RAST 5.0 Arbor Press
RAST 5.0 ARBOR PRESS
TERMINATOR
Order Number 62201-7500
Operation Manual
Description
Operation
Maintenance
Doc: No: TM-622017500
Revision: E
Release Date: 12-20-00
Revision Date: 08-14-09
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RAST 5.0 Arbor Press
WARNING
NEVER
OPERATE, SERVICE, INSTALL OR ADJUST THIS MACHINE WITHOUT PROPER
INSTRUCTION AND WITHOUT FIRST READING AND UNDERSTANDING THE
INSTRUCTIONS IN THIS MANUAL AND ALL APPLICABLE PRESS AND/OR
WIRE PROCESSING MACHINE MANUALS.
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
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Revision Date: 08-14-09
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Table of Contents
SECTION
1.
General Description
2.
Set-Up and Operation
3.
Maintenance, Perishable Parts, Spare Parts and Troubleshooting
4.
Parts List and Assembly Drawings
5.
Connector Series Chart
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Section 1
General Description
1.1
Description
1.2
Features
1.3
Technical Specifications
1.4
Delivery Check
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RAST 5.0 Arbor Press
Principal Mechanical parts of the RAST 5.0 Terminator 62201-7500
ADJUSTING
KNOB
PRESS
LEVER
ADAPTER
BLOCK
PRESS
FRAME
UPPER
TOOLING
CONNECTOR
SUPPORT
GUIDE SPACER
ADJUSTABLE
GUIDE
BASE PLATE
Figure 1-1
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RAST 5.0 Arbor Press
General Descrition
1.1. Description
The 62201-7500 Rast 5.0 Discrete Wire Arbor Press Terminator is designed to terminate the Rast 5.0 connector
(90833, 90835, 90888, 91338, 91777, 91778, 91779, 91954 and 92000 Series) onto discrete wires of various
sizes (0.35 mm2 to 0.38 mm2) for 4A, (0.5 mm2 to 0.75 mm2) for 6A and (1.0 mm2 to 1.5 mm2) for 16A. These
connectors come in long chains or "stacks" that are cut apart during termination. The tooling will accommodate
from 1 to 12 circuits. The operator loads a connector into the nest, inserts the wires into position, and operates
the press. When termination is complete the operator removes the harness. This terminator is ideally suited for
low to medium volume production.
1.2. Features
Bench mounted operation.
Manual operation, no air or electricity required.
Easily moved from one location to another.
1.3. Technical Specification
Dimensions
Width:
230mm(11.4")
Depth:
145mm(5.7") without connector support
Depth:
480mm(18.9") with connector support
Height:
525mm(20.7")
Weight
22.71kg
(50lbs)
Rate
Approximately 450 discrete wires per hour depending on operator skill.
1.4. Delivery Check
Carefully remove the Terminator from its shipping container and determine that the following items are included
in the package.
Description
62201-7500
Quantity
Rast 5.0
Terminator Press
1
62201-7414
Housing Load Platform 1
TM-622017500 Operation Manual
1
62201-7512
16 AMP Top Wire Guide 1
OR
(one guide or the other is installed in the press)
62201-7513
6 AMP Top Wire Guide
1
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Section 2
Set-Up and Operation
2.1.
Installation
2.2.
Set-Up
2.3.
Operation
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2.1
Installation
3.
Set the press on a bench of suitable height and
capable of supporting at least 70 kg (155 lbs). Using
the two (2) M4 X 12 FSHCs supplied with the press,
mount the Housing Load Platform to the press as
shown in Figure 1-1. (See also the assembly
drawing in Section 4.) There are two (2) clearance
holes in the base plate (see Fig, 1-1), for 8 mm or
5/16 in. screws, if it is desired to bolt the press to the
bench. Make sure there is adequate room around
the press for the operator to load connectors and to
store wires and finished harnesses. Make certain
there is adequate lighting.
2.2
a)
b)
c)
height adjusting knob counterclockwise. To
increase the height, turn the knob clockwise.
When the desired height is set, tighten the
locking screws. The height of the connector
after termination should be as follows:
90833, 90888, 91338and 91954 series, height =
23 +0.2 / -0.1 mm.
90835 and 91247 series, height = 25 +0.2 / -0.1
mm.
See also sheet 4 of the application
specifications #AS-99033-0004.
Setup
2.2.1 Termination Height
Refer to Figure 1-1 and 2-1.
TERMINATION HEIGHT
ADJUSTING KNOB
ADAPTER
BLOCK
ADAPTER BLOCK
LOCKING SCREWS
Figure 2-1
ADAPTER BLOCK AND SCREWS
In order to insure the connector top half is correctly
seated in the lower half and that the wires are
correctly terminated, it may necessary to adjust the
termination height. This is done as follows:
1. To adjust the termination height, loosen the
three (3) socket head cap screws that lock the
adaptor block to the press frame.
2. To decrease the termination height (the height
of the connector after termination) turn the
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Figure 2-2
SETTING THE CONNECTOR GUIDE
2.2.2 Adjusting for Connector Size
The Rast 5 connectors come in various circuit sizes
from 1 to 12, and also in five types, two (2) of which
(90835 and 91247 Series) are 16A connectors and
are slightly taller and require the removal of a shim.
See Section 2.2.3 for details. Adjusting for circuit
size is as follows:
1. Place a stack of connectors of the correct size
on the connector support and slide it forward
until it is between the adjustable guide block and
the fixed guide block.
2. Push it up against the fixed guide block.
3. Loosen the two (2) locking screws (See Figure
2-2).
4. Slide the adjustable guide block toward the
connector until the connector stack can be slid
between the guides with no noticeable side play.
The connector holdown plates on both sides
should be in far enough that they hold the
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connectors from moving up but not enough to
interfere with horizontal movement.
NOTE: The guide shim should stay all the way
in unless 90835 or 91247 series connectors are
being run, See Section 2.2.3
5. Tighten the locking screws.
ADJUSTABLE
GUIDE
1. Loosen the two (2) adjustable guide locking
screws (See Figure 2-2).
2. If changing to the larger 16A connectors, pull
the guide shim out until it stops.
OR If changing to the smaller 6A connectors, push
the shim in until it stops.
3. In the bottom of the groove in between the
adjustable guide and the wire guides there is a
plate that must be removed if 16A connectors
are to be loaded or installed if changing to the
6A connectors. (See Figure 2-3.)
4. Adjust the adjustable guide per Section 2.2.2.
5. Tighten the locking screws.
TERMINATED
CONNECTOR
GUIDE SPACER
WIRE GUIDES
PUT SPACER IN FOR 6A
CONNECTOR TAKE OUT
FOR 16A CONNECTOR
Figure 2-3
2.2.3
Changing To or From The 16 AMP and
The 6 AMP Connectors
The Rast 5 connectors come in two different ampere
ratings 6 and 16 AMPS. The 16 AMP connectors
(90835 91779 and 92000 series) are slightly taller
than the 6 AMP connectors (90833, 90888, and
91338 series), therefore the tooling has to be
adjusted to accommodate the different heights. That
is done as follows:
6A-TOP WIRE GUIDE
622017513
16A-TOP WIRE GUIDE
622017512
Figure2-4
TOP WIRE GUIDES
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Revision Date: 08-14-09
WIRE RELEASE
LEVER
WIRES
WIRE GUIDES
Figure 2-5
CONNECTOR / WIRE ASSEMBLY
READY TO BE REMOVED
2.2.4 Setup For Wire Size
There are two (2) wire top guides,one for 6A wire
and one for 16A wire (See Figure 2-4). These must
be changed depending on the wire being used.
1. Remove the hold-down screw.
2. Remove one part, put the other part in place and
replace the screw.
NOTE: The 6A guide has two stops-one for
.50mm2 / .75mm2 and one for .35mm2 /
.38mm2. Install the guide with the desired wire
size marking facing the operator.
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2.2.5 Adjusting the Wire Tension
It is necessary to make an adjustment to the wire
stop when changing from one wire size to another.
Refer to Figure 2-5.
1. Turn the stop screw clockwise (CW) to decrease
the tension or counterclockwise (CCW) to
increase the tension applied to the wire. Adjust
the tension so the wire can be pushed through
the guides, into the connector, and held firmly in
place upon release.
together terminating the wires and latching the
connector halves together. It will also cut the
connector from the stack.
5. Return the press lever to the up position.
6. Remove the connector and wire or cable
assembly from the terminator by pressing
down on the wire release lever to the left of the
wire guides and sliding the assembly out to the
right. (See Figure 2-5.) Reference sheet 4 of
Application Specification #ES-990033-0004 to
determine if termination is correct.
2.3 Operation
1. Load a stack of connectors in between the
guide blocks as shown in Figure 2-2.
2. Push the connector stack forward until the first
connector “clicks” into position (there are
detents that prevent the connectors from
backing up).
3. Load the wires individually by inserting them in
the wire guides then pushing them through the
holes in the connector and up against the stop
(See Figure 2-4).
4. When the wires are loaded, cycle the press by
pulling forward and down on the press lever.
This will press the two halves of the connector
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Figure 2-6
ADDING CONNECTOR STACKS
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Section 3
3.1
Maintenance
3.2
Perishable Parts
3.3
Spare Parts
3.4
Troubleshooting
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CAUTION: Always disconnect power supply before all maintenance
3.1 Maintenance
(See Chart below for maintenance scheduling,)
Cleaning
The Rast 5.0 Manual Terminator should be cleaned at least once a day with a soft brush to remove dust
and debris.
CAUTION: Using compressed air to clean the Terminator is not recommended as debris could
become jammed in the tooling and/or come flying out at the operator.
Lubrication
The press needs regular lubrication on a monthly basis. Place a small amount of lubricant with Teflon, such
as Permatex “Superlube”, on the sliding surfaces.
An example of a maintenance chart is shown below. Copy and use this chart to track the maintenance of your
Terminator 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 3.1.
YEAR _________
CHECK SHEET MONTH
Week
Daily
Cycles
Daily
Clean
Days of the Week
MON TUE WED THU FRI SAT SUN
Solution
1
2
3
4
Cleaning
Reapply grease
Reapply oil
Inspect all tooling, feed
fingers etc. for wear
Soft Brush Industrial
Degreaser
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.
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3.2
Perishable Parts
Customers are responsible for maintaining this press. 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 kits 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.
3.3 Spare Parts
Customers are responsible for maintaining this press. 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.
3.4 Troubleshooting
Symptom
Termination height is
too high / too low.
Wire not sliding easily
into position
Wire not staying in position
when loaded
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Cause
Solution
Termination punch height
not set correctly
Wire guide spring tension
set too high
There is debris in the openings
Connector is partly closed.
Wire guide spring tenstion
set too low
Release Date: 12-20-00
Revision Date: 08-14-09
Readjust the termination height.
See Section 2.2.1. Termination Height.
Readjust the spring tension,
See Section 2.2.5 Adjusting the Wire Ternsion.
Check both the tooling and the
connector for debris and clean as
required.
Inspect the connector chain for damage.
Readjust the spring tension
per Section 2.2.5 Adjusting the Wire Ternsion.
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Section 4
4.1
Parts Lists and Assembly Drawings
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Revision Date: 08-14-09
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Parts List and Assembly Drawings (See Figure 4-1)
Item No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
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Order No.
Description
62201-7409
Lever, Pivot
62201-7412
Base, Mounting
62201-7414
Platform, Housing Load
62201-7420
Shaft, Ram
62201-7425
Guard, Ram
62201-7426
Nameplate, Molex
62201-7427
Plate, Base
62201-7428
Spacer, Locator
62201-7430
Press, Toggle
62201-7501
Base, Tool
62201-7502
Blade, Cutoff
PP
62201-7503
Block, Ram
62201-7504
Guide, Right Housing
62201-7507
Guide, Housing Front
62201-7508
Guide, Left Housing
62201-7509
Locator, Housing Right
62201-7510
Locator, Housing Left
62201-7511
Spacer, Housing (6 AMP)
62201-7512
Guide, Top Wire (16 AMP)
62201-7513
Guide, Top Wire (6 AMP)
62201-7514
Guide, Wire
RSP
62201-7516
Hold-down, Spring
62201-7517
Key, Shaft
62201-7518
Cover, Guide
62201-7521
Spacer, Right Guide
62201-7522
Shaft, Pivot
62201-7523
Angle, Guard
63600-0939
Spring, Wire Guide RSP
63600-0947
Spring, Locator
RSP
69808-1204
Washer, Fender
N/A
M5 by 20 Long SHCS
N/A
M8 by 45 Long SHCS
RSP - Part is a Molex Recommended Spare Part.
PP - Part is a Perishable Part.
Release Date: 12-20-00
Revision Date: 08-14-09
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
12
1
1
1
1
1
1
12
2
2
2**
1**
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Assembly
30
27
4
(2)
14
15
5
13
29
(2)
16
9
11
17
19
12
6
25
20
1
(12)
26
23
21
(12)
18
28
10
7
30
24
22
32
2
8
(2)
31
3
Figure 4-1
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Section 5
5.1 Connector Series Chart
Products: 5.00mm (.197") Pitch Appli-Mate™ RAST 5.0 IDT Connector Assemblies 1 thru 12 Circuits.
Connector
Circuit Size
Series No.
2
3
4
91954
5
6
7
8
9
10
11
12
91954-0001
91954-0008
91954-0015
91954-0022
91954-0029
919540100
91954-0107
91954-0114
91954-0121
91954-0201
91954-0208
91954-0301
91954-0308
91954-0401
91954-0408
91954-0501
91954-0508
91954-0601
91954-0608
919540701
91954-0801
91954-0808
91954-0901
91954-1001
91954-0002
91954-0009
91954-0016
91954-0023
91954-0101
91954-0108
91954-0115
91954-0122
91954-0202
91954-0209
91954-0302
91954-0309
91954-0402
91954-0409
91954-0502
91954-0509
91954-0602
2
90833
3
4
5
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91954-0006
91954-0013
91954-0020
91954-0027
91954-0007
91954-0014
91954-0021
91954-0028
91954-0102 91954-0103 91954-0104 91954-0105 91954-0106
91954-0109 91954-0110 91954-0111 91954-0112 91954-0113
91954-0116 91954-0117 91954-0118 91954-0119 91954-0120
91954-0203
91954-0210
91954-0303
91954-0310
91954-0403
91954-0204
91954-0211
91954-0304
91954-0311
91954-0404
91954-0205
91954-0212
91954-0305
91954-0312
91954-0405
91954-0206 91954-0207
91954-0306 91954-0307
91954-0313 91954-0314
91954-0406 91954-0407
91954-0503 91954-0504 91954-0505 91954-0506 91954-0507
91954-0603 91954-0604 91954-0605 91954-0606 91954-0607
91954-0702 91954-0703 91954-0704 91954-0705 91954-0706
91954-0802 91954-0803 91954-0804 91954-0805 91954-0806 91954-0807
91954-0809
91954-0902
91954-1002
Connector
Circuit Size
Series No.
90833-0001
90833-0008
90833-0015
90833-0022
90833-0048
90833-0057
90833-0064
90833-0073
90833-0500
90833-0507
90833-0526
90833-0534
90833-0541
90833-1251
90833-1258
90833-1271
90833-1283
90833-2001
4A
Connector Assembly Order No.
91954-0003 91954-0004 91954-0005
91954-0010 91954-0011 91954-0012
91954-0017 91954-0018 91954-0019
91954-0024 91954-0025 91954-0026
90833-0002
90833-0009
90833-0016
90833-0025
90833-0050
90833-0058
90833-0065
90833-0074
90833-0501
90833-0508
90833-0528
90833-0535
90833-0542
90833-1252
90833-1259
90833-1272
90833-1284
90833-2002
6A
Connector Assembly Order No.
90833-0003 90833-0004 90833-0005
90833-0010 90833-0011 90833-0012
90833-0017 90833-0018 90833-0019
90833-0026 90833-0027 90833-0028
90833-0051 90833-0052 90833-0053
90833-0059 90833-0060 90833-0061
90833-0066 90833-0069 90833-0070
90833-0006
90833-0013
90833-0020
90833-0032
90833-0054
90833-0062
90833-0071
90833-0007
90833-0014
90833-0021
90833-0047
90833-0056
90833-0063
90833-0072
90833-0502
90833-0509
90833-0529
90833-0536
90833-0505
90833-0513
90833-0532
90833-0539
90833-0506
90833-0524
90833-0533
90833-0540
90833-0503
90833-0510
90833-0530
90833-0537
90833-0504
90833-0511
90833-0531
90833-0538
90833-1253 90833-1254 90833-1255 90833-1256 90833-1257
90833-1260 90833-1261 90833-1262 90833-1264 90833-1267
90833-1273 90833-1276 90833-1277 90833-1279 90833-1282
90833-2006 90833-2007 90833-2008 90833-2010 90833-2011
Release Date: 12-20-00
Revision Date: 08-14-09
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Connector
Circuit Size
Series No.
5
6
7
90833
8
9
10
11
12
90888
2
91338
1
91777
1
2
3
4
91778
5
6
7
8
9
10
11
12
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90833-2012
90833-2028
90833-2750
90833-2777
90833-3500
90833-3520
90833-4250
90833-4266
90833-5000
90833-6000
90833-6024
90833-7000
90833-8000
90888-0001
90888-0028
91338-0102
91338-0601
91338-3105
91338-3801
91777-0102
91777-3103
91778-0001
91778-0008
91778-0015
91778-0022
91778-0029
91778-0101
91778-0108
91778-0115
91778-0122
91778-0201
91778-0208
91778-0301
91778-0308
91778-0401
91778-0408
91778-0501
91778-0508
91778-0601
91778-0608
91778-0701
91778-0708
91778-0801
91778-0808
91778-0901
91778-1001
6A
Connector Assembly Order No.
90833-2019 90833-2023 90833-2024 90833-2025 90833-2026
90833-2029
90833-2751 90833-2752 90833-2764 90833-2765 90833-2773
90833-2778 90833-2779 90833-2780 90833-2781
90833-3501 90833-3502 90833-3503 90833-3513 90833-3514
90833-3521 90833-3522 90833-3523 90833-3524
90833-4251 90833-4254 90833-4255 90833-4256 90833-4261
90833-2027
90833-2776
90833-3518
90833-4264
90833-5001
90833-6001
90833-6025
90833-7001
90833-8001
90888-0003
90888-0031
91338-0103
91338-0607
91338-3403
90833-5004 90833-5010 90833-5012
90833-6005 90833-6006 90833-6007 90833-6008 90833-6023
90888-0005
90888-0033
91338-0104
91338-0700
91338-3501
90888-0006
90888-0034
91338-0105
91338-0801
91338-3507
90888-0011 90888-0023 90888-0024
91777-0103
91777-3104
91778-0002
91778-0009
91778-0016
91778-0023
91778-0030
91778-0102
91778-0109
91778-0116
91778-0123
91778-0202
91778-0209
91778-0302
91778-0309
91778-0402
91778-0409
91778-0502
91778-0509
91778-0602
917780609
91778-0702
91778-0709
91778-0802
91778-0809
91778-0902
91778-1002
91777-0104
91777-3105
91778-0003
91778-0010
91778-0017
91778-0024
91777-0105
91777-3106
91778-0004
91778-0011
91778-0018
91778-0025
91777-0106
91777-3107
91778-0005
91778-0012
91778-0019
91778-0026
91777-0107 91777-3102
91778-0103
91778-0110
91778-0117
91778-0124
91778-0203
91778-0210
91778-0303
91778-0310
91778-0403
91778-0104
91778-0111
91778-0118
91778-0125
91778-0204
91778-0211
91778-0304
91778-0311
91778-0404
91778-0105
91778-0112
91778-0119
91778-0126
91778-0205
91778-0212
91778-0305
91778-0312
91778-0405
91778-0106 91778-0107
91778-0113 91778-0114
91778-0120 91778-0121
91338-0403 91338-0501 91338-0507
91338-3102 91338-3103 91338-3104
91338-3601 91338-3607 91338-3700
91778-0006
91778-0013
91778-0020
91778-0027
91778-0007
91778-0014
91778-0021
91778-0028
91778-0206 91778-0207
91778-0306 91778-0307
91778-0313 91778-0314
91778-0406 91778-0407
91778-0503 91778-0504 91778-0505 91778-0506 91778-0507
91778-0510 91778-0511 91778-0512
91778-0603 91778-0604 91778-0605 91778-0606 91778-0607
91778-0703 91778-0704 91778-0705 91778-0706 91778-0707
91778-0803 91778-0804 91778-0805 91778-0806 91778-0807
Release Date: 12-20-00
Revision Date: 08-14-09
UNCONTROLLED COPY
Page 18 of 19
RAST 5.0 Arbor Press
Connector
Circuit Size
Series No.
90835-0001
90835-0038
90835-0045
90835-9001
90835-0500
90835-0522
90835-9021
90835-1251
90835-1284
91779-0001
91779-0008
91779-9001
91779-0101
91779-0108
91779-0115
91779-9106
91779-0201
92000-0001
92000-0101
92000-0108
92000-0201
2
90835
3
3
4
2
91779
3
4
2
92000
3
4
Americas Headquarters
Lisle, Illinois 60532 U.S.A.
1-800-78MOLEX
amerinfo@molex.com
90835-0003
90835-0039
90835-0046
90835-9002
90835-0501
90835-0523
90835-9022
90835-1254
90835-1285
91779-0002
91779-0009
91779-9002
91779-0102
91779-0109
91779-0116
91779-9201
91779-0202
92000-0002
92000-0102
16A
Connector Assembly Order No.
90835-0019 90835-0034 90835-0035
90835-0040 90835-0041 90835-0042
90835-0047 90835-0048 90835-0057
90835-9003 90835-9004 90835-9005
90835-0502 90835-0518 90835-0519
90835-0534 90835-0536 90835-0537
90835-9023 90835-9024 90835-9025
90835-1268 90835-1269 90835-1273
90835-9101 90835-9102 90835-9103
91779-0003 91779-0004 91779-0005
91779-0010 91779-0019
91779-9003 91779-9004
91779-0103 91779-0104 91779-0105
91779-0110 91779-0111 91779-0112
91779-9101 91779-9102 917799-103
91779-9202 91779-9203 91779-9204
91779-0203 91779-0204 91779-0205
92000-0003 92000-0004 92000-0005
92000-0103 92000-0104 92000-0105
90835-0036 90835-0037
90835-0043 90835-0044
90835-0058
90835-9006
90835-0520 90835-0521
90835-9026 90835-9027
90835-1281 90835-1283
90835-9104
91779-0006 917790007
91779-0106
91779-0113
91779-9104
91779-9205
91779-0206
92000-0006
92000-0106
91779-0107
91779-0114
91779-9105
91779-9206
92000-0007
92000-0107
92000-0202 92000-0203 92000-0204
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
Doc: No: TM-622017500
Revision: E
Release Date: 12-20-00
Revision Date: 08-14-09
UNCONTROLLED COPY
Page 19 of 19