C-Grid® SL™ FFC Termination Kit
C-Grid® SL™ FFC Termination Kit
(For T2 and Terminator Crimp Module)
Order No. 63801-8550
Instruction Manual
Description
Operation
Maintenance
Doc. No: TM-638018550
Revision: B
Release Date: 03-11-13
Revision Date: 11-23-15
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Page 1 of 23
C-Grid® SL™ FFC Termination Kit
Table of Contents
Contents
C-Grid® SL™ FFC Termination Kit .................................................................................................................................................1
Safety Warnings and Information ....................................................................................................................................................3
Tooling Technical Assistance ..........................................................................................................................................................4
Principal Mechanical Parts of the FFC Termination Kit ...............................................................................................................5
Section 1 .....................................................................................................................................................................................6
General Description ................................................................................................................................................................6
1.1
Description .................................................................................................................................................................6
1.2
Features.....................................................................................................................................................................6
1.3
Technical Specification ..............................................................................................................................................6
1.4
Delivery Check...........................................................................................................................................................6
1.5
Crimp Tooling Accessories (optional) ........................................................................................................................6
1.6
Tools ..........................................................................................................................................................................6
1.7
Application Tooling Specification Sheets ...................................................................................................................6
Section 2 .....................................................................................................................................................................................7
Set-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.
Punch and Anvil Alignment ......................................................................................................................................14
4.2
FFC Guide Adjustment ............................................................................................................................................14
4.3
Slide Switch Adjustment ..........................................................................................................................................14
4.4
FFC Crimp Punch Installation and Removal ............................................................................................................15
Section 5 ...................................................................................................................................................................................16
Maintenance .........................................................................................................................................................................16
5.1
Cleaning...................................................................................................................................................................16
5.2
Lubrication ...............................................................................................................................................................16
5.3
Spare Parts ..............................................................................................................................................................17
5.4
Perishable Parts ......................................................................................................................................................17
Section 6 ...................................................................................................................................................................................18
6.1
Parts List and Assembly Drawing ............................................................................................................................18
6.2
Assembly .................................................................................................................................................................20
6.2
Guard Assembly ......................................................................................................................................................21
6.3
Product List ..............................................................................................................................................................22
Doc. No: TM-638018550
Revision: B
Release Date: 03-11-13
Revision Date: 11-23-15
UNCONTROLLED COPY
Page 2 of 23
C-Grid® SL™ FFC Termination Kit
Safety Warnings and Information
Read and understand all of the instructions and safety information in this
manual before operating or servicing this equipment.
Keep this manual available when using this equipment.
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
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.
WARNING
Never wear clothing or jewelery that is loose or
that could potentially enter the equipment
and get caught.
Failure to observe this warning could result in
severe injury or death.
WARNING
Never operate, service, install, or adjust this
equipment without proper instruction or without
first reading and understanding the instructions
in this manual and all applicable press manuals.
Doc. No: TM-638018550
Revision: B
Release Date: 03-11-13
Revision Date: 11-23-15
WARNING
Excessive noise levels.
Always wear proper ear protection when
Operating or servicing this equipment.
WARNING
Never install or service the press while
connected to any electrical power source.
Disconnect power by unplugging the press
from its power source.
Failure to observe this warning could result
In severe injury or death.
WARNING
Always hand cycle the module in the press
to ensure the tooling is properly aligned.
Failure to observe these precautions may result
In injury or property damage.
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C-Grid® SL™ FFC Termination Kit
WARNING
WARNING
Never use this equipment in a press or wire processing
machine without guards or safety devices that are
intended to prevent hands from remaining in the die space.
This equipment is supplied with no guards and is intended
to be used with the guards the press and/or
the wire processor.
Failure to observe this warning could result in severe
injury or death.
Do not use compressed air to clean
the 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
The Molex Crimp Module is designed to operate ONLY in the TM-3000 and TM-4000 press with standard shut height
at 135.80mm (5.346”).
Installation in crimp presses with other than standard shut heights can cause severe tool damage. Check the shut height of the
crimp press before operating the Crimp Module. Molex will not be liable for any damages as a result of installation in a crimp
press with nonstandard or improperly set shut height.
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
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 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 Molex application tools. 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 the applicator it is recommended to have the following: a copy of the Tooling Manual, the
specific Application Tooling Specification and a person familiar with the application tool 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)
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
Doc. No: TM-638018550
Revision: B
Release Date: 03-11-13
Revision Date: 11-23-15
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C-Grid® SL™ FFC Termination Kit
Principal Mechanical Parts of the FFC Termination Kit
TOOLING LOCATOR
GUARD
PUNCH
CABLE CLAMP
PRESS JUMPER
LIMIT SWITCH
CABLE ASSEMBLY
SLIDE INTERLOCK
CABLE
GUIDES
TERMINATION NEST
CARRIER
BREAK-OFF LIP
INSERTION
NEST
CABLE GUIDES
EXTENSION
CABLE STOP
Figure 1-1
Doc. No: TM-638018550
Revision: B
Release Date: 03-11-13
Revision Date: 11-23-15
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C-Grid® SL™ FFC Termination Kit
Section 1
General Description
1.1
Description
The C-Grid® SL™ FFC Termination Kit gives the T2
and Terminator Crimp Module the ability to crimp flat
flex cable (FFC) to the 70430 series connectors using
the TM-3000 or TM-4000 press
Product
C-Grid® SL™ FFC Single Row Assembly
Series 70430 and 70431, 2 through 20 circuits
See Product List for applicable part numbers.
1.4
Delivery Check
This FFC Termination Kit is installed ONLY in the Molex
63801-8500 T2 and Terminator Crimp Module. This
unit will not work in other industry-standard presses.
Carefully remove the FFC Termination Kit from its
shipping container; note that the following items
are included in the package:
Molex offers the following presses for operating the
Crimp Module with the FFC Termination Kit:
TM-638018550 Operation Manual
FFC Termination Kit
Guard panels for FFC Kit
Safety Switch and bracket
Jumper wire assembly
TM-3000 Press 120 V 60 Hz. 63801-7200
TM-3000 Press 240 V 50 Hz. 63801-7300
TM-4000 Press 240 V 60 Hz. 63801-7600
1.2
Features
1.5 Crimp Tooling Accessories (optional)
Molex Order No. 63800-2810
Fine adjustment allows users to achieve FFC crimp
height target by adjusting a wedge (0.74 mm total
adjustment) for conductor crimp height.
Built-in terminal insertion tool and carrier strip breakoff tool.
Quick crimp punch removal.
Compatible ONLY with the Molex TM-3000 and TM4000 Universal Presses
1.3
Technical Specification
Dimensions
(Lower Tooling Only)
Width:
145mm
Depth:
260mm
Height: 44mm
1
1
1
1
1
Eye loupe
1.6 Tools
The following tools are recommended for setup
and adjustments to the applicator:
1.
2.
3.
4.
Metric and English hex wrench sets
Adjustable wrench
Feeler gages/ shim stock
Eye loupe (5X)
1.7 Application Tooling Specification Sheets
(5.7")
(10.2")
(1.7")
Weight (Termination Kit Only)
3.8kg (8.5lbs)
Termination specifications for the C-Grid® SL™
FFC product may be found in document number
PS-70430, available on the Molex website.
Note: Document PS-70430 also includes
dimensional requirements for the flat flex cable.
Guarding
The FFC Termination Kit is supplied with special
guard panels that must be installed on the TM3000 or TM-4000 press.
Do not operate the FFC Termination
Kit without guard panels installed.
Doc. No: TM-638018550
Revision: B
Release Date: 03-11-13
Revision Date: 11-23-15
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C-Grid® SL™ FFC Termination Kit
Section 2
Set-Up and Operation
Read the following instructions before attempting to terminate FFC product in the Crimp Module.
REMOVE
M6 BHSC (2)
REMOVE
FEED MECHANISM
KEEP
DOWELS IN
PLACE (2)
M5 x 12mm
LONG SCREWS
REMOVE
TOOLING CLAMP
Figure 2-1
2.1 Crimp Module Preparation
KEEP
DOWELS IN
PLACE (2)
REMOVE
TOOLING CLAMP
For the FFC Termination 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 Figure 2-1.
2.2 Press Preparation
The press must have its foot switch cord disconnected and guard door removed.
At the back of the press, disconnect
the 3-pin foot switch cord and the
power cord. See Figure 2-2.
For safety reasons, also disconnect
the power cord.
To remove the press guard door,
open the door and remove the (4)
screws from the door hinges. See
Figure 2-3.
Doc. No: TM-638018500
Revision: WIP
Release Date: 07-16-12
Revision Date: 07-16-12
REMOVE THE
(4) SCREWS
FROM THE
(2) HINGES
Figure 2-3
EXISTING
DOOR ASSEMBLY
Figure 2-2
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C-Grid® SL™ FFC Termination Kit
Install the guard door that is included with the FFC
Termination Kit. Adjust the door on the hinges until it closes
properly on the press.
SHUT HEIGHT
GAUGE
2.3 Shut Height
The shut height for the Crimp Module is 135.80mm (5.346").
The shut height for the crimp press is calibrated using a Shut
Height Gauge. See Figure 2-1. The gauge is designed to
apply the proper load at 135.80mm (5.346") shut height.
Molex offers an industry standard shut height gauge (order
number 63800-7900) that will fit in the TM-3000 and TM-4000
crimp presses. It is recommended that the crimp press shut
height be checked regularly.
PRESS QUICK CHANGE
MOUNTING PLATE
PRESS
Figure 2-4
The Crimp Module is designed to operate in the TM-3000 and TM-4000 crimp presses with standard shut height of 135.80mm
(5.346"). Installation in crimp presses with non-standard shut can cause severe tool damage. It is recommended before
installation, a check of the shut height be performed. The correct shut height is required to prevent the FFC punch from striking
the support anvil.
Measuring Press Shut Height
Always turn off and disconnect the power supply to the press.
1.
2.
3.
4.
5.
6.
7.
8.
Open the guard door.
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.
Place the shut height gauge onto the press quick change mounting plate. Align the gauge to the ram as shown in Figure 24.
Manually cycle the press to the down stroke position. See Section 2.2, How to Manually Cycle the Press, or follow the TM3000 Operation Manual (order number TM638017299) Section 3.3 Manually Cycling the Press.
Read the shut height measurement from the front of the gauge. Follow the gauge manufacturers’ instruction; usually the
gauge reads “0” when shut height is 135.80mm (5.346").
If adjustments are necessary, refer to the TM-3000 press manual for adjustment of the press shut height.
Repeat the above steps until the correct shut height is obtained.
Shut height gauges must be calibrated on a regular basis.
2.4 How to Manually Cycle the Press
MOTOR
Always turn off and disconnect the power supply to the
press.
T-HANDLE
WRENCH
Always hand cycle the Crimp Module in the press to
ensure the tooling is properly aligned.
Note: When the press guard is open make sure the power is
disconnected from the motor (MOTOR ON light is not illuminated)
TURN
CLOCKWISE
Hand cycling the press is necessary to confirm correct tool alignment
and terminal feed adjustment. It also allows setup personnel to observe
the crimping cycle in slow-motion.
Figure 2-5
Doc. No: TM-638018550
Revision: B
Release Date: 03-11-13
Revision Date: 11-23-15
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C-Grid® SL™ FFC Termination Kit
Manually Cycling the TM3000 and TM4000 Presses
1.
2.
3.
4.
Insert the hand-cycle T wrench (furnished with the press) through the access hole in the center of the motor’s rear cover and
locate it on the motor shaft. See Figure 2-5.
Rotate the wrench clockwise. This turns the motor and moves the ram down and up.
Always return the press ram back to top dead center to ensure that the ram is in the startup position.
Remove the T-handle wrench.
NOTE: When the T-handle wrench is inserted onto the motor shaft the
power is automatically disconnected from the motor. Press the green
MOTOR ON button to restore power to the motor.
2.5 FFC Termination Kit Installation in the Crimp Module
RAM
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.
M5 SCREW
TOOLING
LOCATOR
FFC PUNCH
M4 SHCS
FRAME
M6 x 8MM
LONG SCREW
DOWELS (2)
Figure 2-6
MOVE FFC SLIDE
FORWARD
DOWELS (2)
Figure 2-7
SLIDE LOCK PLUNGER
5
Locate the base plate of the FFC tooling on the four dowel pins protruding from the Crimp Module base plate. Fasten the
right side of the FFC Baseplate to the crimp module with an M6 x 8mm long screw. See Figure 2-7.
NOTE: Do not use a screw longer than 8mm, otherwise the Crimp Module will not fit properly in the press.
6
The left side of the FFC base plate is clamped to the Crimp Module base plate with the slide safety switch bracket and an
M6 x 16mm long screw. See Figure 2-8.
NOTE: Do not use a screw longer than 16mm, otherwise the Crimp Module will not fit properly in the press.
7
Place the ram back in the Crimp Module frame and tighten the M4 screw to prevent the ram from falling out.
Doc. No: TM-638018550
Revision: B
Release Date: 03-11-13
Revision Date: 11-23-15
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C-Grid® SL™ FFC Termination Kit
2.6 Crimp Module Installation and Removal
Always turn off and disconnect the power to the
press.
Installation
1. Open the press guard door.
2. Clean the quick change mounting plate of scrap or chips
that may interfere with the Crimp Module installation.
Molex recommends a soft brush; do not use compressed
air to clean the equipment. The forces created by
compressed air can force debris into the tool.
SLIDE SAFETY
SWITCH BRACKET
M6 x 16MM
LONG SCREW
Figure 2-8
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 base plate rests on the quick change mounting plate.
d. Visually align the Crimp Module’s base plate notches on the left with the location clamps on the press quick-change
mounting plate.
e. Slide the Crimp Module to the left until the two notches in the base plate engage against the location clamps. See
Figure 2.9.
f. To lock the crimp module, turn the M5 socket head cap screw counterclockwise until tight.
PRESS
RAM YOKE
LOCATION
CLAMPS
RAM ADAPTER
QUICK CHANGE
MOUNTING PLATE
M5 SHCS
LOCKING
CLAMP
BASE PLATE
Figure 2-9
CRIMP MODULE
Doc. No: TM-638018550
Revision: B
Release Date: 03-11-13
Revision Date: 11-23-15
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C-Grid® SL™ FFC Termination Kit
4. Install the side guard on the Crimp Module. Use the (2) M5
x12mm screws (see section 2.1) to fasten the guard on the
Crimp Module. See Figure 2-10.
5. Close the press guard door.
6. Hand cycle the press. See Section 2.2 How to Manually
Cycling the Press. Make sure the ram moves up and down
freely.
7. Connect the jumper wire assembly. (This allows the press to
cycle only if the FFC slide is fully pushed in AND the foot
pedal is pressed). The two-wire connector from the slide
safety switch cable gets plugged into the receptacle. The
pigtail (with the 3-pin connector) from the jumper wire junction
box is connected to the 3-pin connector on the back of the
press. Finally, the foot switch cable is connected to the 3-pin
connector on the jumper wire junction box. See Figure 2-11
M5 x 12mm
SCREWS
SIDE GUARD
Figure 2-10
JUMPER WIRE ASSEMBLY
SLIDE SAFETY
SWITCH CABLE
TO FOOT
SWITCH
TO PRESS
Figure 2-11
8. Reconnect 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 crimp the FFC under press
power. Specifications for the FFC cable can be found in document PS-70430.
2. Inspect the quality of crimp and measure the crimp height. For FFC, a standard micrometer can be used. If adjustments
are necessary, disconnect the power from the press. Open the guard door. The desired crimp height can be achieved by
loosening the COND LOCK screw and turning the turning conductor cam adjusting knob clockwise to lower the crimp
height or counterclockwise to raise the crimp height. Tighten the COND LOCK screw to prevent the conductor crimp
adjustment from moving. See figure 2-12.
Doc. No: TM-638018550
Revision: B
Release Date: 03-11-13
Revision Date: 11-23-15
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C-Grid® SL™ FFC Termination Kit
CONDUCTOR
LOCK SCREW
Figure 2-12
INSULATION
ADJUSTING CAM
(Not used for FFC)
CONDUCTOR
ADJUSTING KNOB
3. Close the guard door and repeat steps 1 – 3 until the desired crimp height is obtained.
4. Additional assessment of the FFC crimp should be done by micro-sectioning the crimped area. Molex does not offer
equipment to do this.
2.8 Insulation Crimp Height Adjustment
The insulation adjusting cam of the Crimp Module has no influence on the FFC
crimp height.
2.9 Operation
CAUTION: The operator and observers must wear eye protection when the
press is in operation or being serviced.
CAUTION: DO NOT operate theTM3000 or TM4000 press without guards.
CABLE STOP IN
OPEN POSISION
CONNECTORS
IN NEST
Figure 2-13
1. Lift the cable stop and load the connector(s) into the nest making sure the
terminals are lined 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 press the front edge of the cable against the cable stop. This will achieve the proper location for the cable
being pressed onto the connector.
4. Close the cable clamp located on the left side of the slide.
5. Slide the FFC nest into the press until the slide lock plunger clicks in. The nest position switch will not let the press cycle
unless the nest is fully pushed in.
6. Push the foot pedal to cycle the press and terminate the connector(s) onto the cable.
7. Pull out the slide lock plunger and hold while sliding the FFC nest out of the press.
8. Remove the connector and cable assembly from the termination nest and load it into the insertion nest on the front of the
FFC slide with the cable draped over the insertion bar. See Figure 2-14.
Doc. No: TM-638018550
Revision: B
Release Date: 03-11-13
Revision Date: 11-23-15
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C-Grid® SL™ FFC Termination Kit
9. Place the second and third fingers of each hand around the handles on the insertion nest. Put the thumbs on the front of the
insertion bar. While applying a light pressure with the index fingers on the cable over the carrier strip, squeeze the insertion
nest toward the insertion bar. The carrier strip should drop into the slot in the insertion bar.
CONNECTOR AND
CABLE ASSEMBLY
CABLE OVER
INSERTION BAR
10.
11.
12.
13.
14.
INSERTION
NEST
PUSH NEST TOWARDS
INSERTION BAR
Figure 2-14
PUSH INSERTION
BAR TOWARDS
PRESS
PUSH DOWN
TO BREAK
CARRIER STRIP
INSERTION
BAR
CARRIER STRIP IN SLOT
OF INSERTION BAR
Figure 2-15
Continue to squeeze the insertion nest toward the insertion bar until the terminals are fully seated in the housing.
While holding the cable and connector back against the insertion bar, slide the nest and slide assembly away.
Push down on the connector to break the carrier strip off. The cable will spring the connector back up. See Figure 2-15.
Remove the completed harness.
Remove the carriers from the insertion bar by pushing the upper insertion bar forward. This will expel the carrier strips from
the tool.
Section 3
Troubleshooting
Symptom
FFC crimp height too high
FFC crimp height too low
FFC crimps damaged
FFC crimp not centered to
trace of FFC
Doc. No: TM-638018550
Revision: B
Cause
FFC crimp punch adjusted too high
FFC crimp punch is worn
FFC being crimped is too thick
Wrong press shut height
FFC crimp punch adjusted too low
FFC being crimped is too thin
Wrong press shut height
Worn FFC crimp punch
Damaged anvil in housing nest
Improper application
FFC guide not adjusted
FFC not clamped
Release Date: 03-11-13
Revision Date: 11-23-15
Section
Solution
Readjust crimp height
Replace punch
Review PS-70430
Reset shut height
Readjust crimp height
Review PS-70430
Reset shut height
Adjust guide
Adjust clamp
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C-Grid® SL™ FFC Termination Kit
LOCK NUT
Section 4
OPENING FOR
TOOL LOCATOR
Other Adjustments
STOP
SCREW
4.1. Punch and Anvil Alignment
FFC GUIDE
The alignment of the punch and anvil is determined by the
tooling locator mounted to the ram. As the tooling locator
enters the rectangular opening behind the housing nest, it
centers the tooling on the FFC slide to the FFC punch.
GUIDE EXTENSION
The FFC slide has an adjustable stop screw to prevent the
slide from being pushed in too far. The stop screw should be
adjusted so the slide goes slightly farther than necessary.
The tooling locator can then pull the slide away from the stop
screw.
FFC GUIDE
Figure 4-1
The stop screw should not be adjusted to cause binding between the FFC slide and tooling locator. See Figure 4-1.
4.2 FFC Guide Adjustment
The FFC guides 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 of the slide switch should be done using a multi-meter or a test light.
1. To adjust the slide switch, move the FFC slide all the way into the press. Make sure the plunger has locked the slide in
position.
2. Loosen M6 screw holding the slide switch mounting bracket and unplug the slide switch cable. Using a test light or multimeter, move the slide switch bracket forward or back until the switch makes contact (test light goes on or meter reads
zero ohms). See Figure 4-2.
3. Move the FFC slide in and out to ensure that the switch adjustment is stable. Tighten the M6 screw when adjustment is
complete.
M6 SCREW
SLIDE SWITCH
MOUNTING BRACKET
PLUNGER
LOCKED
Doc. No: TM-638018550
Revision: B
Release Date: 03-11-13
Revision Date: 11-23-15
Figure 4-2
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C-Grid® SL™ FFC Termination Kit
4.4 FFC Crimp Punch Installation and Removal
Always turn off and disconnect the power supply to the press.
NOTE: Always clean mounting surfaces of crimp tooling and tooling holders before installation.
Molex 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.
2.
3.
4.
5.
6.
Disconnect power from the press. Open the guard door.
Remove the Crimp Module from the press. See Section 2.3, Crimp Module Installation and Removal.
Use a 3mm hex wrench to remove the M4 socket head cap screw retaining the ram. See Figure 4.3.
Pull the ram out of the Crimp Module frame.
Pull out the punch release. While holding it out, pull the FFC crimp punch out of the bottom of the ram. See Figure 4.3.
Reverse the previous steps to reinstall the punch.
LIFT RAM UP
PULL OUT THE
PUNCH RELEASE
REMOVE
PUNCH
Figure 4-3
Doc. No: TM-638018550
Revision: B
Release Date: 03-11-13
Revision Date: 11-23-15
REMOVE
THE M4 SHCS
UNCONTROLLED COPY
Page 15 of 23
C-Grid® SL™ FFC Termination Kit
Section 5
Maintenance
5.1 Cleaning
Always turn off and disconnect the power supply to the press.
For efficient operation, the Crimp Module should be cleaned daily. Use a soft bristle brush to remove debris from critical areas
such as the crimp tooling. For best results, remove the crimp tooling from the press. Brush and then use a clean cloth to wipe
off the upper and lower tooling mounting areas. Before reinstalling tooling, wipe all sides of the punches and anvils with a clean
cloth.
5.2 Lubrication
GREASE
FITTING
FOR RAM
Always turn off and disconnect the power supply to the press.
1.
2.
3.
4.
Make sure the press ram is fully up.
Disconnect power from the press. Open the guard door.
Use a grease gun on the Zerk fitting to grease the ram guides. See
Figure 5-1.
For the ram, use synthetic grease with Teflon® or an equivalent.
(The Crimp Module is shipped greased with Permatex® No. 82329.)
Figure 5-1
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 below. Use this chart to track the maintenance of your Crimp Module or use it
as a template to create a schedule.
Daily: Clean. See Section 5.1.
As Required: Lubricate. See Section 5.2.
CHECK SHEET MONTH
Week
1
2
3
4
Cleaning
Reapply grease. Reapply oil
Inspect all tooling
(Punch, anvil etc.) for wear
YEAR _________
Days of the Week
WED THU FRI
Cycles
Daily Clean
25,000
Yes
Soft Brush Industrial
Degreaser
25,000
Yes
Replace if worn
MON
TUE
SAT
SUN
Notes
Schedule should be adjusted up or down depending on usage. Molex recommends that a log of preventive maintenance be
kept with the press.
Doc. No: TM-638018550
Revision: B
Release Date: 03-11-13
Revision Date: 11-23-15
UNCONTROLLED COPY
Page 16 of 23
C-Grid® SL™ FFC Termination Kit
5.3 Spare Parts
Customers are responsible for maintaining the Crimp Module. Spare parts are available. Moving and functioning parts can be
damaged or wear out over time and will require replacement. Having some spare parts on-hand will reduce production down
time. Recommended Spare Parts are noted as RSP in the Termination Kit parts list.
Recommended Spare Parts are noted as RSP in the 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 replacement. The user should monitor their process and collect
data on actual frequency as tool wear varies on different terminal materials and tool life can be increased with good
maintenance practices or decrease with lack of maintenance.
Judgment on tool replacement should be based on the attributes of the crimp they produce.
Doc. No: TM-638018550
Revision: B
Release Date: 03-11-13
Revision Date: 11-23-15
UNCONTROLLED COPY
Page 17 of 23
C-Grid® SL™ FFC Termination Kit
Section 6
6.1 Parts List and Assembly Drawing
Item
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
33
34
35
36
37
38
Doc. No: TM-638018550
Revision: B
C-Grid® SL™ FFC Termination Kit 63801-8550
Engineering No.
Description
Quantity
Perishable Tooling
62201-4218
62201-4218
Carrier Bar
1 PP
62201-8705
62201-8705
Anvil
1 PP
62201-8709
62201-8709
Terminal Locator
1 PP
62201-8715
62201-8715
Termination Punch
1 PP
Other Components
62200-6002
62200-6002
Left Gib
1
62200-6003
62200-6003
Gib
1
62200-6007
62200-6007
Slide Bar
1
62200-6008
62200-6008
Left Slide Bar
1
62200-6017
62200-6017
Locator Block
1
62200-6021
62200-6021
Spacer
1
62200-6022
62200-6022
Spring
1 RSP
62200-6026
62200-6026
Cable Stop Arm
2
62200-6027
62200-6027
Plunger Mount
1
62200-6028
62200-6028
Spring Support
1
62200-7721
62200-7721
Cable Assembly With Limit Switch
1
62200-7729
62200-7729
Stop Block
1
62201-4201
62201-4201
Base Plate
1
62201-4206
62201-4206
Nest Locator Bar
1
62201-4211
62201-4211
Plate
1
62201-4214
62201-4214
Back Bar
1
62201-8704
62201-8704
Connector Nest
1
62201-8712
62201-8712
Insert Nest
1
62201-8713
62201-8713
Insert Nest Cover
1
62201-8716
62201-8716
Cable Guide
2
62201-8725
62201-8725
Cable Stop
1
62201-8730
62201-8730
Cable Guide Extension
1
63600-0575
63600-0575
5mm I.D. Collar Set Screw
2
63600-0576
63600-0576
Toggle Clamp
1 RSP
63600-0621
63600-0621
Plunger
1 RSP
63801-7212
63801-7212
Guard Handle
1
63801-7287
63801-7287
Bracket Guard
1
63801-8551
63801-8551
Front Guard
1
63801-8552
63801-8552
Guard Side
1
63801-8553
63801-8553
FFC Switch Bracket
1
63801-8554
63801-8554
FFC Press Jumper
1
Hardware
N/A
N/A
M2 by 12 Long SHCS
2**
N/A
N/A
M2 Flat Washer
2**
N/A
N/A
M3 by 8 Long SHCS
2**
Order No.
Release Date: 03-11-13
Revision Date: 11-23-15
UNCONTROLLED COPY
Page 18 of 23
C-Grid® SL™ FFC Termination Kit
C-Grid® SL™ FFC Termination Kit 63801-8550
39
N/A
N/A
M4 by 6 Long BHCS
2**
40
N/A
N/A
M4 by 8 Long FHCS
8**
41
N/A
N/A
M4 by 8 Long SHCS
2**
42
N/A
N/A
M4 by 10 Long BHCS
2**
43
N/A
N/A
M4 by 10 Long SHCS
4**
44
N/A
N/A
M4 by 12 Long 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 Long Dowel Pin
2**
57
N/A
N/A
4mm by 20 Long Dowel Pin
2**
58
N/A
N/A
5mm by 12 Long Dowel Pin
4**
** Available from an industrial supply company such as MSC (1-800-645-7270).
Doc. No: TM-638018550
Revision: B
Release Date: 03-11-13
Revision Date: 11-23-15
UNCONTROLLED COPY
Page 19 of 23
C-Grid® SL™ FFC Termination Kit
6.2 Assembly
39
41 (2)
(2)
28
(2)
26
44 (4)
24
45 (2)
4
19
(2) 53
23
9
10
48
11
(2) 47
22
12
14
(2)
58
(2)
(2)
25
42
(2)
38
54 (2)
35
34
50
43 (2)
15
29
(2)
43
(2)
(2) 52
27 (2)
(2)
51
21
13
58
(2)
37
49
3
16
18
36
2
5
(2) 46
(2)
57 (2)
56
54 (2)
8
1
45 (2)
55 (2)
(2)
46
20
17
7
(8)
6
54 (4)
40
Figure 6-1
Doc. No: TM-638018550
Revision: B
Release Date: 03-11-13
Revision Date: 11-23-15
UNCONTROLLED COPY
Page 20 of 23
C-Grid® SL™ FFC Termination Kit
6.2 Guard Assembly
31
30
50 (2)
33
32
Figure 6-2
Doc. No: TM-638018550
Revision: B
Release Date: 03-11-13
Revision Date: 11-23-15
UNCONTROLLED COPY
Page 21 of 23
C-Grid® SL™ FFC Termination Kit
6.3 Product List
Terminal
Series No.
70430
Terminal Order No.
15-38-8020
15-38-8040
15-38-8060
15-38-8080
15-38-8100
15-38-8120
15-38-8140
15-38-8160
15-38-8180
15-38-8200
15-47-4020
15-47-4030
15-47-4040
15-47-4050
15-47-4060
15-47-4070
15-47-4080
15-47-4090
15-47-4110
15-47-4120
15-47-4130
15-47-4140
15-47-4150
15-47-4160
15-47-4170
15-47-4180
15-47-4190
15-47-4220
15-47-4230
15-47-4242
15-47-4250
70430-0352
70430-4102
70430-5000
70430-5008
70430-5016
Doc. No: TM-638018550
Revision: B
15-38-8027
15-38-8047
15-38-8067
15-38-8087
15-38-8107
15-38-8127
15-38-8147
15-38-8167
15-38-8187
15-38-8207
15-47-4021
15-47-4031
15-47-4041
15-47-4051
15-47-4061
15-47-4071
15-47-4081
15-47-4091
15-47-4111
15-47-4121
15-47-4131
15-47-4141
15-47-4151
15-47-4161
15-47-4171
15-47-4181
15-47-4191
15-47-4221
15-47-4231
15-47-4241
15-47-4251
70430-0353
70430-4103
70430-5001
70430-5009
70430-5017
15-38-8028
15-38-8048
15-38-8068
15-38-8088
15-38-8108
15-38-8128
15-38-8148
15-38-8168
15-38-8188
15-38-8208
15-47-4022
15-47-4032
15-47-4042
15-47-4052
15-47-4062
15-47-4072
15-47-4082
15-47-4092
15-47-4112
15-47-4122
15-47-4132
15-47-4142
15-47-4152
15-47-4162
15-47-4172
15-47-4182
15-47-4192
15-47-4222
15-47-4232
15-47-4242
15-47-4252
70430-1005
70430-4107
70430-5002
70430-5010
70430-5018
15-38-8029
15-38-8049
15-38-8069
15-38-8089
15-38-8109
15-38-8129
15-38-8149
15-38-8169
15-38-8189
15-38-8209
15-47-4023
15-47-4033
15-47-4043
15-47-4053
15-47-4063
15-47-4073
15-47-4083
15-47-4093
15-47-4113
15-47-4123
15-47-4133
15-47-4143
15-47-4153
15-47-4163
15-47-4173
15-47-4183
15-47-4193
15-47-4223
15-47-4233
15-47-4243
15-47-4253
70430-1050
70430-4202
70430-5003
70430-5011
Release Date: 03-11-13
Revision Date: 11-23-15
15-38-8030
15-38-8050
15-38-8070
15-38-8090
15-38-8110
15-38-8130
15-38-8150
15-38-8170
15-388190
15-38-8037
15-38-8057
15-38-8077
15-38-8097
15-38-8117
15-38-8137
15-38-8157
15-38-8177
15-38-8197
15-38-8038
15-38-8058
15-38-8078
15-38-8098
15-38-8118
15-38-8138
15-38-8158
15-38-8178
15-38-8198
15-38-8039
15-38-8059
15-38-8079
15-38-8099
15-38-8119
15-38-8139
15-38-8159
15-38-8179
15-38-8199
15-47-4024
15-47-4034
15-47-4044
15-47-4054
15-47-4064
15-47-4074
15-47-4084
15-47-4094
15-47-4114
15-47-4124
15-47-4134
15-47-4144
15-47-4154
15-47-4164
15-47-4174
15-47-4184
15-47-4194
15-47-4224
15-47-4234
15-47-4244
15-47-4254
70430-4043
70430-4253
70430-5004
70430-5012
15-47-4025
15-47-4035
15-47-4045
15-47-4055
15-47-4065
15-47-4075
15-47-4085
15-47-4095
15-47-415
15-47-4125
15-47-4135
15-47-4145
15-47-4155
15-47-4165
15-47-4175
15-47-4185
15-47-4195
15-47-4225
15-47-4235
15-47-4245
15-47-4255
70430-4053
15-47-4026
15-47-4036
15-47-4046
15-47-4056
15-47-4066
15-47-4076
15-47-4086
15-47-4096
15-47-4116
15-47-4126
15-47-4136
15-47-4146
15-47-4156
15-47-4166
15-47-4176
15-47-4186
15-47-4196
15-47-4226
15-47-4236
15-47-4246
15-47-4256
15-47-4027
15-47-4037
15-47-4047
15-47-4057
15-47-4067
15-47-4077
15-47-4087
15-47-4097
15-47-4117
15-47-4127
15-47-4137
15-47-4147
15-47-4157
15-47-4167
15-47-4177
15-47-4187
15-47-4197
15-47-4227
15-47-4237
15-47-4247
15-47-4257
70430-5005 70430-5006 70430-5007
70430-5013 70430-5014 70430-5015
UNCONTROLLED COPY
Page 22 of 23
C-Grid® SL™ FFC Termination Kit
Terminal
Series No.
70431
Terminal Order No.
15-38-9020
15-38-9060
15-38-9100
15-38-9120
15-38-9160
15-38-9220
15-47-4028
15-47-4108
15-47-4188
15-47-5020
15-47-5044
15-47-5072
15-47-5100
15-47-5124
15-47-5152
15-47-5180
15-47-5204
15-47-5232
704315050
15-38-9022
15-38-9062
15-38-9102
15-38-9122
15-38-9162
15-38-9222
15-47-4038
15-47-4118
15-47-4198
15-47-5022
15-47-5050
15-47-5074
15-47-5102
15-47-5130
15-47-5154
15-47-5182
15-47-5210
15-47-5234
704315080
15-38-9030
15-38-9070
15-38-9103
15-38-9130
15-38-9170
15-38-9230
15-47-4048
15-47-4128
15-47-4208
15-47-5024
15-47-5052
15-47-5080
15-47-5104
15-47-5132
15-47-5160
15-47-5184
15-47-5212
15-47-5240
704315100
15-38-9032
15-38-9072
15-38-9110
15-38-9132
15-38-9172
15-38-9232
15-47-4058
15-47-4138
15-47-4218
15-47-5030
15-47-5054
15-47-5082
15-47-5110
15-47-5134
15-47-5162
15-47-5190
15-47-5214
15-47-5242
704315110
15-38-9040
15-38-9080
15-38-9112
15-38-9140
15-38-9180
15-38-9240
15-47-4068
15-47-4148
15-47-4228
15-47-5032
15-47-5060
15-47-5084
15-47-5112
15-47-5140
15-47-5164
15-47-5192
15-47-5220
15-47-5244
704315200
15-38-9042 15-38-9050 15-38-9052
15-38-9082 15-38-9090 15-38-9092
15-38-9142
15-38-9182
15-38-9242
15-47-4078
15-47-4158
15-47-4238
15-47-5034
15-47-5062
15-47-5090
15-47-5114
15-47-5142
15-47-5170
15-47-5194
15-47-5222
15-47-5250
15-38-9150
15-38-9190
15-38-9250
15-47-4088
15-47-4168
15-47-4248
15-47-5040
15-47-5064
15-47-5092
15-47-5120
15-47-5144
15-47-5172
15-47-5200
15-47-5224
15-47-5252
15-38-9152
15-38-9192
15-38-9252
15-47-4098
15-47-4178
15-47-4258
15-47-5042
15-47-5070
15-47-5094
15-47-5122
15-47-5150
15-47-5174
15-47-5202
15-47-5230
15-47-5254
Visit our Web site at http://www.molex.com
Doc. No: TM-638018550
Revision: B
Release Date: 03-11-13
Revision Date: 11-23-15
UNCONTROLLED COPY
Page 23 of 23
