Modular Plug Bench Top Terminator
Order No ATS-623001400 Release Date: 06-05-98 UNCONTROLLED COPY Page 1 of 17
Revision: C Revision Date: 01-05-09
MODULAR PLUG BENCH TOP TERMINATOR
Instruction Manual
Order No. 62300-1400
For Shielded Modular Plug 95043 Series
Description
Operation
Maintenance
Modular Plug Bench Top Terminator
Order No ATS-623001400 Release Date: 06-05-98 UNCONTROLLED COPY Page 2 of 17
Revision: C Revision Date: 01-05-09
WARNING
NEVER USE THIS MACHINE WITHOUT THE GUARDS OR SAFETY DEVICES THAT ARE
INTENDED TO PREVENT HANDS FROM REMAINING IN THE TERMINATION OR
FEED AREAS. RUNNING THIS MACHINE WITHOUT GUARDS, UNDER ANY
CIRCUMSTANCES, CAN CAUSE SERIOUS INJURY.
NEVER OPERATE, SERVICE, OR ADJUST THIS MACHINE WITHOUT PROPER
INSTRUCTION AND WITHOUT FIRST READING AND UNDERSTANDING THE
INSTRUCTIONS IN THIS MANUAL.
NEVER ADJUST OR SERVICE THIS MACHINE WHILE IT IS CONNECTED TO ANY
ELECTRICAL POWER SOURCE. DISCONNECT POWER BY UNPLUGGING THE
MACHINE FROM ITS POWER SOURCE.
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
Modular Plug Bench Top Terminator
Order No ATS-623001400 Release Date: 06-05-98 UNCONTROLLED COPY Page 3 of 17
Revision: C Revision Date: 01-05-09
Table of Contents
SECTION
1. General Description
2. Setting Up and Operation
3. Maintenance and Troubleshooting
4. Parts Lists, Assembly Drawings, and Schematics
Modular Plug Bench Top Terminator
Order No ATS-623001400 Release Date: 06-05-98 UNCONTROLLED COPY Page 4 of 17
Revision: C Revision Date: 01-05-09
Section 1
General Description
1.1. Description
1.2. Features
1.3. Technical Specifications
1.4. Delivery Check
1.5. Tools
1.6. Products
Modular Plug Bench Top Terminator
Order No ATS-623001400 Release Date: 06-05-98 UNCONTROLLED COPY Page 5 of 17
Revision: C Revision Date: 01-05-09
Figure 1
-
1
General Description
1.1 Description
The 62300-1400 Modular Plug Bench Top
Terminator is designed to terminate pre-
stripped, prepared cable to the 8 circuit Shielded
Modular Plug (95043 series). The operator
prepares the cable, slides on a ferrule, inserts
the end into the plug, then inserts this assembly
into the terminator. When the plug is in position,
pressing the foot switch will activate the ram,
pressing the wires into the terminals, and setting
the strain relief.
1.2 Features
All electrical, no shop air required.
Small and light weight for easy relocation.
Quiet operation.
Simple design for low maintenance.
1.3 Technical Specifications
Dimensions
Width 150mm (5.91 in)
Depth 305mm (12.0 in)
Height 150mm (5.91 in)
Unpacked weight
10.5 kg (23.2lbs)
Power Requirements
Voltage: 110V AC 50/60Hz, 7A
Modular Plug Bench Top Terminator
Order No ATS-623001400 Release Date: 06-05-98 UNCONTROLLED COPY Page 6 of 17
Revision: C Revision Date: 01-05-09
Rate
This machine terminates up to 600 per hour,
depending on operator skill and connector size.
1.4 Delivery Check
Carefully remove the terminator from its shipping
container. Check to see that following items are
included in this package:
Decription: Quantity
62300-1400 Terminator 1
69002-5715 Foot Switch Assembly 1
ATS-623001400 Instruction Manual 1
1.5 Tools
The following tools are recommended for setup and
adjustments to the this tool.
Metric Hex Wrench Set
Needle nose pliers
Eye Loupe - 5X
1.6 Products:
Shielded Modular Plug, 8 position for Round Cable.
95043 Series Number
95043-1881 95043-2806 95043-2895 95043-5893 95043-7882
95043-2800 95043-2807 95043-2896 95043-5894 95043-7883
95043-2801 95043-2881 95043-3981 95043-5895 95043-7884
95043-2802 95043-2891 95043-4881 95043-5896 95043-7885
95043-2803 95043-2892 95043-5881 95043-6891 95043-7886
95043-2804 95043-2893 95043-5891 95043-7880 95043-7887
95043-2805 95043-2894 95043-5892 95043-7881 95043-7897
Modular Plug Bench Top Terminator
Order No ATS-623001400 Release Date: 06-05-98 UNCONTROLLED COPY Page 7 of 17
Revision: C Revision Date: 01-05-09
Section 2
Setting Up And Operation
2.1. Installation
2.2. Setup
2.3. Operation
Modular Plug Bench Top Terminator
Order No ATS-623001400 Release Date: 06-05-98 UNCONTROLLED COPY Page 8 of 17
Revision: C Revision Date: 01-05-09
Figure 2
-
1
2.1 Installation (See Figure 1-1)
1. Set the terminator on a firm work surface. Be
sure there is adequate room around the
terminator to handle the harnesses.
2. Plug the power cord into a suitable power
source.
3. Make sure there is adequate lighting.
WARNING: When servicing this machine, always
disconnect the power cord.
2.2 Setup
Termination Depth Adjustment
(See Figure 1-1)
The termination depth can be adjusted using the
following steps.
1. Remove the four (4) socket head cap screws,
two on each side, that hold the plastic guard
plate in place and remove the guard plate.
2. Locate the two (2) tool holder screws in the
center of the ram and loosen them.
3. There are three (3) SHCS; one has a lock nut
on the top of the ram. This is the tooling
adjusting screw. Loosen the lock nut and turn
the adjusting screw (CW) clockwise to increase
termination depth or (CCW) counterclockwise to
decrease the depth.
4. Make sure tool holder is firmly up against the
adjusting screw and tighten the two (2) holding
screws.
5. Double check the termination depth and repeat
steps 2, 3 and 4 as necessary. When satisfied
that the wires are seated correctly, replace the
guard.
Brake Adjustment
1. Remove the two (2) screws that hold the rear
motor cover.
2. Carefully remove the rear cover and slide it
around on the wire out of the way.
3. Locate the three (3) brake shoe springs loading
nuts. See Figure 2-1.
4. Increase the compression on the brake shoe
springs by turning the loading nuts (CW)
clockwise.
NOTE: Nuts should all be adjusted to the same
distance from the plate.
5. Replace the rear cover but do not replace the
screws at this time.
6. Turn the power on. If the ram still actuates,
repeat step 2 through 5 until ram operates
normally.
7. Replace the two (2) rear cover screws.
2.3 OPERATION
Terminator Panel Buttons (See Figure 1-1)
1. “ON-OFF” This button turns on or off the power
to the terminator.
2. “AUTO-STEP” This button sets the mode of
operation - “AUTO” (Automatic) or “STEP”
(Jog).
3. Power Light indicates power is on to the
terminator.
Operation
1. Slide a shield onto a length of pre-stripped
cable then insert the cable into a modular
connector. See Figure 2-2.
2. Slide the shield onto the connector.
Modular Plug Bench Top Terminator
Order No ATS-623001400 Release Date: 06-05-98 UNCONTROLLED COPY Page 9 of 17
Revision: C Revision Date: 01-05-09
Figure 2
-
2
3. Insert the connector assembly into the opening
in the guard guiding it into the termination nest
and up to the stop. See Figure 2-2.
4. When the connector is correctly seated in the
nest, press the foot switch to terminate the
connector and ferrule onto the cable.
NOTE: Depress the foot switch to cycle
the press. If the foot switch is held down,
the press will continue to cycle.
5. Push down on the cable and remove the
harness. Repeat steps 1 through 4 for the
other end if required.
Modular Plug Bench Top Terminator
Order No ATS-623001400 Release Date: 06-05-98 UNCONTROLLED COPY Page 10 of 17
Revision: C Revision Date: 01-05-09
Section 3
Maintenance
3.1. Cleaning
3.2. Lubrication
3.3. Perishable Parts
3.4. Spare Parts
3.5. Troubleshooting
Modular Plug Bench Top Terminator
Order No ATS-623001400 Release Date: 06-05-98 UNCONTROLLED COPY Page 11 of 17
Revision: C Revision Date: 01-05-09
3.1 Cleaning
WARNING: Always disconnect the power cord from the power source during all maintenance operations.
For efficient operation, this Semiautomatic Modular Plug Terminator Machine should be cleaned daily with a
soft bristle brush to remove any carrier strip debris and terminal plating dust from the tooling area. For
continuous operation this may have to be done several times throughout the day.
See Chart 3.1 for recommended Preventive Maintenance Schedule.
When it is necessary to change tooling, care should be taken to remove any debris from tapped holes or
mounting surfaces. Debris can prevent tooling from being properly locked into position.
CAUTION: Using compressed air to clean tooling is not recommended. Chips can wedge in the tooling and/or
fly at an operator.
3.2 Lubrication
There is a covered port on the top of the ram. 3 - 4 drops of SAE 10W motor oil, or equivalent, should be put in
this port approximately once a month. See Figure 1-1.
WARNING: Never use penetrates such as WD40 for any lubrication on the Termination machine.
An example of a maintenance chart is shown below. Copy and use this chart to track the maintenance of your
Press or use this as a template to create your own schedule or use your company’s standard chart, if applicable.
Preventive Maintenance Chart
Daily: Clean. See Section 3.1.
Monthly: Lubricate ram, See Section 3.2.
CHECK SHEET MONTH _________YEAR _________
Days of the Week
Week Monthly Daily Clean MON TUE WED THU FRI SAT SUN Solution
1
2
3
4
Lubricate Yes SAE 10 non-detergent oil
Cleaning Yes Soft Brush Industrial
Degreaser
Inspect all tooling
for wear Yes Replace if signs of wear.
Modular Plug Bench Top Terminator
Order No ATS-623001400 Release Date: 06-05-98 UNCONTROLLED COPY Page 12 of 17
Revision: C Revision Date: 01-05-09
Schedule should be adjusted up or down depending on usage. Molex recommends that a log of preventive
maintenance be kept with the press.
3.3 Perishable Parts
Customers are responsible for maintaining the Modular Plug Terminator Machine. Perishable parts are those
parts that come in contact with the product and will wear out over time. Molex recommends that all customers
keep at least one set of the perishable tool kit in stock at all times. This will reduce the amount of production
down time. These parts are identified in the parts list in Section 4.
3.4. Spare Parts
Customers are responsible for maintaining the Modular Plug Terminator Machine. Spare parts are moving and
functioning parts that 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 in Section 4.
3.5 Troubleshooting
Symptom Cause Solution
Damage to power cord. Repair or replace cord.
Power cord properly
plugged in but
power will not come on Fuse blown. Replace blown fuse with proper size fuse.
Termination not deep
enough and ferrule
not adequately crimped
Termination depth not set correctly.
Readjust the termination depth.
See Section 2.1.SETUP,
Termination Depth Adjustment.
Faulty foot switch. Repair or replace as required.
Ram actuates when
power is turned on Brake out of adjustment. Reset the brake.
See Section 2.1.SETUP, Brake Adjustment.
Ram not stopped at full up position.
Make sure when moving the ram
in “Step” mode that the ram is
stopped at the top of its stroke.
Ram runs in “Step”
but not in “Auto”
Ram position switch faulty
On the back of the motor mounting
block is a miniature limit switch that
indicates the position or the ram.
If faulty, replace it.
Modular Plug Bench Top Terminator
Order No ATS-623001400 Release Date: 06-05-98 UNCONTROLLED COPY Page 13 of 17
Revision: C Revision Date: 01-05-09
Section 4
4.1 Parts List and Assembly Drawings
4.2 Schematic Drawings
Modular Plug Bench Top Terminator
Order No ATS-623001400 Release Date: 06-05-98 UNCONTROLLED COPY Page 14 of 17
Revision: C Revision Date: 01-05-09
4.1 Parts List
62300-1400 Modular Plug Terminator
Item Order No Description RSP / PP Parts / Notes Quantity
1 62300-1401 Guard, Front 1
2 62300-1402 Mount, Guard 1
3 62300-1403 Base, Nest 1
4 62300-1404 Nest PP 1
5 62300-1405 Switch, Toggle 1
6 62300-1406 Switch, Toggle 1
7 62300-1407 Light, Red Indicator 1
8 62300-1408 Die, Upper PP 1
9 62300-1409 Ram 1
10 62300-1410 Plate, Ram Top 1
11 62300-1411 Block, Cam Bearing 1
12 62300-1412 Pin, Cam 1
13 62300-1413 Cam 1
13 62300-1414 Box, Gear 1
14 62300-1415 Motor 1
15 62300-1416 Shaft, Rear Motor 1
16 62300-1417 Pin, Locking 1
17 62300-1418 Coupling, Brake 1
18 62300-1419 Plate, Front Brake 1
19 62300-1420 Pad, Brake 1
20 62300-1421 Disk, Clutch 1
21 62300-1422 Spring, Brake 3
22 62300-1423 Ring, Brake 1
23 62300-1424 Nut, Fixed 3
24 62300-1425 Base, Ring 1
25 62300-1426 Nut, Fixed 3
26 62300-1427 Assembly, Brake Electrical Control 1
27 62300-1428 Nut, Brake Spring Adjusting 3
28 62300-1429 Switch, Miniature 1
29 62300-1430 Switch, Miniature With Lever 1
30 62300-1431 Base, Machine 1
31 62300-1432 Plate, Base 1
32 69002-5717 Assembly, Foot Switch 1
33 62300-1450 Timer (Not Shown) 1
34 62300-1498 Warning Label (Not Shown) 1
35 11-41-0264 Molex Logo (Not Shown) 1
RSP - Part is a Molex Recommended Spare Part.
PP - Part is a Perishable Part.
** Available from an industrial supply company such as MSC (1-800-645-7270).
Americas Headquarters
Lisle, Illinois 60532 U.S.A.
1-800-78MOLEX
amerinfo@molex.com
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
Modular Plug Bench Top Terminator
Order No ATS-623001400 Release Date: 06-05-98 UNCONTROLLED COPY Page 15 of 17
Revision: C Revision Date: 01-05-09
4.1 Assembly Drawings
Modular Plug Bench Top Terminator
Order No ATS-623001400 Release Date: 06-05-98 UNCONTROLLED COPY Page 16 of 17
Revision: C Revision Date: 01-05-09
4.1 Assembly Drawings
Modular Plug Bench Top Terminator
Order No ATS-623001400 Release Date: 06-05-98 UNCONTROLLED COPY Page 17 of 17
Revision: C Revision Date: 01-05-09
4.2 Electrical Drawings
