3
Instructions
For the Assembly of the MDR 101XX-6000
Wiremount Plug using the 10960-2000 MDR
Assembly Press and Related Accessories
The assembly of the MDR plug
requires the following tooling which
must be ordered individually prior to
any tooling set-up:
• 10960-2000 .........Hand Press (Fig. 1)
• 10961 ..................Cutting Unit (Fig. 5); includes
2 spare blades (10970-9)
• 10962-2000 .........Fixture Unit (Fig. 14); includes
14, 20, 26, 36, 40, 50, 68, 80, and
100 position connector stops
• 10964-1 ...............Cable Clamp (Fig. 13); Black,
14-50 position
• 10964-2 ...............Cable Clamp (Fig. 13); Silver,
68-100 position
Optional:
• 10963-2000 .........Fixture Block (Fig. 12); Not required
for initial unit; only needs to be ordered
when additional stations are set-up.
Must also order another 10962-2000.
Initial Tooling Set Up
1.
2.
Unpack the items listed above and set them on a
clean work bench.
Select the 10960-2000 Hand Press and place it in front of
the operator so the handle is toward the operator. It is
recommended for assembling connectors that the press be
positioned in a manner so cable may hang freely below
the press when moving the shuttle block (C of Fig. 4).
Locate the thumbscrew (C of Fig. 2) at the back of the
press. Loosen the thumbscrew and gently lower the
armature of the press away from the operator (Fig. 3).
This allows easy access to the back of the press
to install the cutting unit.
Slide the platen assembly forward using the side bar
which has a round black knob (B of Fig. 4) on the
operator’s left side.
3.
4.
A.
Stop bracket
B.
Stop bracket
thumbscrew
C.
Thumbscrew
for press
D.
Shuttle
stop
2
Figure 2. Back of press
5.
1
Figure 1. 10960-2000 Hand Press
Select the 10961 cutting unit (Fig. 5). Install cutting unit
from the rear of the press. The “A” portion of the cutting
unit faces the front of the press with the “B” portion
going toward the back. Slide cutting unit forward
in the two grooves provided.
6.
Locate cutting unit stop brackets and thumbscrew (D & E
of Fig. 4). Depending on size of assembly choose
stop bracket accordingly.
(Black for 14-50 position and Silver for 68-100 position.)
Stop brackets are installed using the thumbscrew
(A & B of Fig. 2).
7.
8.
Push platen back into place using the side bar.
After installing the stop bracket, position the armature
of the press back in an upright position. Tighten the
thumbscrew (C of Fig. 2) to hold it in place.
9. Located at the back of the press is a silver, dowel shaped
shuttle stop (D of Fig. 2). Set shuttle stop for appropriate
connector pin count.
10. Locate the shuttle block (C of Fig. 4) and install fixture
unit (Fig. 14) on the guide pins. Push the release buttons
on the front of the fixture unit to open the grooved plates.
11. Locate the gauge block (F of Fig. 4). Height adjustment
can be accomplished by placing the gauge block, narrow
side down, in the fixture unit between the two grooved
plates. Close plates manually by squeezing
them together.
B
A
5
Figure 5. 10961 Cutting Unit
3
Figure 3. Press leaned back
A.
Height
adjustment
knob
12. Push shuttle, with fixture unit and gauge block, away
from the operator to the rear of the press until it stops.
13. Pull the press handle down, toward the operator, until
the platen contacts the gauge block.
DO NOT FORCE HANDLE.
14. Adjust the silver knob at the top of the press (A of Fig. 4)
by hand until the platen lightly contacts the gauge block.
Lift press handle up and adjust the silver knob
approximately another one-half turn tighter. Pull handle
down again. It should lightly lock in place when fully
depressed. The platen should apply enough pressure
on the gauge block and shuttle to prevent them from
moving when trying to slide them out.
15. Height adjustment should be checked periodically.
B.
Side bar
knob &
platen
E.
Thumbscrew
Fixture Unit Adjustment
C.
Shuttle
block
Once the size of the connector to be assembled has been
determined the 10962 Fixture Unit requires some adjustments.
1.
2.
Select the correct connector stop (14, 20, 26, 36, 40, 50,
68, 80 or 100 position; B of Fig. 14) for your application.
Locate the yolk shaped cover plate (A of Fig. 14) and
thumbscrew at the top of the fixture unit. Remove
and set aside. Close fixture unit grooved plates by
manually squeezing them together.
D.
Stop brackets
Figure 4. 10960-2000 Hand Press
F.
Gauge block
4
2
3.
4.
5.
6.
7.
Grasp the stop so the numbers face up, the rounded end
to the rear and the grooved end facing the operator. With
the grooved end raised up, slide the back end against the
small spring that contacts the stop under the cover plate.
Make sure the stop pushes against the spring. Lower the
grooved end (front end) down into the slot and maintain
downward pressure. The spring should be pushing
forward against the connector stop which should be
held in place by the silver colored pin against
a tab mechanism underneath.
Holding the connector stop down in place, replace the
yolk shaped cover plate and tighten the thumbscrew.
To verify the connector stop is correctly installed, press
the release buttons on the front of the fixture unit (A of
Fig. 7) and the connector stop should spring to the back.
Close the grooved plates and the stop should spring
forward again.
If planning to terminate with flat cable, then proceed to
Step 7. Otherwise, turn the fixture unit over and locate
the size indexes on the
A.
two strips adhered to the
Adjustment
bottom sides (Fig. 6).
knob
Adjust the cable clamp
stop (B of Fig. 6) by
turning the adjustment
B.
knob (A of Fig. 6) on the
Cable
rear of the unit to align
clamp
stop
the grooves in the cable
clamp stop with the
correct size index.
Return fixture unit
to shuttle block.
Figure 6. Back side of 10962-2000
Fixture unit is now
Fixture Unit
ready for use.
0.025” Flat Ribbon Cable Preparation
1.
If the cable is shielded, cut jacket back, exposing the
pleated foil. Peel pleated foil back above the jacket
and leave attached.
Split insulated conductors to separate them individually.
Cable is now ready for termination.
2.
3.
Connector Termination
1.
Place the fixture unit onto either the fixture block (Fig.
12) or the shuttle block on the press (C of Fig. 4) with the
slot on the fixture unit toward the operator and the cable
clamp stop adjustment knob at the rear of the unit,
away from the operator.
Select a connector and both covers of the correct size.
2.
A.
Release
buttons
7
6
Figure 7. “U” cover plate
3.
Cable Preparation
Before assembly of the MDR 101XX-6000 Wiremount Plug
can take place, the cable must be prepared. After selecting the
appropriate conductor count cable, use the corresponding
method for round jacketed discrete wire or flat ribbon cable.
4.
Discrete Wire Cable Preparation
1.
2.
Remove approximately 3 inches of the outer jacket of
insulation revealing the braided shielding.
Cut the braided shielding about 1/2 inch above the end
of the jacket and peel it back over the jacket.
CAUTION:
Do not score the underlying insulation
of the conductors when cutting the braid.
Unwrap and remove the foil as far back as the jacket.
Remove any fiber or plastic stiffeners so only
conductors are revealed.
Cable is now ready for termination.
3.
4.
5.
Place the first cover, shaped like the letter “U”, into the
slot at the top of the fixture unit (Fig. 7), open end toward
the operator and the grooved side with the posts facing
up. Push the cover down in the slot and back against the
spring loaded connector stop previously installed
to lock it in place.
For termination choose the appropriate type of cable:
Discrete Wire Cable
A. Place prepared cable into the cable clamp (Fig. 13)
with the jacket even with the top of the clip’s edge.
B. Arrange the individual cable conductors into bundles
so that the first to be assembled are closest to
the clamp opening.
C. Place the clamped cable into the fixture unit while
guiding the first conductors into the open “U”
of the cover. Push the clamp back until it
contacts the previously adjusted stop.
D. Carefully untwist the first set of conductors. Push
the first conductor to the back of the slot. Gently
pull up and to the left to align wire with the groove
in rear left of the cover and then down into the
corresponding wire slot. Stretch it slightly and
lay it into the grooved wire holding slot. Be sure
the wire is properly seated into the “U” shaped
cover (Fig. 8) by gently pushing it into the slot.
3
8
9
Figure 8. Wires in “U” slot cover
Figure 9. 2nd cover on top of wires
10
11
Figure 10. Cut wires
Figure 11. Connector body
5.
6.
E. Repeat for the next conductor, except position it to
the rear and right. Place the next wire in the left slot
(adjacent to the first one), followed by another wire
in the right slot, etc., until all conductors are
in position. Proceed to Step 5.
0.025” Flat Ribbon Cable
A. To use the fixture unit, first remove the cable clamp
stop (B of Fig. 6) from the fixture unit. This is done
so that the flat cable may be inserted into the
fixture unit without obstruction.
B. Slide the prepared cable end into the fixture slot so
the first conductor is towards the back, facing
the left side.
C. Lay the conductors into the grooved wire holding slot
accordingly until all conductors are positioned.
Proceed to Step 5.
Pick up second cover and rub the paper liner to ensure
transfer of adhesive to the cover. Remove the paper liner
from the back of the second cover and place the cover
(adhesive side down) over the wires and first cover,
aligning it with the first cover’s guide pins. Keep the
notched end toward the operator. Press it down on
the first cover’s guide posts (Fig. 9).
Slide the platen assembly forward using the side bar
on the operator’s left side to reveal the cutting unit.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Push shuttle block with fixture unit and cable
subassembly away from the operator, back under
the cutting unit, until it contacts the shuttle stop.
Pull the press handle down and release, cutting
the wires (Fig. 10).
Push platen back into place using the side bar.
Pull the shuttle out. Placing one finger near the center
of the covers to prevent movement or wire dislocation,
remove the cut wires from the fixture unit.
Push the release buttons on the front of the fixture unit to
allow placement of the connector body over the covers
(Fig. 11). Make sure the alignment tab on the inside end
of the connector body is aligned with the notch on the
second cover, nearest the operator. Push the connector
body down over the covers until a slight “click” is heard.
Push shuttle block, with fixture unit and cable
subassembly, away from the operator until it stops.
Pull press handle completely down, pressing connector
body onto the covers and subassembly.
Lift handle and pull shuttle block and assembly
toward the operator.
Completed assembly may now be removed
from the fixture unit.
4
Blade Replacement
Remove the cutting unit (Fig. 5) from the press. Loosen
the set of hex screws on each side of the cutting unit,
approximately two turns. Blades may now be removed.
Install new blades* ensuring the beveled edge is facing out.
Blades are self aligning. Tighten the screws and reinstall
the cutting unit.
*Order 10970-9 replacement blades which are packaged
2 blades per set.
Multiple Wiring Stations
Increased through-put and greater press utilization can be
achieved by setting up additional wiring stations. When
required, order one each of the 10963-2000 fixture block
and one each of the 10962-2000 fixture unit. After the
wires are properly positioned in the fixture unit, move
the unit to the press for final termination of connector.
12
13
Figure 12. 10963-2000 Fixture Block
Figure 13. 10964-1 10964-2 Cable Clamps
A.
Cover
plate
B.
Connector
stops
14
Figure 14. 10962-2000 Fixture Unit with connector stops
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