molex FineAdjust APPLICATOR Operation Manual

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

FineAdjust Applicator

Read

and

understand

all of the instructions and safety information in this manual

before

CAUTION:

WARNING

WARNING

Heavy Object

WARNING

WARNING

Never

install or service this machine while

WARNING

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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FineAdjust Applicator

WARNING

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: [phone]
Fax:[phone]

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

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Revision: G Revision Date: 01-15-13

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

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

ADJUSTING CAM

BASE PLATE

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AND RETAINER

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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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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Revision: G Revision Date: 01-15-13

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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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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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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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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FineAdjust Applicator

Press St

roke

mm In.

Figure

2-9

FEED FINGER

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

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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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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Revision: G Revision Date: 01-15-13

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

Doc. No: TM-638004900 Release Date: 09-04-03 UNCONTROLLED COPY Page 16 of 50
Revision: G Revision Date: 01-15-13