molex FineAdjust APPLICATOR Operation Manual

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Page 1

FineAdjust Applicator

 Description  Operation  Maintenance

Doc. No: TM-638004900 Release Date: 09-04-03 UNCONTROLLED COPY Page 1 of 50 Revision: G Revision Date: 01-15-13

FineAdjust™ APPLICATOR

Operation Manual

Order No 63800-4900

Page 2

FineAdjust Applicator

Read

and

understand

all of the instructions and safety information in this manual

before

CAUTION:

WARNING

Heavy Object

WARNING

Never

install or service this machine while

WARNING

Never

operate, service, install, or adjust this

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

WARNING

Safety Warnings and Information

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

DANGER:

Indicates an imminently hazardous situation which, if not avoided, could result in death or serious injury.

WARNING:

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

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.

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.

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.

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.

To avoid muscle strain or back injury, use lifting aids and proper lifting techniques when removing or replacing. Failure to observe these precautions may result in injury or property damage.

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.

Always hand cycle the applicator in the equipment to ensure the tooling is properly aligned.

Failure to observe these precautions may result in Injury or property damage.

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Page 3

FineAdjust Applicator

WARNING

Do not use

compressed air to clean

WARNING

CAUTION

The Molex applicators a

re designed to operate in presses with standard shut heights of 135.80mm (5.346”).

CAUTION

Never

perform any se

rvice or maintenance other than as described in this manual.

Never use this press or wire processing machine 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.

Always wear proper ear protection when Operating or servicing this applicator.

Installation in crimp presses with other than standard shut heights can cause severe tool breakage. It is advisable that before installation, a check of the shut height be performed. 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.

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.

this 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.

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 Press. 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 press a copy of the Tooling Manual and Specific Applicator Tooling Specification Sheet should be present and a person that is familiar with the applicator should be present. Be sure the following information is supplied:

1. Customer name

2. Customer address

3. Person to contact such as (name, title, e-mail, and telephone number

4. Applicator 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: +1 (630) 969-4550 Fax:+1 (630) 505-0049

Visit our Web site at http://www.molex.com

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Page 4

FineAdjust Applicator

Table of Contents

Contents

FineAdjust™ APPLICATOR .......................................................................................................................................... 1

Order No 63800-4900 .................................................................................................................................................... 1

Safety Warnings and Information .................................................................................................................................. 2

Table of Contents ........................................................................................................................................................ 4

Section 1 ................................................................................................................................................................... 6

General Description .............................................................................................................................................. 6

Principal Mechanical Parts of the FineAdjust Applicator ....................................................................................... 7

1.1 Description................................................................................................................................................. 8

1.2 Features .................................................................................................................................................... 8

1.3 Technical Specification .............................................................................................................................. 8

1.4 Delivery Check .......................................................................................................................................... 8

1.5 Tools .......................................................................................................................................................... 9

1.6 Specification Sheets .................................................................................................................................. 9

Section 2 ................................................................................................................................................................. 10

Set-Up and Operation ......................................................................................................................................... 10

2.1 Shut Height .............................................................................................................................................. 11

2.2 Set-Up ..................................................................................................................................................... 11

2.3. Adjustments ............................................................................................................................................. 13

2.4 Crimp Tooling Installation and Removal .................................................................................................. 16

Section 3 ................................................................................................................................................................. 18

Maintenance ....................................................................................................................................................... 18

3.1 Cleaning .................................................................................................................................................. 19

3.2 Lubrication ............................................................................................................................................... 19

3.3 Spare Parts.............................................................................................................................................. 20

3.4 Perishable Parts ...................................................................................................................................... 20

3.5 Storage .................................................................................................................................................... 21

Section 4 ................................................................................................................................................................. 22

Styles of FineAdjust ............................................................................................................................................ 23

4.1 STYLE A-FineAdjust Applicator ............................................................................................................... 24

4.1 STYLE A FineAdjust Applicator Assembly............................................................................................... 26

4.1 STYLE A FineAdjust Applicator Assembly (Cont.) ................................................................................... 27

4.2 STYLE B-FineAdjust Applicator ............................................................................................................... 28

4.2 STYLE B FineAdjust Applicator Assembly............................................................................................... 30

4.2 STYLE B FineAdjust Applicator Assembly (Cont.) .................................................................................. 31

4.3 STYLE C-FineAdjust Applicator ............................................................................................................... 32

4.3 STYLE C FineAdjust Applicator Assembly .............................................................................................. 34

4.3 STYLE C FineAdjust Applicator Assembly (Cont.) ................................................................................. 35

4.4 Troubleshooting ....................................................................................................................................... 36

Appendix A .............................................................................................................................................................. 38

Crimp Terminations ............................................................................................................................................ 38

A.1 Conductor Brush and Terminal Position ................................................................................................. 39

A.2 Conductor Bell Mouth and Terminal Cutoff Tab ....................................................................................... 40

A.3 Conductor Height Measurement .............................................................................................................. 41

A.4 Insulation Crimp ....................................................................................................................................... 41

A.5 Pull Force Testing .................................................................................................................................... 43

Appendix B .............................................................................................................................................................. 45

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FineAdjust Applicator

Statistical Process Control (Summary) ............................................................................................................... 45

B.1 Crimp Process Control ............................................................................................................................ 46

B.2 Process Capability ................................................................................................................................... 46

B.3 Production ............................................................................................................................................... 47

Appendix C ............................................................................................................................................................. 49

Options .................................................................................................................................................................... 49

Terminal Oiler ................................................................................................... Error! Bookmark not defined.50

Order No. 63890-0719 ...................................................................................... Error! Bookmark not defined.50

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FineAdjust Applicator

General Description

1.1 Description

1.2 Features

1.3 Technical Specifications

1.4 Delivery Check

1.5 Crimp Tooling Accessories

1.6 Tools

1.7 Specification Sheets

Section 1

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FineAdjust Applicator

Figure 1

-1

PIVOT ARM

FORWARD FEED

INSULATION

RAM

DRAG FRAME

DRAG RELEASE

TRACK

FEED FINGER

CONDUCTOR

BACK STROKE

LUG BOLT

WIRE STOP

ANVIL MOUNTING BLOCK

ANVILS

FRONT COVER

TRACK

CUT-OFF PLUNGER

FEED

FINGER

BACK STROKE

Principal Mechanical Parts of the FineAdjust Applicator

ADJUSTING KNOB

REAR COVER

LOCKING SCREW

LEVER

ADJUSTING KNOB

LOCKING SCREW

ADJUSTING SCREW

ADJUSTING CAM

BASE PLATE

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AND RETAINER

Page 8

FineAdjust Applicator

General Descrition

1.1 Description

The Molex FineAdjust™ Applicator is designed to provide an effective method of applying a wide range of side feed terminals to a pre-stripped discrete wire. It is the most advanced version of a "universal" crimping tool available. It is designed to allow for quick adjustments of crimp height, track position, and terminal feed without taking the applicator out of the press and without shimming. This allows easy adjustment of crimp height to the target value with improved process capability, even after a wire changeover.

This applicator works in the Molex TM-2000 and TM-3000 Universal Press and in most industry standard presses. The FineAdjust™ applicator offers minimal setup time without the need for shimming, is versatile, reliable, easy to install, and is designed for mid-volume to high-volume, semi or fully automatic operations.

Molex offers the following crimp presses for operating the Fine Adjust Applicator™:

 TM-2000 Press 120 V 60 Hz. 63800-8300  TM-2000 Press 240 V 50 Hz. 63800-8400  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

The FineAdjust Applicator is also compatible with most OEM presses (Artos, Mecal, Komax, Megomat, Toyojamco, etc). It also adapts to most wire processing machines.

1.2 Features

 Fine adjustment allows users to achieve target with

little effort by adjusting in increments (14 settings) of .015mm (.0006") for conductor crimp height and (29 settings) in increments of .063mm (.0025") for insulation height.

 Independent adjustment rings allow users to quickly

adjust the conductor or insulation crimp height without affecting each other.

 Quick tooling removal with the push of a button for fast

and easy punch change.

 Track adjustment for bell mouth and cut-off tab is

adjusted while the applicator is in the press for fast and easy setup.

 Compatible with the Molex TM-2000, TM-3000, TM-

4000 Universal Press, and most industry standard presses. However, it does NOT fit into Molex TM40/42 press.

 Directly adapts to most automatic wire processing

machines.

 Quick set-up time; plus the crimp height, track and feed

adjustments can be preset in applicator.

 Applicator designed to industry standard mounting and

shut height 135.80mm (5.346").

 Automatic terminal feed with applicator in press.  Adjustable terminal feed with applicator in press.  Terminals are separated from carrier strip automatically

during crimping operation.

 Quiet operation with low maintenance and easy to

keep clean.

 The FineAdjust™ available for most Molex brand

terminals.

1.3 Technical Specification

Dimensions

Width: 132mm (5.2") Depth: 101mm (4.0") Height: 152mm (6.0")

Weight

4.1kg (9lbs)

Press Stroke Compatibility

41.28mm (1 5/8")

28.58mm (1 1/8")

Guarding The FineAdjust™ Applicator is supplied with no guards and is intended to be used with the guards supplied by the press manufacturer.

Caution: DO NOT use the applicator without guards

1.4 Delivery Check

Carefully remove the FineAdjust Applicator from its shipping container and determine that the following items are included in the package.

FineAdjust Applicator 1 (Tooled for desired terminal)

11-18-4238 Short Feed Cam 1 Specification Sheets 1 TM-638004900 Operation Manual 1 Sample Crimped Terminals 5

Crimp Tooling Accessories

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Page 9

FineAdjust Applicator

63890-0719 Terminal Oiler (Appendix C) 63800-2800 Digital Crimp Micrometer

1.5 Tools

The following tools are recommended for setup and adjustments to the applicator:

1. Metric standard hex wrench set

2. Adjustable wrench

3. Wire stripper / cutter

4. Scissors

1.6 Specification Sheets

Molex ships specification sheets with every applicator. The specification sheet contains the following:

ΕΕΕΕ Terminal numbers ΕΕΕΕ Wire AWG ranges ΕΕΕΕ Insulation diameter ranges ΕΕΕΕ Strip lengths ΕΕΕΕ Pull force ΕΕΕΕ Crimp heights ΕΕΕΕ Bell mouth ΕΕΕΕ Bend, twist, and roll limits ΕΕΕΕ Tooling parts list and assembly

The specification sheet should be filed. These are available on the Molex website (www.molex.com).

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Page 10

FineAdjust Applicator

Section 2

Set-Up and Operation

2.1. Shut Height

2.2. Set-Up

2.3. Adjustments

2.4. Crimp Tooling Installation and Removal

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Page 11

FineAdjust Applicator

PRESS

PRESS QUICK

SHUT HEIGHT

Read the following instructions before attempting to operate the applicators.

2.1 Shut Height

The Molex FineAdjust Applicators are designed to operate in crimp presses with standard shut height of 135.80mm (5.346"). Installation in crimp presses with other than standard shut heights can cause severe tool breakage. It is recommended that before installation, a check of the shut height be performed. The correct shut height is required to prevent the punches from hitting the anvils and the cut-off tooling from bottoming out on the base plate. It also allows the movement of applicators from press to similar press without adjusting the applicator or press shut height.

The shut height of the press can be checked with a shut height gauge, which is calibrated under load to achieve the 135.80mm (5.346") measurement. It is recommended that the shut height be checked monthly. A shut height gauge is available from most press manufacturers.

Measuring Press Shut Height

GAUGE

CHANGE

MOUNTING PLATE

Figure 2-1

1. Always disconnect the power supply from the press. Remove the machine guards if necessary.

2. Remove the applicator from the press. See “Applicator Installation and Removal” (below) for additional information. Make

sure that the bottom of the press ram and quick change mounting plate are free from foreign material.

3. Place the shut height gauge into the press on the press quick change mounting plate. See Figure 2-1.

4. Manually cycle the press to the down stroke position. (Follow press manufacturer’s instructions on manually cycling the

press.)

5. Read the shut height measurement from the front of the gauge. Follow gauge manufacturers’ instruction, usually the gauge

reads “0” when set correctly.

6. If adjustments are necessary, refer to the press manufacturer 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.

2.2 Set-Up

IMPORTANT

Power must be shut off and electrical cord disconnected. Manual press cycling is an absolutely required procedure for safety and preventing equipment damage. Always cycle by hand when trouble shooting or changing adjustments, tooling, applicator, or accessories.

The principal mechanical parts of the FineAdjust are illustrated in Section 4.1 Assembly Drawings.

Applicator Installation and Removal

1 All presses must be equipped with a common universal type quick-change mounting plate and adapter on the press.

Contact the press manufacturer for specific information. 2 Always turn off and disconnect the power supply to the press. Remove the press guards. 3 Clean the quick change mounting plate of scrap or chips that may interfere with the FineAdjust applicator installation. 4 For the TM-2000 and TM-3000 Presses follow the procedure below:

a. Using a 4mm hex wrench, turn the M5 SHCS clockwise until the locking clamp is fully opened.

b. Visually align the applicator base plate slots with the location clamps on the press quick-change mounting plate.

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Page 12

FineAdjust Applicator

ENGAGE PRESS

BASE PLATE

LOCKING CLAMP

QUICK

LOCATOR

TERMINAL

FEED FINGER

1ST

TERMINAL

c. Slide the applicator onto the quick-change mounting plate

until the two notches on the left side engage against the stops, and at the same time, guide the lug bolt into the adapter on the press. See Figure 2-2.

d. To lock applicator, turn the M5 SHCS counter clockwise until

tight.

YOKE

5 Some presses have locking latches on the quick change

mounting plate, which have to be flipped up to secure the

applicator. Others have knurled finger screws or "T" type latches.

APPLICATOR

Most of these are located on the right side of the quick change

mounting plate to secure the position of the applicator. These

must be in place and secured before operating the press. 6 Replace the press guards.

Remove the applicator by reversing the previous steps. When storing an applicator, always leave a strip of terminals in the applicator to prevent damage to the tooling. See Section 3.5 Storage.

Fitting Terminal Strip

1. The specified terminals are printed on the setup sheet for the

applicator. Only use the Molex terminals on the setup sheet

CHANGE

MOUNTING

PLATE

CLAMPS

M5 SHCS

Figure 2-2

which is supplied with the applicator.

2. Always disconnect the power supply from the press. Remove the machine guards if necessary.

3. Rotate the drag release until the drag frame is in the upright position. This will allow the terminal to slide with ease through

the applicator track. See Figure 2-3.

4. Push the terminal strip until the first terminal comes to rest centered above the anvil.

5. Rotate the drag release to engage the terminal drag frame.

6. Cycle the press by hand so that the feed finger transfers the next terminal to a centered position over the anvil. Check that

all other parts slide and engage without any interference. It is recommended to go through this procedure several times.

STRIP

Figure 2-4

DRAG RELEASE

Figure 2-3

CENTERED

ABOVE ANVILS

RELEASE M4 SHCS

7. When unloading the terminal strip, make sure the power is turned off and disconnected from the press. Remove the

machine guards if necessary.

8. Rotate the drag release until the drag frame is in the upright position.

9. Raise feed finger and pull terminal strip back until disengaged from applicator track. See Figure 2-3. If preferred, cut the

terminal carrier strip and pull it through the applicator with needle nose pliers.

10. Replace the machine guards before operating the press.

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Page 13

FineAdjust Applicator

APPLICATOR

6mm X 20mm

M6 X 10mm

M10

TERMINAL

M4 X 12mm

DRAG RELEASE

Punch and Anvil Alignments

Note: Always clean mounting surfaces of crimp tooling and tooling holders before

alignment.

1. Always disconnect the power supply from the press. Remove the machine

guards if necessary.

2. With a terminal in position over the anvils, slightly release anvil mounting

screw. See Figure 2-4.

3. Gently hand-cycle the ram of the press to bottom of its stroke. Tighten anvil-

DOWEL PIN (2)

mounting screws in this position to ensure perfect alignment of punches and

anvils.

4. Hand cycle the press ram to the highest position.

BASE PLATE

5. Replace the machine guards before operating the press.

2.3. Adjustments

Cover Plate Adjustments

1. Always disconnect the power supply from the press. Remove the machine

Figure 2-5

BHCS (2)

guards if necessary.

2. Remove the applicator from the press. Refer to Applicator Installation and Removal.

3. Rotate the drag release until the drag frame is in the upright position. The rear cover plate should be adjusted so that the

terminal strip will slide smoothly through the track with no resistance.

4. Some applicators require the removal of the applicator frame from the base plate. This is done by removing the two M6

BHCS located on the bottom of the base plate. See Figure 2-5.

5. Loosen the two M4 BHCS to adjust the position of the rear cover. See Figure 2-6.

6. Slide terminal strip through the track to ensure accurate cover positioning.

7. After the correct position is achieved, tighten the two M4 BHCS.

8. Reattach the applicator frame to the base plate if needed. Locate the position of the frame using the dowel pins. Tighten

the two M6 BHCS to secure the frame to the base plate.

REAR COVER

BHCS (2)

SCREWDRIVER

UP POSITION

Figure 2-6

LOCK SCREW

Figure 2-7

Track Position Adjustment

1. Disconnect power from the press. Remove the machine guards if necessary.

2. To position the terminal track in or out, first use a 6mm hex wrench to loosen the M10 lock screw located on the front of the track.

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Page 14

FineAdjust Applicator

Press St

roke

mm In.

Figure

2-9

FEED FINGER

TERMINAL

Figure 2

-8

PUSH DOWN

3. Put a regular screwdriver through the hole in the lock screw and turn the adjusting screw to position the terminal in the correct location. See Figure 2-7. Turning the screw clockwise will move the track towards the operator; to move the track towards the applicator turn the screw counterclockwise. Depending on the amount of movement, the feed finger mount may need to be loosened and readjusted. See Feed Finger adjustment.

7 To lock the track in position, tighten the M10 lock screw. 8 If the feed finger mount was loosened during the track positioning, remember to tighten its mounting screw. 9 Replace machine guards. 10 Hand cycle the press to ensure the terminal is positioned properly on the anvils and does not have an excessive cutoff tab.

Also, verify the terminal feed operation.

11 Restore power to the press, crimp a terminal under power, and observe the quality of the termination. 12 Repeat the above steps until the desired terminal position is obtained.

Feed Finger Adjustments

M3 SHCS

1. Position the feed finger to properly feed the next terminal in position. Typically, terminals are fed by the carrier strip.

2. Depending on the feed cam installation (pre-feed or postfeed), move the press ram until the feed is forward (this makes the feed finger mount more accessible), and then disconnect power from the press. Remove the machine guards if necessary.

3. Using a 2.5mm hex wrench, loosen the M3 SHCS located on the feed finger mount. While holding the feed finger lever down slightly, slide the feed finger to the desired position. See Figure 2-8.

LEVER

FEED FINGER

MOUNT

4. If the feed finger mount cannot be moved far enough, remove the M3 SHCS completely and install it in another tapped hole in the feed finger lever. In addition, the feed finger mount can be reversed (the feed finger must be reversed as well) to gain additional adjustment.

5. Tighten the M3 SHCS to lock the feed finger in position.

Feed Stroke Cam Adjustments

1. The terminal feed stroke is driven by a cam mounted to the applicator ram. Two feed cams are shipped with the applicator. The standard cam is installed in the applicator. The spare cam is for presses with short strokes (for example, 28mm). Using the standard cam with a shortstroke press may result in insufficient feed stroke or incorrect feed timing.

2. Determine what feed timing is desired. Typically, when the applicator is mounted in a wire processing machine, the feed stroke cam should be assembled in the down stroke position. While the press is idle in the up position, a terminal will not be present over the anvil. For most bench applications, the cam is installed in the up stroke position. This will leave a terminal over the anvil when the press is idle in the up position. See Figure 2-9.

3. Turn off and disconnect the power supply from the press. Remove the machine guards if necessary.

4. Remove the applicator from the press. See Applicator Installation and Removal.

5. Pull back on the feed pivot lever and remove the ram from the applicator.

6. Holding on to the ram, use a 3mm hex wrench to remove the M4 SHCS holding the cam on the back of the ram.

7. Position the cam in the desired position for feeding and attach with the M4 screw. See Figure 2-9.

Feed Cam

Order No.

63800-0305

11-18-4238

41.28 1-5/8

28.58 1-1/8

41.28 1-5/8

28.58 1-1/8

Feed Timing

Up stroke

(terminal present

over anvil)

Down stroke

(terminal not present

over anvil)

Down stroke

(terminal not present

over anvil)

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Page 15

FineAdjust Applicator

PIVOT CLAMP

FORWARD

M5 SHCS

BACK

Figure 2

-11

INSULATION

CONDUCTOR

Forward Feed Adjustments

1. The forward feed position must locate the terminal that is

FEED LOCK

being crimped exactly over the anvils.

2. Disconnect the power from the press. Remove the machine guards if necessary.

3. Make sure there is a terminal over the anvils and the feed finger is fully forward (closest to the anvils).

4. Loosen the M5 SHCS.

5. Turn the forward feed adjusting knob to position the

FEED

STROKE

ADJ. KNOB

STROKE

ADJ. KNOB

terminal. To decrease the feed position, turn the forward feed adjusting knob clockwise. To increase the feed position turn the forward feed adjusting knob counterclockwise. See Figure 2-10.

6. When adjusting to decrease the feed position, it is

Figure 2-10

M5 FHCS

necessary to pull the terminal strip backwards until it is against the feed finger. When increasing the feed position, the feed finger will push the terminal farther over the anvils.

7. After properly adjusting the forward feed position of the terminal, tighten the M5 SHCS with a 4mm hex wrench.

Back Stroke Feed Adjustments

CAM (TOP)

1. To properly feed the terminal strip, the back feed stroke should have enough over-travel to pick up the next terminal. Too much over travel may, in some cases, cause a double-feed.

2. Disconnect the power from the press. Remove the machine guards if necessary.

3. To achieve the correct backstroke location, adjust the position of the hinge bushing. First, use a 3mm hex wrench to loosen the M5 FHCS holding the pivot clamp. Turning the backstroke adjustment knob (which is located above the hinge bushing) clockwise will raise the hinge bushing and will increase the backstroke. Turning the knob counter clockwise (CCW) will lower the hinge bushing and will

CAM (BOTTOM)

decrease the feed backstroke. When adjustment is complete, tighten the pivot clamp securely. See Figure 2-10.

4. Since back feed stroke adjustment may not be visibly obvious, the terminal feed should be cycled (by hand, if possible) to observe the changes.

5. Back feed stroke adjustments may affect the entire feed linkage; re-adjustment of the forward feed stroke could be necessary. See Forward Feed Adjustments.

Conductor Crimp Punch Adjustments

1. With the guards intact, place a stripped length of suitable wire into the terminal and terminate the wire under power.

2. Inspect the quality of conductor crimp and measure the crimp height. See Appendix A.3 Conductor Crimp Height

Measurement.

3. If adjustments are necessary, turn off and disconnect the power supply from the press. Remove the machine guards.

4. The desired crimp height can be achieved by rotating the conductor-adjusting cam. See Figure 2-11. Each increment

represents approximately 0.015mm (.0006") for a total adjustment of 1.80mm (.071"). The "A" setting is the loosest crimp height and the "N" setting is the tightest. If you find that the crimp height is not acceptable, you can rotate the adjusting cam until the desired crimp height is obtained. See Section 2.1, Shut Height. No shimming of the applicator is required.

5. Replace the machine guards and repeat the previous steps until the desired crimp height is obtained. See Appendix A.3,

Conductor Crimp Height Measurement.

6. Perform a pull test on conductor crimp to verify the mechanical integrity of the crimp. See Appendix A.5, Pull Force Test.

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Page 16

FineAdjust Applicator

Figure 2

-12

WIRE STOP

M5 SHCS

RAM

PUNCH RELEASE

Insulation Crimp Punch Adjustment

1. Place a stripped length of the appropriate wire into the terminal and crimp under power.

2. Observe quality of insulation crimp and measure the crimp height. See Appendix A.4, Insulation Crimp.

3. If adjustments are necessary, always turn off and disconnect the power supply from the press. Remove the machine guards.

4. Rotate the insulation-adjusting cam to achieve the desired insulation height. Each increment represents approximately 0.06mm (.0025") for a total adjustment of 3.00mm (.118"). The "1" setting is for the highest (most loose) crimp height and the "29" setting the lowest (most tight) crimp height.

5. Repeat the previous steps until the desired insulation height is obtained.

Note: Due to the large variety of insulation wall thickness, materials, and diameter, Molex does not specify insulation crimp height. For each different wire type, the insulation crimp height can be measured, recorded, and inspected as a quality indicator.

Wire Stop Adjustment

For automatic wire processing machines, the wire stop can be used to assist in the stripping of the terminal from the punches. However, in certain circumstances the wire stop will need to be removed when running on an automated machine.

1. Check the setup documents to obtain the correct strip length.

2. Place the correct wire into the terminal and crimp the wire under power.

3. Observe quality of crimp and the wire position. See Appendix A.1 Conductor Brush and Terminal Position.

4. If adjustments are necessary, turn off and disconnect the power supply from the press. Remove the machine guards.

5. Use a 4mm hex wrench to loosen the M5 SHCS located on the side of the frame. See Figure 2-12.

6. Adjust the position of the wire stop by moving the wire stop, towards the operator decreases the brush length and towards the press increases it.

7. Tighten the M5 SHCS.

8. Hand cycle the press to ensure the applicator is functioning properly. Then crimp a terminal under power and observe the quality of the termination.

2.4 Crimp Tooling Installation and Removal

Installation and Removal of the Upper Tooling (Punches)

Caution: Always disconnect power supply before installing or removing tooling.

SCREWDRIVER

NOTE: Always clean mounting surfaces of crimp tooling and tooling holders

before installation.

1. Always turn off and disconnect the power supply from the press. Remove the machine guards if necessary.

2. Remove the applicator from the press. See Section 2.2, Applicator Installation and Removal.

3. Pull back the feed arm and remove the ram from the applicator.

4. With a small screw driver, push in the punch release button located on the front of the ram. See Figure 2-13.

5. Pull the punches out the bottom of the ram.

6. Reverse the previous steps to reinstall the punches.

BUTTON

PUNCHES

Figure 2-13

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Page 17

FineAdjust Applicator

REMOVE M4 SHCS

Installation and Removal of the Lower Tooling (Anvils)

Caution: Always disconnect power supply before installing or removing tooling.

NOTE: Always clean mounting surfaces of crimp tooling and tooling holders

before installation.

1. Always turn off and disconnect the power supply from the press. Remove the machine guards if necessary.

2. Make sure the ram is all the way in the up position.

3. Remove the M4 SHCS that are holding the lower tooling in place and pull out the tooling. See Figure 2-14.

4. Put in the new anvils, leaving the mounting screws loose. For tightening, see Section 2.2, Punch and Anvil Alignment.

Figure 2-14

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Page 18

FineAdjust Applicator

Maintenance

3.1 Cleaning

3.2 Lubrication

3.3 Spare parts

3.4 Perishable Parts

3.5 Storage

Section 3

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Page 19

FineAdjust Applicator

OIL FEED FINGER

GREASE RAM

OIL

3.1 Cleaning

Caution: Always disconnect power supply before installing or removing tooling.

For efficient operation, the FineAdjust Applicator should be cleaned daily. Use a soft bristle brush to remove debris from critical areas such as the crimp tooling. For best results, remove the crimp tooling from the press. Brush and then use a clean cloth to wipe off the upper and lower tooling mounting areas. Before reinstalling tooling, wipe all sides of the punches and anvils with a clean cloth.

3.2 Lubrication

WARNING: Disconnect electrical power before all maintenance.

1. Grease the ram including the cam.

2. Oil the feed finger assembly and all moving parts.

3. Lubricate with multipurpose synthetic lubricant with Teflon or an equivalent. Molex ships its applicators pregreased with Permatex multi-purpose synthetic grease with Teflon No. 82329. A SAE 30WT non-detergent oil or light spindle oil or 3-n-1 oil should be used on pivot points.

WARNING: Never use penetrants such as WD40 for any lubrication on the machine.

4. Lubricate all points shown in Figures 3-1 with the specified oil and grease (or equivalent).

ASSEMBLY

An example of a maintenance chart is shown below. Copy and use this chart to track the maintenance of your FineAdjust Applicator or use this as a template to create you own schedule or use your company’s standard chart, if applicable.

AND FEED CAM

Figure 3-1

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Page 20

FineAdjust Applicator

Days of the Week

MON

TUE WED

THU

FRI SAT SUN

Cleaning

Inspect all tooling,

Items

Cycles Brass Alloys

Cycles Steel

Actual

Punches

300,000/500,000

200,000/400,000

Anvils

500,000/750,000

400,000/750,000

Cut-off Plungers

300,000/500,000

200,000/400,000

Feed Fingers

300,000/900,000

Cut-off Punches

500,000/750,000

200,000/400,000

Cut-off Blades

300,000/500,000

200,000/300,000

Preventive Maintenance Chart

Daily: Clean. See Section 3.1. As Required: Lubricate. See Section 3.2.

CHECK SHEET MONTH YEAR _________

Week

Daily

Cycles

Daily

Clean

Solution

Reapply grease

25,000 Yes

Reapply oil

feed fingers etc.

25,000 Yes

for wear

Schedule should be adjusted up or down depending on usage. Molex recommends that a log of preventive maintenance be kept with the press.

Soft Brush Industrial

Degreaser

Replace if signs

of wear.

3.3 Spare Parts

Customers are responsible for maintaining the FineAdjust Applicator. Spare parts are available. Moving and functioning parts 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.

3.4 Perishable Parts

Customers are responsible for maintaining the FineAdjust Applicator. 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 kits in stock at all times. This will reduce the amount of production down time. For the proper

perishable tool kit information, refer to the Crimp Tooling Specification Sheet supplied with the Applicator.

Tooling Replacement Schedule

The following is offered as a general guideline for tooling replacement. The manufacturer should monitor the process and collect data on actual frequency as tool wear varies on different terminal materials and tool life can be increased with good maintenance practices or decrease with lack of maintenance.

Judgment on tool replacement should be based on the attributes of the crimp they produce.

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Page 21

FineAdjust Applicator

Punches

On Terminal

Notes

Scoring

Uneven Curls

Replace

Tip Loss

Open seam

Replace

Anvils

Rounded Edges

Large Extrusion

Replace

Chipping

Burrs

On Tabs

Replace

Worn Cut Edges

Burrs

Replace

Cut-Off Plungers and Punches

Chipped or Rounded

Burr on Tab

Replace

Cut Edge

Burr on Tab

Replace

Cut-off Dies

Burrs on Cut Area

Replace

See the following chart for common signs of wear.

3.5 Storage

To prevent the bottoming of the ram, which can cause damage to the crimp punches and anvils leave a strip of terminals in the applicator or place a piece of wood or rubber between the punches and the anvils.

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Page 22

FineAdjust Applicator

Parts Lists, Assembly Drawings and Troubleshooting

4.1 Style A FineAdjust Applicator

4.2 Style B FineAdjust Applicator

4.3 Style C FineAdjust Applicator

4.4 Troubleshooting

Section 4

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Page 23

FineAdjust Applicator

STYLE A

STYLE C

NUT

FLAT HEAD

STYLE B

KNOB

FLAT HEAD

FLAT SURFACE

KNOB

Styles of FineAdjust

CAP SCREW

In the effort to continually improve the FineAdjust Applicator, we have multiple styles working in the field. To determine the style of applicator you are using, look at the pictures above. Figure 4-1, 4-2, and 4-3 point out the major differences between the styles of this applicator. Identify your applicator style and use the appropriate parts list and assembly drawing to order replacement parts.

Figure 4-2

FLAT SURFACE

KNOB

Figure 4-1

HEX HOLE

CAP SCREW

LEVER

FULL TRACK

Figure 4-3

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Page 24

FineAdjust Applicator

STYLE A

FineAdjust Applicator

Item Order No.

Engineering No.

Description

Qty

1 11-18-

4238 60700

-1

Feed Cam (Short) Optional

2 11-32-

5346 600000Y422

M4 Ball Spring Plunger

3 11-41-

0127 60678

-27

Compression Spring (

Associated

# C0180

016-0500)

63600

0481 63600

0481 Shoulder Screw M5

by 10

mm Long 1

63800

0115 63800

0115 Spacer Tube

63800

0117 63800

0117 Feed Pawl Lever

63800

0118 63800

0118 Hinge Bushing

63800

0119 63800

0119 Feed Finger

63800

0120 63800

0120 Feed Arm

63800

0121 63800

0121 Lever Feed Pivot

63800-

0122 63800

0122 Feed Adjusting Screw

63800

0123 63800

0123 Slider

Feed Cam

63800

0125 63800

0125 Torsion Spring

Hinge

63800

0127 63800

0127 Torsion Spring

Feed Pawl

63800

0129 63800

0129 Washe

r –3.40mm

Thick 1

63800

0140 63800

0140 Cylinder Pin

63800

0141 63800

0141 Slider

63800

0142 63800

0142 Roller

Cam Follower

63800

0143 63800

0143 Pin-Cam Follower

63800

0144 63800

0144 Key Stock 3

mm by 3mm

by 29mm Long

63800

0301 63800-

0301 Back Frame

63800

0302 63800

0302 Face Plate

63800

0303 63800

0303 Base Plate

63800

0304 63800

0304 Ram-Terminator Tooling

63800

0305 63800

0305 Feed Cam

63800

4906 63800

4906 Insulation Striker

63800

0308 63800

0308 Terminal

Track

63800

4309 63800

4309 Rear Support Block

63800

0310 63800

0310 Adjusting Screw

63800

0311 63800

0311 Locking Screw

63800

0312 63800

0312 Drag Frame

63800

0313 63800

0313 Drag Cam

63800

0314 63800

0314 Retaining Bar

63800

-0316 63800

0316 Guide Pin

Drag Frame

63800

0330 63800

0330 Lug Bolt

63800

0331 63800

0331 Conductor Adjusting Cam

63800

0332 63800

0332 Insulation Adjusting Cam

63800

0335 63800

0335 Serial Tag

63800

0345 63800

0345 Retaining Plate

41 63800-4946 63800

-4946

Conductor Striker

63800

0347 63800

0347 Retaining Rod

63800

0348 63800

0348 Detent Spacer

N/A N/A Compression Spring (Lee Spring # LC

032E-0MW)

4**

N/A N/A Extension Spring (Lee Spring #LE

041C-9) 1**

N/A N/A Snap Ring

3.2mm

ID by 7

mm OD by .62

mm Thick 2**

N/A N/A Washer .512" ID by 1.125" OD by 0.15” Thick

1**

N/A N/A Washer .512" ID by 1.125" OD by 0.18” Thick

1**

4.1 STYLE A-FineAdjust Applicator

Parts List and Assembly Drawings (See Figure 4-4 and 4-5)

13 63800-0124 63800-0124 Pin-Feed Adjusting 1

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Page 25

FineAdjust Applicator

STYLE A

FineAdjust Applicator

Item Order No.

Engineering No.

Description

Qty

N/A N/A M3 by 6

mm Long FHCS

2**

N/A N/A M4 Hex Nut

1**

N/A N/A M4 by 8

mm Long BHCS

1**

N/A N/A M4 by 8

mm Long SHCS

3**

N/A N/A M4 by 10

mm Long Set Screw

1**

N/A N/A M4 by 12

mm Long BHCS

2**

N/A N/A M4 by 45

mm Long SHCS

1**

N/A N/A M5 by 6

mm Long BHCS

1**

N/A N/A M5 by 10

mm Long SHCS

1**

N/A N/A M5 by 35

mm Long SHCS

4**

N/A N/A M6 by 1

0mm

Long BHCS

2**

N/A N/A M6 by 8

mm Long Set Screw

1**

N/A N/A M12 Self Locking Hex Nut

1**

N/A N/A 3mm by 12

mm Long Roll Pin

2**

N/A N/A 5mm by 20

mm Long Dowel Pin

1**

N/A N/A 5mm by 25

mm Long Dowel Pin

1**

N/A N/A 6mm by 10

mm Long Dowel Pin

1**

N/A N/A 6mm by 12

mm Long Dowel Pin

2**

N/A N/A 6mm by 20

mm Long Dowel Pin

1**

N/A N/A 6mm by 45

mm Long Dowel Pin

2**

N/A N/A #2 (.098 Dia.) by .125 in. Long Drive Screw

2**

** Available from an industrial supply company such as MSC (1

800-645-7270).

Check Applicator Number Tag or Part Number on part when ordering.

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Page 26

FineAdjust Applicator

(2)

See Figure 4

-5

(2)

4.1 STYLE A FineAdjust Applicator Assembly

(2)

(4)

(2)

Doc. No: TM-638004900 Release Date: 09-04-03 UNCONTROLLED COPY Page 26 of 50 Revision: G Revision Date: 01-15-13

STYLE A

Figure 4-4

Page 27

FineAdjust Applicator

(4)

Reference

STYLE A

4.1 STYLE A FineAdjust Applicator Assembly (Cont.)

(2)

See Figure 4-4

Figure 4-5

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Page 28

FineAdjust Applicator

STYLE B

FineAdjust Applicator

Item Order No.

Engineering No.

Description

Qty

1 11-18-

4238 60700

-1

Feed Cam (Short) Optional

2 11-32-

5346 600000Y422

M4 Ball Spring Plunger

3 11-41-

0127 60678

-27

Compression Spring (Assoc

iated # C0180

016-0500)

63600

0481 63600

0481 Shoulder Screw M5 by 10

mm Long 1

63800

0115 63800

0115 Spacer Tube

63800

0120 63800

0120 Feed Arm

63800

0121 63800

0121 Lev

er Feed Pivot

63800

0123 63800

0123 Slider

Feed Cam

63800

0127 63800

0127 Torsion Spring

Feed Pawl

63800

0140 63800

0140 Cylinder Pin

63800

0142 63800

0142 Roller

Cam Follower

63800

0143 63800-

0143 Pin-Cam Follower

63800

0144 63800

0144 Key Stock 3 by 3 by 19mm Long

63800

0304 63800

0304 Ram-Terminator Tooling

63800

0308 63800

0308 Terminal Track

63800

0310 63800

0310 Adjusting Screw

63800

0311 63800

0311 Locking Screw

63800

0312 63800

0312 Drag Frame

63800

0313 63800

0313 Drag Cam

63800

0314 63800

0314 Retaining Bar

63800

0316 63800

0316 Guide Pin

Drag Frame

63800

0330 63800

0330 Lug

Bolt 1

63800

0331 63800

0331 Conductor Adjusting Cam

63800

0332 6

3800-0332 Insulation Adjusting Cam

63800

0345 63800

0345 Retaining Plate

63800

0347 63800

0347 Retaining Rod

63800

0348 63800

0348 Detent Spacer

63800

4309 63800

4309 Rear Support Block

63800

4902 63800

4902 Face Plate

63800

4906 63

800-4906 Insulation Striker

63800

4946 63800

4946 Conductor Striker

63801

0129 63801

0129 Washer 3.40mm Thick

63801

3202 63801

3202 Feed Cam

63801

3211 63801

3211 Back Frame

63801

3225 63801

3225 Torsion Spring

63801

3281 63801

3281

Base Plate

63801

4462 63801

4462 Feed Finger Mount

63801

4561 63801

4561 Feed Finger

63890

0817 63890

0817 Feed Pawl Lever

63890

0881 63890

0881 Adjusting Screw

63890

0883 63890

0883 Adjusting Knob Retainer

63890

0884 63890

0884 A

djustable Pivot

63890

0885 63890

0885 Slider

63890

0886 63890

0886 Feed Positioning Screw

63890

0887 63890

0887 Pivot Clamp

63890

0899 63890

0899 Feed Adjusting Knob

63890

0999 63890

0999 Serial Tag

4.2 STYLE B-FineAdjust Applicator

Parts List and Assembly Drawings (See Figure 4-6 and 4-7)

9 63800-0124 63800-0124 Pin-Feed Adjusting 1

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Page 29

FineAdjust Applicator

STYLE B

FineAdjust Applicator

Item Order No.

Engineering No.

Description

Qty

69028

0660 69028

0660 Compression

Spring (Lee Spring # LC

032E-0MW)

4**

N/A N/A #2 (.098

in. Diameter

) by .125 in. Long Drive Screw

2**

N/A N/A M3 by 5

mm Long SHCS

1**

N/A N/A M3 by 6

mm Long FHCS

2**

N/A N/A M3 by 12

mm Long SHCS

1**

N/A N/A M3 by 20

mm Long SHCS

2**

N/A N/A M4 by 8mm

Long SHCS

3**

N/A N/A M4 by 8

mm Long Set Screw

1**

N/A N/A M4 by 10

mm Long Set Screw

1**

N/A N/A M4 by 12

mm Long BHCS

3**

N/A N/A M4 by 16

mm Long SHCS

1**

N/A N/A M5 by 6

mm Long BHCS

1**

N/A N/A M5 by 8

mm Long FHCS

1**

N/A N/A M5 by 1

0mm

Long SHCS

1**

N/A N/A M5 by 35

mm Long SHCS

4**

N/A N/A M6 by 8

mm Long Set Screw

1**

N/A N/A 3mm by 12

mm Long Roll Pin

2**

N/A N/A 5mm by 20

mm Long Dowel Pin

1**

N/A N/A 5mm by 25

mm Long Dowel Pin

1**

N/A N/A 6mm by 10

mm Long Dowel Pin

2**

N/A N/A 6mm by 20

mm Long Dowel Pin

2**

N/A N/A 6mm by 45

mm Long Dowel Pin

2**

N/A N/A Extension Spring (Lee Spring #LE

041C-9) 1**

N/A N/A Snap Ring 3.2

ID by 7

mm OD by .62

mm Thick

2**

N/A N/A Washer .512

” ID by 1.125

” OD by 0.15” Thick

1**

74 N/A N/A Washer .512

” ID by 1.125

” OD by 0.18” Thick

1**

** Available from an industrial supply company such as MSC (1

800-645-7270).

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Page 30

FineAdjust Applicator

STYLE B

(2)

See

(2)

4.2 STYLE B FineAdjust Applicator Assembly

Figure 4-7

(2)

Figure 4-6

(4)

(2)

Doc. No: TM-638004900 Release Date: 09-04-03 UNCONTROLLED COPY Page 30 of 50 Revision: G Revision Date: 01-15-13

Page 31

FineAdjust Applicator

(4)

Reference

STYLE B

4.2 STYLE B FineAdjust Applicator Assembly (Cont.)

(2)

Figure 4-7

See Figure 4-6

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Page 32

FineAdjust Applicator

STYLE C

FineAdjust Applicator

Item Order No.

Engineering No.

Description

Qty

1 11-18-4238 60700

-1

Feed Cam (Short) Optional

2 11-32-

5346 600000Y422

M4 Ball Spring Plunger

3 11-41-

0127 60678

-27

Compression Spring (Assoc

iated # C0180

016-0500)

63443

6202 63443

6202 Terminal Track

63600

0481 63600

0481 Shoulder Screw M

5 by 10

mm Long 1

63600

1561 63600

1561 Washer 6 I.D. by 10 O.D. by 0.3mm Thick

63600

2644 63600

2644 Stripper Bolt 6 O.D. by 10mm Long

63800

0120 63800

0120 Feed Arm

63800

0121 63800

0121 Lever Feed Pivot

63800

0123 63800

0123 Slider

Feed Cam

63800

0127 63800

0127 Torsion Spring

Feed Pawl

63800

0140 63800

0140 Cylinder Pin

63800

0142 63800

0142 Roller

Cam Follower

63800

0143 63800

0143 Pin-Cam Follower

63800

0144 63800

0144 Key Stock 3 by

3 by 19mm Long

63800

0304 63800

0304 Ram-Terminator Tooling

63800

0310 63800

0310 Adjusting Screw

63800

0311 63800

0311 Locking Screw

63800

0312 63800

0312 Drag Frame

63800

0314 63800

0314 Retaining Bar

63800

0316 63800

0316 Guide

Pin-Drag Frame

63800

0345 63800

0345 Retaining Plate

63800

0347 63800

0347 Retaining Rod

63800

4309 63800

4309 Rear Support Block

63800

4903 63800

4903 Face Plate

63800

4906 63800

4906 Insulation Striker

63800

4946 63800

4946 Condu

ctor Striker

63801

3202 63801

3202 Feed Cam

63801

3211 63801

3211 Back Frame

63801

3225 63801

3225 Torsion Spring

63801

3281 63801

3281 Base Plate

63801

4462 63801

4462 Feed Finger Mount

63801

4561 63801

4561 Feed Finger

63801

-5862 63801

5862 Drag Cam Lever

63801

6444 63801

6444 Conductor Adjusting Cam

63801

6445 63801

6445 Insulation Adjusting Cam

63801

6446 63801

6446 Detent Spacer

63801

6447 63801

6447 Ram Adapter

63890

0817 63890

0817 Feed Pawl Lever

41 63890-0885 63890

0885 Slider

63890

0881 63890

0881 Adjusting Screw

63890

0883 63890

0883 Adjusting Knob Retainer

63890

0884 63890

0884 Adjustable Pivot

63890

0886 63890

0886 Feed Positioning Screw

63890

0887 63890

0887 Pivot Clamp

47 63890-0899 63890

0899 Feed Adjusting Knob

63890

0999 63890

0999 Serial Tag

4.3 STYLE C-FineAdjust Applicator

Parts List and Assembly Drawings (See Figure 4-8 and 4-9)

11 63800-0124 63800-0124 Pin-Feed Adjusting 1

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Page 33

FineAdjust Applicator

STYLE C

FineAdjust Applicator

Item Order No.

Engineering No.

Description

Qty

69028

0660 69028

0660 Compression Spring (Lee Spring # LC

032E-0MW)

4**

N/A N/A #2 (.098

in. Diameter) by .125 in. Long Drive Screw

2**

N/A N/A M3 by 5

mm Long SHCS

1**

N/A N/A M3 by 6

mm Long FHCS

2**

N/A N/A M3 by 12

mm Long SHCS

1**

N/A N/A M3 by 20

mm Long SHCS

2**

N/A N/A M4 by 8

mm Long SHCS

3**

N/A N/A M4 by 8

mm Long Set Screw

1**

N/A N/A M4 by 10

mm Long Set Screw

1**

N/A N/A M4 by 12

mm Long BHCS

1**

N/A N/A M4 by 16

mm Long SHCS

1**

N/A N/A M5 by 6

mm Long BHCS

1**

N/A N/A M5 by 8

mm Long FHCS

1**

N/A N/A M5 by 10

mm Long SHCS

1**

N/A N/A M5 by 35

mm Long SHCS

4**

N/A N/A M6 by 8

mm Long Set Screw

1**

N/A N/A M6 by 10

mm Long BHCS

2**

N/A N/A M8 by

20mm Long FHCS

1**

N/A N/A 3mm by 12

mm Long Roll Pin

2**

N/A N/A 5mm by 20

mm Long Dowel Pin

1**

N/A N/A 5mm by 25

mm Long Dowel Pin

1**

N/A N/A 6mm by 10

mm Long Dowel Pin

2**

N/A N/A 6mm by 20

mm Long Dowel Pin

2**

N/A N/A 6mm by 45

mm Long Dowel

Pin 2**

N/A N/A Extension Spring (Lee Spring #LE

041C-9) 1**

N/A N/A Snap Ring 3.2

mm ID by 7

mm OD by .62

mm Thick 2**

** Available from an industrial supply company such as MSC (1

800-645-7270).

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FineAdjust Applicator

STYLE C

See

(2)

(4)

4.3 STYLE C FineAdjust Applicator Assembly

Figure 4-9

(2)

Figure 4-8

(2)

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FineAdjust Applicator

Reference

(2)

STYLE C

4.3 STYLE C FineAdjust Applicator Assembly (Cont.)

(3)

Figure 4-9

(2)

See Figure 4-8

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FineAdjust Applicator

erminals bent or damaged

Replace terminals

Feed finger worn or not properly adjusted

Check proper finger setting

Drag plate

not

holding terminal strip back

Check compression springs

Terminal jammed under cover plate

Clear and reinsert terminals

Conductor

punch worn

Replace

Adjust base and track for proper

Cut-off plunger adjusted to

o tight against anvil

Readjust

Cut-off plunger spring damag

ed or broken

Replace spring

Cut edges worn, plunger sides or

Remove scoring marks. If problem not

Wrong tooling

Replace with proper tooling

Tooling worn or

damaged

Replace tooling

Wrong cam setting

Back off one setting

Press shut height

too high

Calibrate press

shut height

Wrong tooling

Replace with proper tooling

Cam out of adjustment

Readjust conductor cam

Press shut h

eight

is too low

Calibrate press

shut height

Cam out of adjustment

Readjust insulation cam

Wrong tooling

Replace with proper tooling

Press shut height

is too low

Calibrate press

shut height

Wrong tooling

Replace with proper tooling

Tooling worn or damaged

Replace tooling

Install a terminal oiler.

4.4 Troubleshooting

Symptom Cause Solution



Terminals

not feeding

Excessive Bellmouth

Cut-off plunger does

not return to

original position

Conductor crimp is

too loose

Conductor crimp is

too tight

Insulation crimp is

too tight

Terminal sticks

during crimping

   

 Track out of position

  

plunger retainer scored

           

 Gold plating and/or some high tensile materials

alignment with the punches and anvil

solved, replace with new cut-off parts

See Appendix C

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FineAdjust Applicator

For more information use the Quality Crimping Handbook

There is no charge for this book, which can be found on the Molex Website (www.molex.com) or contact your

local Molex sales engineer

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FineAdjust Applicator

Appendix A

Crimp Terminations

A.1 Conductor Brush and Terminal Position

A.2 Conductor Bell mouth and Terminal Cut-off Tab

A.3 Conductor Crimp Height Measurement

A.4 Insulation Crimp

A.5 Pull Force Testing

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FineAdjust Applicator

INSULATION

BRUSH

STRIP

BELL

CRIMP H

EIGHT

BEND

BEND UP

ROLLING

CONDUCTOR

TWISTING

CUT-OFF

SEAM

Figure A

-6

A-5 Insulation

dge centered in the

ransition

rea,

A-6

Insulation

dge

under insulation

grip,

Figure A

-5

Figure A

-3

Figure A

-1

Figure A

-2

Figure A

-4

Terminal Terminology

LENGTH

A.1 Conductor Brush and Terminal Position

MOUTH

CRIMP

TAB

A-1 Optimum crimp setup

The insulation edge should be centered in the middle of the transition area. The conductor brush should extend past the conductor crimp and not extend into the contact area.

CRIMP

DOWN

A-2 Insulation under conductor crimp

(with a good conductor brush length)

Cause: Strip length too short. Solution: Verify strip length specification and adjust as necessary.

A-3 Insulation under conductor crimp,

(with a long conductor brush length)

Cause: Wire stop position incorrect.

Solution: Adjust wire stop to center the insulation in the transition area.

A-4 Insulation under conductor crimp,

(with a short or no conductor brush length)

Cause: 1) Strip length too short and

2) Wire stop position incorrect.

Solution: 1) Verify strip length specification and adjust as necessary.

Cause: 1) Strip length too long.

Solution: 1) Verify strip length specification and adjust as necessary.

2) Adjust wire stop to center the insulation in the transition area.

(with the conductor brush too long)

2) Irregular wire cut-off or wire strands pulled from insulation bundle.

Readjust wire stop for bench applications.

2) Check for worn stripping blades

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(with the conductor brush too short)

Cause: Strip length too long.

Solution: Verify strip length specification and adjust as necessary.

Readjust wire stop for bench applications.

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FineAdjust Applicator

Figure A

2.1

Figure A

2.2

Figure A

2.3

A-8 I

nsulation edge under insula

tion crimp

A-

2.1 O

ptimum crimp setup

A-

2.2 Excessive

ell mouth,

cut-

off tab flush with Insulation

rimp

A-

2.3 No or

small bell

mouth,

long cut

off tab

A-2.4 Excessive Bell mouth,

good cut

off tab

A-2.5 Excessive Cutoff Tab, Good Conductor Bell mouth

Figure A

2.5

Figure A

-8

Figure A-7

A-7 Insulation edge under insulation crimp,

(with a good or wrong conductor brush length)

Cause: Strip length too long.

Solution: Verify strip length specification and adjust as necessary.

Adjust the wire stop.

(with a short or no conductor brush length)

Cause: 1) Wire stop position incorrect.

2) Operator not consistently using the wire stop. Solution: 1) Adjust the wire stop to center the insulation in the transition area.

2) Operator training, reduce crimping rate.

A.2 Conductor Bell Mouth and Terminal Cutoff Tab

Tooling was set up to produce conductor bell mouth to nominal specification and/or approximately 1x to 2x terminal material thickness. The cutoff tab is approximately 1x terminal material thickness.

Cause: 1) Wrong conductor crimp tooling used.

2) Camber in the terminal strip.

Solution: 1) Verify that correct tooling is installed.

2) Adjust terminal track into the applicator.

Cause: 1) Wrong conductor crimp tooling used.

2) Camber in the terminal strip.

Solution: 1) Verify that correct tooling is installed.

2) Adjust terminal track towards the operator.

Figure A-2.4

Cause: 1) Worn conductor punch tooling.

2) Incorrect conductor punch tooling.

Solution: Replace tooling if necessary

Cause: 1) Worn cutoff tooling.

2) Incorrect cut-off tooling. Solution: Replace tooling if necessary.

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FineAdjust Applicator

Figure A

3.1

EXTRUSION

MICROMETER

Figure A

4.1 Preferred Insulation Crimp

Figure A

4.2 Acceptable Insulation Crimp

A.3 Conductor Height Measurement

NOTE: Conductor height should be measured with a blade type micrometer or a caliper.

CAUTION: Care must be taken not to measure the extrusions

A.3.1 Crimp height off target Cause: 1) Changed wire type, stranding or vendor.

2) Changed insulation diameter.

3) Changed crimp tooling.

4) Changed crimping press.(Shut-height)

5) Changed press type. (Manufacturer)

6) Changed terminal reel. (Lot code)

7) Changed tooling set-up.

8) Damaged or worn tooling.

Solution: Adjust tooling back to target

CALIPER

(Refer to Section 2)

A.3.2 Crimp height variability too high Cause: 1) Wire variability.

2) Terminal variability.

3) Damaged, loose, or worn tooling.

4) Measurement error *.

5) Cut or missing wire strands.

Solution: 1 or 2) Inspect incoming product for variability.

POINTS

3) Tooling replacement or tightening.

4) Gauge capability analysis.

CRIMP HEIGHT MEASUREMENT

5) Tooling crimp height adjustment.

6) Stripping process adjustment.

* Most common cause of crimp height variability

A.4 Insulation Crimp

A.4.1 Preferred Insulation Crimp

It is preferred that the insulation crimp completely surrounds the outside diameter of the insulation. The terminal should hold on to the wire as firmly as possible without cutting through to the conductor strands. It should be noted that a preferred crimp only occurs in a small portion of the full insulation range a terminal can accommodate. A preferred insulation crimp is recommended for high vibration or movement applications.

An overlap insulation crimp is normally only developed for high vibration or movement applications where the wire diameter is near the lower terminal specification limit.

A.4.2 Acceptable Insulation Crimp

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FineAdjust Applicator

A terminal is normally specified to cover a wide range of insulation wall thickness over a range of wire sizes. Within this specified range, an insulation crimp may not completely surround the wire or fully hold the full diameter of the wire. This condition will still give an acceptable insulation crimp for most applications. a) A large insulation crimp should firmly grip at least 88% of the wire. b) A smaller insulation crimp should firmly grip at least 50% of the wire and firmly hold the top of the wire.

A.4.3 Marginal Insulation Crimp

An insulation diameter near the maximum and minimum specification of a terminal may cover less than what is normally considered acceptable. These strain reliefs should only be used on applications that have low vibration or movement. a) Troubleshooting of marginal insulation crimp that covers in case of less than 88% of a large insulation diameter.

Cause: Not enough terminal grip length. Solution: 1) Evaluate if the same terminal is available in a different wire range.

2) Try crimping the wire one setting tighter. This will embed the terminal more into the insulation. The insulation wall thickness is normally enough; therefore cutting strands is not a worry. Terminal insulation grips kicking back away from the terminal or slight insulation bulging may be noticed. Evaluate the terminal loaded into housing for acceptability

b) An insulation crimp that covers less than 50% of a small insulation diameter.

Cause: Too much terminal grip. Solution: 1) Find out if the same terminal is available in a different wire range.

2) Find out if overlap crimp tooling is available.

A.4.4 Marginal Insulation Crimp

For insulation diameters that are small, or for thin-walled insulations, a

loose crimp ensures no strand damage and offers insulation containment. Insulation crimps that pierce through the insulation will offer more strain relief. In some cases insulation terminal grips will push the strands to the side. Yet, there is always the possibility that a wire strand could be nicked. In severe cases, a wire strand may be cut. Careful application evaluation is needed for both of these cases.

Cause: 1) Crimp tooling adjustment.

2) Wire diameter variability.

Figure A-4.3 Marginal Insulation Crimp

Figure A-4.4 Marginal Insulation Crimp

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FineAdjust Applicator

Test Values For Pullout Test UL486A

Conductor Size

Pullout Force

AWG mm2 N LBF

30 0.05 6.7 1.5

28 0.08 8.9 2

26 0.13 13.4 3

24 0.20 22.3 5

22 0.324

35.6 8

20 0.519

57.9 13

18 0.823

89.0 20

16 1.31 133.5

14 2.08 222.6

12 3.31 311.5

10 5.261

356.0

9 8.367

400.5

A.5 Pull Force Testing

A.5.1 Pull Force Procedure

Wire connectors and soldering lugs for use with copper conductors. (Per UL486A November 15, 2003) UL Section 12

Pullout Test.

12.1 The connectors subjected to the static heating test or secureness test shall be subjected to a direct pull of the value specified for one minute. Only those connectors that have been subjected to the secureness test are to be subjected to the pullout test. The connector is acceptable if it does not become separated from the conductor or conductors after completion of the test.

12.2 For an insulated connector in which the insulation is assembled to the connector during installation, the test should be conducted with the insulation in place if it is always supplied with the connector by the manufacturer. Otherwise, the test should be conducted without the insulation assembled to the connector. Breaking or tearing of the insulation of an insulated connector is acceptable in the pullout test. The pull is to be exerted by means of a tension testing machine or equivalent, so that there will be no sudden application of force or jerking during the test.

The following is the procedure Molex uses for the qualification of pull force:

1. Cut wire length approximately 150mm (6.0”) long.

2. Strip one end to 13mm (.50”), or long enough so no wire insulation is under the insulation grip.

3. Terminate the appropriate terminal to the wire to the nominal crimp height.

4. Visually inspect the termination for bell mouth, wire brush, and cut strands.

5. Set pull tester to 25.4mm (1.0”) per minute. For most applications, a higher rate will not have a significant impact on the data. Verify higher pull rates with data taken at 25.4mm (1.0”) per minute.

6. Knot the non-terminated end of the wire.

7. Regardless of pull tester type, both wire and terminated end must be securely clamped. (Note: When clamping the terminated end, do not clamp the conductor crimp.)

8. Activate pull test.

9. Record a minimum of 25 readings of maximum pull force. After the application has been qualified, a minimum of 5 pull force measurements should be done to confirm each setup.

10. Compare lowest reading to minimum pull force specification.

A.5.2 Pull Test Problems

A.5.2.1 Wire breaks before conductor grip. Pull force low Material Evaluation Cause: Wire material properties, and/or coatings. Solution: Test non-terminated wire for breaking strength. Change wire, if

necessary.

Stripping Evaluation Cause: Cut or nicked strands from stripping operation.

1) Wire being manually stripped.

2) Poor automatic stripping cutoff.

3) Worn strip tooling.

Solution: 1) Switch to semiautomatic or automatic wire stripping machine.

2) Correct stripping machine setup.

A.5.2.2 Wire pulls out of conductor grip, crimp height good

Material Evaluation Cause: 1) Terminal material thickness too small.

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FineAdjust Applicator

2) Terminal serration depth/form wrong.

3) Terminal plating thickness wrong.

4) Gold plating application.

Solution: 1) Evaluate a new terminal.

2) Or Contact terminal manufacturer.

3) Evaluate selective Gold application.

Stripping Evaluation Cause: Wrong strip length, poor conductor brush. Solution: Adjust strip length.

Figure A-5.0 Pull Force Testing

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FineAdjust Applicator

B.1 Crimp Process Control

B.2 Process Capability

B.3 Production

Appendix B

Statistical Process Control (Summary)

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FineAdjust Applicator

Cpk +/- Sigma

% Yield

PPM

0.67 2 95.45

45,500

1 3 99.73

2,699

1.33 4 99.99

1.67 5 99.99+

0.57

2 6 99.99++

B.1 Crimp Process Control

The crimp process is the interaction of a terminal, wire, tooling, personnel, methods and procedures, and environmental attributes that, when controlled, produce a quality termination. Quality control is an important aspect of quality crimping. It should not take excessive setup or inspection time to implement, and can save a harness manufacturer thousands of dollars in potential rework or re-manufacturing.

The key to quality is to target nominal specifications while continuously reducing variability. Achieving target is determined by the adjustability of the tooling. The FineAdjust applicator allows crimp height adjustment to .005mm (.0002”) of target.

Variability is the slight changes that occur from crimp to crimp. There are two types of variability, common and special. Common sources of variation are those causes that affect the process uniformly, and are created from numerous small sources. Common variability is inherent tolerances within a reel of wire or terminals. In addition, common variability is created by the natural tolerances of the stripping and crimping machines. Reduction of variability at the common level normally has to come from changes at the wire, terminal, and tooling manufacturer.

The second source of variability is referred to as special cause. Unlike common cause, special sources of variation occur irregularly and unpredictably. Without checks throughout a run, a tool becoming loose after the first hundred crimps, or a damaged tool from a jam, may be undetected until thousands of crimps are made.

This section assumes that crimp height is being measured with a resolution of .0025 mm (.0001”), and pull force is measured with a resolution of 1 N (.25 lbf).

B.2 Process Capability

Molex qualifies each FineAdjust Applicator design for pull force and crimp height.

This qualification is performed on a common wire stranding, and is targeted at 2.0 Cpk. Before a new crimping tool is put in production, it is recommended that the customer using their specific wire in their process should do a capability study. A capability study is based on the assumption of a normal distribution (bell-type curve). It provides an estimate on the probability of a measurement being outside of specification.

PPM - Parts per million – number of potential defects

per million crimps produced.

A minimum of a 25-piece sample should be run off the crimping process. The average and standard deviation should be calculated for each specification.

A capability index (Cp) is defined by the formula below. Cp may range in value from 0 to infinity, with a larger value indicating a more capable process. A value greater than (>) 1.33 is normally considered acceptable.

Tolerance

6*Standard Deviation

The Cpk index indicates whether the process will produce units within the tolerance limits. Cpk has a value equal to Cp if the process is centered on the mean of specification; if Cpk is negative, the process mean is outside the specification limits; if Cpk is between 0 and 1 then some of the 6 sigma spread falls outside the tolerance limits. If Cpk is larger than 1, the 6 sigma spread is completely within the tolerance limits. Cpk is calculated with the lesser of the following formulas:

(USL - MEAN) (LSL - MEAN)

3*Standard Deviation 3*Standard Deviation

USL = Upper Specification Limit, LSL = Lower Specification Limit

Six sigma is a goal of many companies because it represents virtually zero defects. The ability of a company to achieve a six-sigma level is dependent on the amount of common variability in their process. Hand stripping of the wire will produce more variability than a stripping machine. A crimping hand tool will produce more variability than a press and die set. Bench terminations will produce more variability than a wire-processing machine.

A portion of the variability in crimping will come from what instruments are used to measure the parts and the ability of an operator to repeat the measurement. A crimp micrometer will measure more accurately than a dial caliper. An automatic pull force system will measure

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FineAdjust Applicator

X and R Chart

better than a hook type scale. It is important that the measurement gauge has enough resolution. Two operators may measure the same part differently, or the same operator may measure the part different when using two types of gauges. A gauge capability study is recommended to identify what part of the variability is coming from measurement error. Micro-terminals crimped to small wire sizes need a tight crimp height range to maintain pull force. The variability from measurement error can keep Cpks low.

The capability of the crimping tools should be reconfirmed if the production data is significantly different from the capability study.

B.3 Production

Once the level of capability is established, the tool is ready for production.

Many harness manufacturers run only a few hundred or few thousand wires at one time. In this case, it is not practical or economical to run a twenty-five-piece capability with every set-up.

Setup Confirmation

After the setup of the crimping process, crimp five terminals with a loose insulation crimp. Visually inspect or measure bell mouth, cut-off tab length, conductor brush, insulation position, and conductor crimp height. Make the appropriate adjustments to the machine. (Refer to trouble shooting sections if needed). After all adjustments have been made, crimp five more samples for pull force evaluation. The pull force is a good indicator for cut or nicked strands, short conductor brush, small bell mouth, or incorrect crimp height. Calculate the average. Compare the average and minimum reading with the capability study data.

After the pull force has been confirmed, set the insulation crimp to the appropriate setting. Re-check crimp height and make the proper adjustments if necessary.

Crimp five more samples and document the average crimp height, the maximum reading, and the minimum reading.

The range is considered the maximum reading minus the minimum reading. With a crimp micrometer and an experienced operator, the range for crimp terminations is normally only a few ten thousandths of an inch. This data becomes the first point on the control chart.

Production (Control Charting) It should be normal procedure for the operator to visually fan each bundle of crimped wires and visually check bell mouth, conductor brush, insulation position, and cut-off tab length and insulation crimp height. Crimp height should be checked throughout the run. The frequency of each check is determined by the risk you wish to take for scraping parts. A check every 250 to 500 parts is recommended.

Control Charting Crimp height is normally control charted since it is a quick nondestructive measurement and is critical for the electrical reliability of the termination.

There are three primary purposes for control charting. First, the numbers of setup samples are normally small, and its statistical value is limited. Second, since special cause effects on a process are irregular and unpredictable, it is necessary to have a means of catching changes in the process as soon as they occur. This prevents thousands of terminations from being scrapped after the run is over. Third and most important, this data is necessary to assess and improve the crimp process.

Once the tooling process is set-up and the wire size is not changing, keep one control chart for wire color changes, wire length changes, terminal material changes, or setup adjustments. Record the data point on the chart before a crimp height adjustment is made. If data is recorded after each adjustment, the process most likely will assume control and provide little data for improving the process. Write as many notes on the chart as possible. The only truly effective and economically sensible manner of managing a manufacturing process is to understand, monitor, and reduce sources of variability inherent to the process itself. Every minute the process is down for setup or adjustment is unproductive.

31.5

Example Control Chart

30.5

Thousandths

29.5

Crimp Height

Sample

Contol Limit

Control Limit

Upper Specification

Lower Specification

28.5 1 2 3 4 5 6 7 8 9 10 1112 131415 1617 181920 212223 2425

Measurements

Control Limit for sample of 5 = Avg (Avg. of 5 readings)

+ .577 x Avg (Ranges)

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FineAdjust Applicator

What does this sample chart tell us? A process shift occurred between measurement 12 and 13. This type of shift could occur due to a change in wire, a change in terminal lots, a jam in the machine that damaged the tooling, a change in operators, or an adjustment to the insulation crimp. Since the measurements are still within specification, would you stop production to adjust crimp height?

A shift in the process due to a change in material may arrant a crimp height adjustment. A shift after a jam would not indicate an adjustment, but a close evaluation of the tooling. A shift in the process between operators would not indicate an adjustment, but an evaluation of measurement capability.

31.5

30.5

Thousandths

29.5

Crimp Height

28.5

FineAdjust Control Chart

1 2 3 4 5 6 7 8 9 10 1112 131415 1617 181920 212223 2425

Measurements

Sample

Contol Limit

Control Limit

Upper Specification

Lower Specification

The idea of the control chart is to identify what caused the shift to justify if an adjustment to the process is warranted.

The FineAdjust Applicator is extremely easy to adjust. It is just as important to chart and document process control with the FineAdjust applicator.

If the process shift is due to a jam or a change in operators, more evaluation may be necessary than an adjustment.

Many crimping processes have been producing product within specification for decades. Today, with statistical process control, the philosophy of quality is being within specification is being replaced by being on target with continuous reduction in variability. Control charting is a tool that truly allows a company to understand their process.

ATTENTION

Reference must always be made to product application / crimp specification to determine crimp parameters.

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Page 49

FineAdjust Applicator

1 Oiler

Appendix C

Options

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Page 50

FineAdjust Applicator

M5 X 12LG

NUT-UPPER

LID

63890

0713

Terminal Oiler

For FineAdjust and

Mini-Mac Applicators

Application Tooling

Information Sheet

Terminal Oiler

To install a Terminal Oiler (Order No. 63890-0719) to any FineAdjust or Mini-Mac Applicator, use the following procedure.

1. Remove lid assembly from the oiler jar.

2. Remove upper oiler nut from lid assembly.

3. Place oiler mtg. bracket over tube, replace upper nut, and tighten securely.

4. Place lid assembly with mtg. bracket on the oiler jar and turn until hand tight. Do not over tighten.

5. Mount terminal oiler assembly with bracket on the frame of the FineAdjust or Mini-Mac Applicator.

6. Recommended lubricant oil:

Product Name: Transdraw B-19

Vendor Mid-Town Petroleum

9707 South 76th Avenue Bridgeview, IL 60455 Toll-Free: 877-255-3533 Direct: 708-599-8700 Fax: 708-599-1040 E-mail: sales@midtownoil.com www.midtownoil.com www.precisionlubricantsinc.com

7. For replacement wicks use part no. 63890-0727 (package of 25).

Visit our Web site at http://www.molex.com

MTG. BRACKET

Order No. 63890-0719

FRAME

BHCS

APPLICATOR

ASSEMBLY

JAR

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Page 51

Mouser Electronics

Authorized Distributor

Click to View Pricing, Inventory, Delivery & Lifecycle Information:

Molex: 63800-0115 63800-0313 63800-0119 63800-0127 63800-0330 63800-0345 63800-0116 63800-0120 63800-

0121 63800-0124 63800-0129 63800-0140 63800-0141 63800-0142 63800-0310 63800-0311 63800-0312 63800-0314 63800-0316 63800-0331 63800-0332 63800-0348 63800-4309 63800-4946 11-18-4238 63800-0302 63800-0117 63800-0118 63800-0143 63800-0122 11-32-5346 11-41-0127 63800-0126