11
(2)
14
17
5
(5)
(2)
8
4
15
2
15
18
10
15
(5)
3
2
(2)
13
12
1
9
18
Figure 4-2
15
Order No TM-622001700
Revision: B
Release Date: 06-28--13
Revision Date: 10-28-14
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Stick Insertion Tool
4.3
Parts List Tool Kit
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
62200-1000 Terminal Stick Insertion Slide 160 Circuit Tool Kit Figure 4-3
Order No Engineering No.
Description
PP Quantity
11-32-7560 AM-63527A111
Carbide Ball 5/32“ Diameter
2
11-32-7805 AM-63529A211
Quarter Turn Screw M5
2
11-31-3069 AM-61125-200-59
Compression Spring
2
62200-0818
62200-0818
Pusher Blade
PP
5
62200-1003
62200-1003
Stick Drawer 160 Circuit
1
62200-1004
62200-1004
Drawer Cover 160 Circuit
1
62200-1011
62200-1011
Plug Nest 160 Circuit Male
1
62200-1012
62200-1012
40 Circuit Stick Guide Right
1
62200-1013
62200-1013
40 Circuit Stick Guide Left
1
62200-1019
62200-1019
Pusher Blade Holder
1
62200-0721
62200-0721
Pusher Blade Clamp
1
Hardware
N/A
69809-1308
M3 by 8 Long Dowel
8**
N/A
69809-1616
M6 by 16 Long Dowel
2**
N/A
69901-1320
M3 by 20 Long SHCS
2**
N/A
69901-1510
M5 by 10 Long SHCS
2**
N/A
69901-1514
M5 by 14 Long SHCS
2**
N/A
69902-1312
M3 by 12 Long BHCS
2**
N/A
69903-1310
M3 by 10 Long FHCS
3**
N/A
69904-3510
M5 by 10 Long Set Screw Cup
2**
PP - Part is a Perishable Part.
** Available from an industrial supply company such as MSC (1-800-645-7270).
Order No TM-622001700
Revision: B
Release Date: 06-28--13
Revision Date: 10-28-14
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Stick Insertion Tool
Assembly Tool Kit
2
(2) 15
(2)
6
62200-0726
REF
5
62200-0725
REF
7
12 (2)
19 (2)
14
1
(2)
(2)
12 (2)
9
(2)
16
(2)
13
(2)
17
8
3
(2)
18 (3)
10
11
4
(5)
62200-0723
REF
Figure 4-3
Visit our Web site at http://www.molex.com
Order No TM-622001700
Revision: B
Release Date: 06-28--13
Revision Date: 10-28-14
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