Connector Piece Parts Contact/Connector Head Twist On Nut MX MX Boot Procedure Chart Procedure Tool Required Tool Part Number Cable Preparation & Fiber Cleaning Jacket Stripper 86710-0004 Cable Preparation Template 86710-0006 Jacket Stripping Tool 86710-0003 Buffer Stripping Tool 86710-0002 Kevlar & Jacket Cutter 86710-0005 Fiber to Ceramic Contact Bonding Epoxy 86710-0024 Syringe 86710-0023 Contact Protection Tubing 86710-4011 ST Crimp Tool 86710-5200 Kevlar & Jacket Cutter 86710-0005 Tissue 86710-0022 Curing Oven 86710-4000 Fiber Cleaving Universal Cleave Tool 86753-2000 Fiber Polishing ST Polishing Tool 86710-1000 Red Rubber Pad 86710-0046 Foam Pad 86710-0007 Polishing Plate 86710-0040 Lapping Film #1 (3X8) Dark Grey w/ Adhesive 86710-0025 Lapping Film #2 (3X8) Light Grey w/adhesive 86710-0026 Lapping Film #3 (3X8) Yellow w/adhesive 86710-0027 Connector Assembly Boot Assembly Tool 86710-3010 ST Assembly Fixure 86710-3000 Included in Consumable Kit Consumable Kit 86710-5000 Final Inspection 100X Microscope 86710-0030 NOTE: Alcohol must be supplied locally. It is not supplied with the consumable kit. Isopropyl alcohol 91% required. PLEASE READ THROUGH THE ENTIRE PROCEDURE BEFORE STARTING TO ASSEMBLE A CONNECTOR. Cable Preparation Template (TEMPLATE IS NOT TO SCALE) Cable Jacket Jacket Split Excess Kevlar Buffer Fiber.28" (7.1mm) 0.66" (16.8mm) 1.52" (38.6mm) *ST is a registered trademark of Lucent Technologies NOTE FOR MACHINE POLISHING If polishing by machine, refer to the polishing machine operating procedure for 8671X-6000 series. Contact Molex for details. 86001-0009 Rev. 4 USA/30MFO/11.99 1999, Molex
900 Micron 900 Micron Version Version Figure 1a. Boot 900um 900µm Jacket Figure 1a. FOR 900 MICRON VERSION ONLY: 1. When using a non-jacketed fiber skip steps 9, 10 and 11. Using the small boot provided, slide the boot onto the cable as shown (Figure 1a). Crimp tube is not required. Figure 1b. Figure 1b. 900µm Boot Boot900um Jacket Jacket Glass Glass Fiber Fiber 3 mm Cable, Twist On Nut FOR TWIST ON VERSION ONLY: 2. Slide the boot and kevlar retention nut onto the cable as shown (Figure 2a). The non-threaded end of the nut must face the boot. Figure 2a. Figure 2b. Figure 3a. 3 mm Crimp Version FOR CRIMP VERSION ONLY: 3. In this version, the rear nut is replaced by the appropriate crimp tube. Two crimp tubes are provided with each connector. The necked-down crimp tube is specifically designed for 3.0 mm and smaller diameters, and the straight crimp tube is intended for larger cable diameters. When installing the necked-down crimp tube, orient the larger diameter towards the connector and the smaller diameter towards the cable (Figure 3a). Figure 3b. Figure 4 4. For jacketed cable strip the outer jacket using the template (p/n 86710-0006) and jacket stripping tool (p/n 86710-0003 -use 1.3 mm cavity) provided in the tool kit (Figures 2b, 3b). 5. Using the buffer stripping tool (p/n 86710-0002) precisely strip the buffered fiber to the correct length indicated on the stripping template (p/n 86710-0006) (Figures 1b, 2b and 3b respectively). Ensure the tool is free of any debris during this operation. A clogged tool may result in fiber breakage. See owners manual for the proper operation of this tool. NOTE: While holding firmly onto the buffer, it is recommended you strip small lengths, approximately 1/8 inch, of buffer at a time. Verify all strip lengths with the template. Snip off any excess fiber with the kevlar cutters (p/n 86710-0005) supplied with the kit. The cable manufacturer recommends cleaning the fiber and buffer with alcohol. Cleanliness of the fiber is essential to the performance and reliability of the connector. 86001-0009 Rev. 4 USA/30MFO/11.99 1999, Molex
Figure 5 Figure 6 Clean pepoxy y from side and face of ferrule 6. Prepare the epoxy according to the manufacturer s instructions. Molex recommends TRA-BOND F-253 epoxy or equivalent. Fill the syringe with epoxy and remove any air bubbles. Wipe the needle. Insert the needle into the connector until it bottoms out. Keeping the contact bottomed out, inject epoxy until it appears on the face of the ferrule. Immediately release the contact and pressure to the plunger. Wait three to four seconds before removing the contact from the syringe. Apply a small drop of epoxy to the threads on the back end of the connector before screwing on the rear nut. Holding the connector in the assembly fixture, screw the rear nut onto the connector, capturing the strength members in the thread. Remove the assembly fixture (Figure 9). Clean excess epoxy from face of ferrule Do not exceed the pot life of the epoxy (2 hours). Before injecting the epoxy check the ferrule hole for obstructions by holding the connector in front of a light source or by inserting the fiber. To remove any obstruction use a cleaning wire and air dry. Figure 7 7. Clean any epoxy from the side and end face of the ferrule with a lint-free tissue and alcohol. Avoid excess epoxy. No epoxy should be visible on the back of the connector. 8. Slowly insert the fiber into the connector until the fiber is flush with the end face of the connector (Figure 6). Figure 8 SCREW ON VERSION Assembly fixture NOTE: A slight rotation of the connector will help the insertion of the fiber. Pull the fiber back until it just recedes back into the face of the ferrule. Clean the excess epoxy from the face of the ferrule with a lint-free tissue. No epoxy should be present on the face of ferrule end face or the side of the ferrule. 9. Slide the protection tube over the ferrule and fully re-insert the fiber into the connector. The fiber should not protrude beyond the protection tube (Figure 7). Figure 9 Screw on nut Crimp version skip to Step 11. FOR TWIST ON VERSION ONLY: 10. Position the connector in the assembly fixture. The assembly fixture is specific to each connector series (Figure 8). ST (red plastic) assembly fixture 86001-0009 Rev. 4 USA/30MFO/11.99 1999, Molex
Figure 10 Crimp area Cavity "C" Cavity "D" FOR CRIMP VERSION ONLY: 11. Holding the connector in one hand, slide the crimp tubing onto the rear portion of the connector. Using the crimp tool, crimp the main portion of the crimp tube using cavity D (Figure 10). For the neckeddown crimp tube, crimp the small diameter of the crimp tube using cavity C. Figure 11 Curing Cavity Flair the strength members into an even radial pattern by lightly blowing along the axis of the cable. 12. Place the connector with the protective tubing into the oven (Figure 11). Each cavity of the oven is independently controlled. An LED on and a beep will indicate the end of the curing process (approximately 5 minutes). After curing, remove the connector and let it cool. The cable should be maintained vertically outside the oven to avoid any bending during curing. Figure 12 Stop screw Ferrule 13. Very carefully remove the protective tubing. Holding the cleaving tool with the trigger upwards, slowly insert the ferrule with its protruding fiber into the slot of the cleaving tool. Insert the connector until the ferrule end face bottoms out against the stop screw (Figure 12). Release the connector and gently press the trigger to cleave the fiber. Remove the connector from the tool. Fiber Figure 13 Cleaving Tool NOTE: Carefully dispose of the excess cleaved fiber to avoid any possible injury. POLISHING STEP 1: Using the foam pad (p/n 86710-0007) and a sheet of lapping film #2 (p/n 86710-0026), perform figure 8 motions over the entire length of the lapping film (Figure 14) according to the table (Figure 15). Virtually no pressure should be applied on the tool at the beginning of this step. If some epoxy remains visible after this step, complete two to three additional figure 8 motions. Lapping Film 86001-0009 Rev. 4 USA/30MFO/11.99 1999, Molex
Figure Figure 14 14 Lapping Film Gently clean the contact with a lint-free tissue and isopropyl alcohol between each polishing step. For best results, replace the lapping film every two to four terminations. Polishing Pad POLISHING STEP 2 Using the red rubber pad (p/n 86710-0046) mount a sheet of lapping film #3 (p/n 86710-0027), perform figure 8 motions (Figure 14) over the entire length of the film according to the table (Figure 15). Figure 15 Polishing Tool Step Lapping Film Polishing Fluid Number of Figure "8" Motions ST 1 #2 Foam 10 2 #3 Rubber 15-20 3 #7 Rubber 25 Only complete polishing steps #1 & #2 for multimode connector. POLISHING STEP 3 Using the red rubber pad (p/n 86710-0046) mount a sheet of lapping film #7 (p/n 86710-6151). Liberally apply a layer of 91% isopropyl alcohol on the surface of the lapping film and perform figure 8 motions according to table (Figure 15). Be sure to avoid and/or eliminate any air pockets under the film before polishing. Dispose of the cleaved fiber properly. 14. Mount the polished connector onto the boot assembly tool (p/n 86710-3010) (Figure 16). Apply a drop of Loctite 411 to the cable jacket approximately one inch behind the rear nut. Slide the rear boot up to the rear nut. Hook the boot under the nut and pull it over the top of the nut as shown. Slide the boot up until it fits securely over the rear nut. Figure 16 Apply a drop of Loctite 1 inch behind rear nut Boot Assembly Tool 15. Remove the connector from the polishing tool and carefully clean the ferrule with optical tissue and isopropyl alcohol. Using the 100X microscope (p/n 86710-0030) supplied with the kit, inspect the quality of the polish. No scratches or cracks should be visible (Figure 17). NOTE: The microscope should be stored in the closed position when not in use. This will ensure longer battery life. Slide the boot up until if fits securely over the rear nut Figure 17 Chip or Crack Scratch Good Bad 86001-0009 Rev. 4 USA/30MFO/11.99 1999, Molex