molex 62200-7700 User manual

SL Flat Flex Cable Terminator
Order No: TM-622007700 Release Date: 02-18-99 UNCONTROLLED COPY Page 1 of 20
Revision: F Revision Date: 11-23-15
SL Flat Flex Cable Terminator Kit for TM42 PRESS
Operation Manual
Order No. 62200-7700
For Molex 70430 and 70431 Series Connectors
Description
Operation
Maintenance

SL Flat Flex Cable Terminator
Order No: TM-622007700 Release Date: 02-18-99 UNCONTROLLED COPY Page 2 of 20
Revision: F Revision Date: 11-23-15
Table of Contents
SL Flat Flex Cable Terminator Kit for TM42 PRESS .........................................................................................................1
Order No. 62200-7700.......................................................................................................................................................1
Table of Contents ............................................................................................................................................................2
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
Section 2.......................................................................................................................................................................7
Installation.....................................................................................................................................................................7
2.1 Installation .....................................................................................................................................................8
2.1 Set Up ...........................................................................................................................................................9
2.3 Operation.....................................................................................................................................................10
Section 3..................................................................................................................................................................... 12
Maintenance ...............................................................................................................................................................12
3.1 Cleaning ......................................................................................................................................................13
3.2 Lubrication...................................................................................................................................................13
3.3 Perishable Parts ..........................................................................................................................................14
3.4 Spare Parts..................................................................................................................................................14
3.5 Troubleshooting...........................................................................................................................................14
Section 4..................................................................................................................................................................... 15
4.1 Parts List .....................................................................................................................................................16
4.2 Assembly.....................................................................................................................................................18

SL Flat Flex Cable Terminator
Order No: TM-622007700 Release Date: 02-18-99 UNCONTROLLED COPY Page 3 of 20
Revision: F Revision Date: 11-23-15
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 no charge 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
Always wear proper eye protection when
Operating or servicing these tools.
Failure to wear eye protection could result
in serious eye injury from flying debris.
Never use a press without guards or
safety devices that are intended to prevent
hands from remaining in the die space.
Failure to observe this warning could result
in severe injury or death.
WARNING
WARNING
Never wear clothing or jewelery that is loose or
That Could potentially hang into the equipement
And get caught.
Failure to observe this warning could result in
Severe Injury or death.
Never install or service these tool 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
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.
Use extreme caution when using 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.

SL Flat Flex Cable Terminator
Order No: TM-622007700 Release Date: 02-18-99 UNCONTROLLED COPY Page 4 of 20
Revision: F Revision Date: 11-23-15
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.
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 Tools 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 these tools it is recommended to have the following: a copy of the Operation Manual, the
Specific Application Specification Sheet and a person familiar with the tools should be present. The following information is
also recommended to supply:
1. Customer name
2. Customer address
3. Person to contact such as (name, title, e-mail, and telephone number)
4. Tools order number (Lease number also if applicable)
5. Serial number (Lease number also if applicable)
6. Molex Connector product order number
7. Urgency of request
8. Nature of problem
Molex Application Tooling Group
2200 Wellington Court
Lisle, IL 60532, USA
Tel: [phone]
Fax:[phone]
Visit our Web site at http://www.molex.com

SL Flat Flex Cable Terminator
Order No: TM-622007700 Release Date: 02-18-99 UNCONTROLLED COPY Page 5 of 20
Revision: F Revision Date: 11-23-15
Section 1
General Description
1.1. Description
1.2. Features
1.3. Technical Specifications
1.4. Delivery Check
1.5. Tools

SL Flat Flex Cable Terminator
Order No: TM-622007700 Release Date: 02-18-99 UNCONTROLLED COPY Page 6 of 20
Revision: F Revision Date: 11-23-15
General Description
1.1 Description
The 62200-7700 SL Flat Flex Cable Terminator Kit
is designed to be installed in the TM42 Press Order
No. 69002- 5001. It is designed to terminate the
Flat Flex Cable Connector 70430-0037 and 70430-
0048 to Flat Flex Cable. The tooling will
accommodate from 3 and a 14 circuits. The
operator loads a connector into the nest, sets the
cable stop, positions, and clamps the cable. The
nest is slid into the termination area and the press
is activated. When termination is complete the
operator slides the nest out and removes the
harness. It is then loaded into the insertion station
where the terminals are manually inserted and the
carrier strip is broken off. This terminator is ideally
suited for medium volume production.
1.2 Features
Terminator Kit is quickly installed into the Molex
TM42 Press 69002-5001.
Bench Mounted operated.
All electrical, no shop air required.
Simple modification of press allows this
terminator kit to be easily interchanged with other
TM42 terminator kits.
In addition to the 3 and 14 circuit connectors, 2 to
13 circuit connectors may be terminated in this
tool if desired.
1.3 Technical Specifications
Dimensions Press with tooling
Height 50.8mm (2.0”)
Width 152.4mm (6.0”)
Depth 254.0mm (10.0“)
Unpacked weight 1.8kg (4 Lbs))
Electrical
110/220V AC, 5.8/2.9A, 60 Hz, Single Phase.
Production Rate
240 terminations per hour maximum, depending on
operator skill.
1.4 Delivery Check
When carefully remove the TM42 Assembly from
its shipping container and check to determine if
the following items are included in this package.
Decription: Quantity
SL FFC Terminator Kit 62200-7700 1
TM42 Press Manual TM-690025099 1
Terminator Kit Manual TM-622007700 1
1.5 Tools
The following tools are recommended for setup and
adjustments to the this tool.
Metric hex wrench set
Small standard screwdriver
Adjustable wrench
Needle nose pliers
Crimp micrometer
Eye loupe (10x)
Wire stripper/cutter
English hex wrench set for some non-metric tools.

SL Flat Flex Cable Terminator
Order No ATS-622011500 Release Date: 02-18-99 UNCONTROLLED COPY Page 7 of 20
Revision: E Revision Date: 12-07-12
Section 2
Installation
2.1. Installation
2.2. Set-Up
2.3. Operation

SL Flat Flex Cable Terminator
Order No: TM-622007700 Release Date: 02-18-99 UNCONTROLLED COPY Page 8 of 20
Revision: F Revision Date: 11-23-15
HAND REST
Figure 2-2
TM42 PRESS
REEL
ASSEMBLY
KEEP M16
X 20 LG. (2)
BOLSTER SHIM
AND GUIDES
TM42 GUARD
FEED FINGER
ASSY
2.1 Installation
Principal parts of the SL flat Flex Cable Terminator Kit
1. To install the Terminator Kit 62200-7700 into the TM42
Press 69002-5001 it will be necessary to remove the
following parts:
Locating Plate 11-40-0218
Bolster Plate Shim 63800-4205
Feed Finger 69001-0105
Feed Finger 69001-0106
and all Feed Arm assembly parts
Guard Block 69002-5507
Die Guard 69002-5533
Hand Rest 69002-5547
Reel Support assembly parts. See Figure 2-2.
2. Install the locator block 62200-6017 into the TM42 ram on
press.
3. Install the termination punch 62200-6015 into the locator
block on the ram. See Figure 2-3.
4. Next place the terminator assembly unit with the micro
switch assembly towards the back of the press onto the
bolster plate. The terminator assembly should be located
over the two dowel pins in which the guide blocks were
removed .Use the two M16 x 20 BHCS from the guide
plates to secure the assembly but do not tighten.
GUARD
Figure 2-1
SLIDE INTERLOCK
INSERTION
NEST
INSERTION BAR
PUNCH
CABLE CLAMP
CABLE GUIDES
CABLE STOP
LOCATOR BLOCK
TERMINATION NEST
LIMIT SWITCH
CABLE ASSEMBLY

SL Flat Flex Cable Terminator
Order No: TM-622007700 Release Date: 02-18-99 UNCONTROLLED COPY Page 9 of 20
Revision: F Revision Date: 11-23-15
Figure 2-3
M5 x 16 Long
SHCS
LOCATOR
BLOCK
PUNCH
TM42
PRESS
PUNCH
PLATE
Figure 2-4
To Install Cable Assembly to TM42 Press
The first time the terminator kit is installed into the
TM42 Press, the Cable Assembly 62200-7721
attached to the limit switch will need to be connected
to the inside of the press. Follow the steps below.
1. Remove the back cover from the press.
2. Bring the end of the cable assembly with the male
and female quick disconnect terminals up to the
solenoid. See Figure 2-4.
3. Carefully remove one of the female quick
disconnect terminals from the solenoid and push it
on to the male quick disconnect terminals from the
limit switch cable.
4. Push the female quick disconnect terminal from
the limit switch cable onto the vacated solenoid
terminal.
5. Secure the cable down into the area of the limit switch and
replace the rear cover.
6. Plug the limit switch of the cable assembly into the connector
hanging outside the press cover.
7. Slide nest into the press.
8. Manually lower the press’s ram to align the upper and lower
tooling.
9. Tighten the two M16 x 20 BHCS in the nest assembly.
10. Check the termination height and micro switch adjustment.
See Section 2.2, Setup.
11. Make sure all the tooling is aligned.
12. Replace rear cover and install the 62201-4219 guard of the
62200-7700 Terminator Kit assembly.
WARNING: The TM42 Press weighs over 100kg (200lbs); it should not attempt to be lifted by one individual.
Mechanical lifting devices should be used. A person lifting the press can sustain severe back or other injuries.
2.1 Set Up
Termination Height
See also Section 3.9 Conductor Crimp Punch (Crimp Height) Adjustment in the TM42 Instruction Manual.
1. To adjust the termination height, load a connector into the nest with the terminals in the guides.
2. Position and clamp a cable in the nest.
3. Move the nest under the press and terminate the cable and connector. See Section 2.3 Operation for additional
instructions on terminating.
4. Check the quality of the termination and measure the height in accordance with sheet 5 of drawing PS-70430 of
Product Specification. (.038” ± .002” Ref)
CAUTION: Always disconnect power supply before installing or removing tooling.

SL Flat Flex Cable Terminator
Order No: TM-622007700 Release Date: 02-18-99 UNCONTROLLED COPY Page 10 of 20
Revision: F Revision Date: 11-23-15
Figure 2-5
CONDUCTOR
ADJ. INDICATOR
CONDUCTOR ADJ.
LOCK SCREW
CONDUCTOR
ADJ. SCREW
PUNCH RELEASE PIN
PUNCH
PLATE
Figure 2-6
CABLE
ASSEMBLY
LIMIT
SWITCH
SWITCH
SLIDE BRACKET
BASE
PLATE
5. Always power down the press by pressing the
emergency stop button located on the front of the
control panel. Remove the press guard by unscrewing
the four M10 button head screws. Two are located on
the front bolster plate and one is located on each side.
6. Loosen the M6 conductor adjustment lock screw located
on the front of the punch plate. See Figure 2-5.
7. With a screwdriver, turn the conductor adjusting screw,
located on the right side of the punch plate. Rotating
the adjusting screw clockwise one full turn will lower the
crimp height approximately 0.03mm (.001”). Each
increment on the Conductor Adjustment Indicator
represents approximately 0.13mm (.005”) for a total of
0.65mm (.026”). The “1” setting indicates the highest
crimp height and the “6” setting is the tightest.
8. Tighten the conductor adjusting locking screw.
9. Reinstall the machine guard and repeat the above steps until the desired crimp height is obtained.
Nest-in-Position Indicator Switch Adjustment
CAUTION: Always disconnect power supply before installing or removing tooling.
There is a miniature limit switch 62500-0518 in the Cable Assembly-62200-7721 on the back of the lower tooling. This
switch signals the nest in position for termination. See Figure 2-6. If this switch should work loose or has to be
replaced, it may be necessary to adjust its position. To do
this, follow these instructions:
1. Unplug the power cord.
2. Remove the back cover from the TM42 press.
3. Push the slide assembly into the press.
4. Manually lower the TM42 ram using the wrench supplied
with the press. See TM42 press manual for additional
instructions. Lower the ram until the locator in the ram
mates with the slide assembly in the lower tooling.
5. Adjust switch toward the slide assembly until the switch
is fully actuated but not totally bottomed out.
6. Replace back cover on press.
7. Plug cord into power source.
2.3 Operation
CAUTION: Molex recommends that the operator and observers wear eye protection when the press is in
operation or being serviced.
CAUTION: DO NOT use theTM42 press without guards.
1. Lift the cable stop and load a 3 circuit (Order No.70430-0037) connector and/or a 14 circuit (Order No.70430-0048)
into the nest making sure the terminals are lined up in the terminal guides. See Figure.2-7.
2. Lower the cable stop onto the connector(s).