molex 63801-8550 User manual

C-Grid® SL™ FFC Termination Kit
Doc. No: TM-638018550 Release Date: 03-11-13 UNCONTROLLED COPY Page 1 of 23
Revision: B Revision Date: 11-23-15
C-Grid® SL™FFC Termination Kit
(For T2 and Terminator Crimp Module)
Order No. 63801-8550
Instruction Manual
Description
Operation
Maintenance

C-Grid® SL™ FFC Termination Kit
Doc. No: TM-638018550 Release Date: 03-11-13 UNCONTROLLED COPY Page 2 of 23
Revision: B Revision Date: 11-23-15
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

C-Grid® SL™ FFC Termination Kit
Doc. No: TM-638018550 Release Date: 03-11-13 UNCONTROLLED COPY Page 3 of 23
Revision: B 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 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
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.
Excessive noise levels.
Always wear proper ear protection when
Operating or servicing this equipment.
WARNING
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.
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
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.
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.

C-Grid® SL™ FFC Termination Kit
Doc. No: TM-638018550 Release Date: 03-11-13 UNCONTROLLED COPY Page 4 of 23
Revision: B Revision Date: 11-23-15
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. Customer name
2. Customer address
3. Person to contact such as (name, title, e-mail, and telephone number)
4. 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

C-Grid® SL™ FFC Termination Kit
Doc. No: TM-638018550 Release Date: 03-11-13 UNCONTROLLED COPY Page 5 of 23
Revision: B Revision Date: 11-23-15
GUARD
Figure 1-1
SLIDE INTERLOCK
INSERTION
NEST
PUNCH
CABLE CLAMP
CABLE
GUIDES
CABLE STOP
TOOLING LOCATOR
CABLE ASSEMBLY
TERMINATION NEST
CABLE GUIDES
EXTENSION
LIMIT SWITCH
CARRIER
BREAK-OFF LIP
PRESS JUMPER
Principal Mechanical Parts of the FFC Termination Kit

C-Grid® SL™ FFC Termination Kit
Doc. No: TM-638018550 Release Date: 03-11-13 UNCONTROLLED COPY Page 6 of 23
Revision: B Revision Date: 11-23-15
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
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.
Molex offers the following presses for operating the
Crimp Module with the FFC Termination Kit:
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
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 break-
off tool.
Quick crimp punch removal.
Compatible ONLY with the Molex TM-3000 and TM-
4000 Universal Presses
1.3 Technical Specification
Dimensions
(Lower Tooling Only)
Width: 145mm (5.7")
Depth: 260mm (10.2")
Height: 44mm (1.7")
Weight (Termination Kit Only)
3.8kg (8.5lbs)
Guarding
The FFC Termination Kit is supplied with special
guard panels that must be installed on the TM-
3000 or TM-4000 press.
Do not operate the FFC Termination
Kit without guard panels installed.
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
Carefully remove the FFC Termination Kit from its
shipping container; note that the following items
are included in the package:
TM-638018550 Operation Manual 1
FFC Termination Kit 1
Guard panels for FFC Kit 1
Safety Switch and bracket 1
Jumper wire assembly 1
1.5 Crimp Tooling Accessories (optional)
Molex Order No. 63800-2810 Eye loupe
1.6 Tools
The following tools are recommended for setup
and adjustments to the applicator:
1. Metric and English hex wrench sets
2. Adjustable wrench
3. Feeler gages/ shim stock
4. Eye loupe (5X)
1.7 Application Tooling Specification Sheets
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.

C-Grid® SL™ FFC Termination Kit
Doc. No: TM-638018500 Release Date: 07-16-12 UNCONTROLLED COPY Page 7 of 23
Revision: WIP Revision Date: 07-16-12
Figure 2-2
Figure 2-3
REMOVE THE
(4) SCREWS
FROM THE
(2) HINGES
EXISTING
DOOR ASSEMBLY
Figure 2-1
M5 x 12mm
LONG SCREWS
REMOVE
FEED MECHANISM
REMOVE
TOOLING CLAMP
REMOVE
TOOLING CLAMP
REMOVE
M6 BHSC (2)
KEEP
DOWELS IN
PLACE (2)
KEEP
DOWELS IN
PLACE (2)
Section 2
Set-Up and Operation
Read the following instructions before attempting to terminate FFC product in the Crimp Module.
2.1 Crimp Module Preparation
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.

C-Grid® SL™ FFC Termination Kit
Doc. No: TM-638018550 Release Date: 03-11-13 UNCONTROLLED COPY Page 8 of 23
Revision: B Revision Date: 11-23-15
Figure 2-4
PRESS
PRESS QUICK CHANGE
MOUNTING PLATE
SHUT HEIGHT
GAUGE
Figure 2-5
MOTOR
TURN
CLOCKWISE
T-HANDLE
WRENCH
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.
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.
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. Open the guard door.
2. 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.
3. Place the shut height gauge onto the press quick change mounting plate. Align the gauge to the ram as shown in Figure 2-
4.
4. Manually cycle the press to the down stroke position. See Section 2.2, How to Manually Cycle the Press, or follow the TM-
3000 Operation Manual (order number TM638017299) Section 3.3 Manually Cycling the Press.
5. 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").
6. If adjustments are necessary, refer to the TM-3000 press manual for adjustment of the press shut height.
7. Repeat the above steps until the correct shut height is obtained.
8. Shut height gauges must be calibrated on a regular basis.
2.4 How to Manually Cycle the Press
Always turn off and disconnect the power supply to the
press.
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)
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.

C-Grid® SL™ FFC Termination Kit
Doc. No: TM-638018550 Release Date: 03-11-13 UNCONTROLLED COPY Page 9 of 23
Revision: B Revision Date: 11-23-15
SLIDE LOCK PLUNGER
Figure 2-7
MOVE FFC SLIDE
FORWARD
M6 x 8MM
LONG SCREW
DOWELS (2)
DOWELS (2)
Manually Cycling the TM3000 and TM4000 Presses
1. 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.
2. Rotate the wrench clockwise. This turns the motor and moves the ram down and up.
3. Always return the press ram back to top dead center to ensure that the ram is in the startup position.
4. 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
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.
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.
FFC PUNCH
Figure 2-6
M5 SCREW
TOOLING
LOCATOR
M4 SHCS
RAM
FRAME

C-Grid® SL™ FFC Termination Kit
Doc. No: TM-638018550 Release Date: 03-11-13 UNCONTROLLED COPY Page 10 of 23
Revision: B Revision Date: 11-23-15
SLIDE SAFETY
SWITCH BRACKET
M6 x 16MM
LONG SCREW
Figure 2-8
PRESS
RAM YOKE
CRIMP MODULE
BASE PLATE
M5 SHCS
LOCKING
CLAMP
QUICK CHANGE
MOUNTING PLATE
LOCATION
CLAMPS
Figure 2-9
RAM ADAPTER
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.
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.