molex TM-3000, TM-4000 Instruction Manual

Page 1
TM-3000 and TM-4000 Universal Press
Use with Molex FineAdjust, Mini-Mac Applicators and the Molex
Description Operation Maintenance
Order No: TM-638017299 Release Date: 06-06-05 UNCONTROLLED COPY Page 1 of 47 Revision: D Revision Date: 12-0-02-09
TM-3000 UNIVERSAL PRESS TM-4000 UNIVERSAL PRESS
Tape Terminal Crimp Module
Instruction Manual
Page 2
TM-3000 and TM-4000 Universal Press
WARNING
NEVER USE THIS MACHINE WITHOUT THE GUARDS OR SAFETY DEVICES THAT ARE INTENDED TO
PREVENT HANDS FROM REMAINING IN THE DIE SPACE. RUNNING THIS MACHINE WITHOUT GUARDS, UNDER ANY CIRCUMSTANCES, CAN CAUSE SERIOUS INJURY.
NEVER LIFT THIS PRESS WITHOUT THE AID OF MECHANICAL LIFTING DEVICES.
NEVER OPERATE, SERVICE, OR ADJUST THIS MACHINE OR INSTALL APPLICATOR DIES WITHOUT
PROPER INSTRUCTION AND WITHOUT FIRST READING AND UNDERSTANDING THE INSTRUCTIONS IN THIS MANUAL.
NEVER SERVICE THIS MACHINE WHILE IT IS CONNECTED TO ANY ELECTRICAL POWER SOURCE.
DISCONNECT POWER BY UNPLUGGING THE PRESS FROM ITS POWER SOURCE AND FROM THE COMPRESSED AIR SUPPLY.
NEVER INSTALL OR REMOVE APPLICATOR DIES WITH THE MOTOR RUNNING, OR AIR SUPPLY
CONNECTED.
CAUTION THIS PRESS IS SHIPPED FROM THE FACTORY AT A SHUT HEIGHT OF 135.80mm (5.346”).
FAILURE TO HAND CYCLE THE PRESS WHEN INSTALLING APPLICATORS CAN CAUSE SEVERE DAMAGE TO THE TOOLING AND/OR PRESS.
CAUTION MOLEX CRIMP SPECIFICATIONS ARE VALID ONLY WHEN USED WITH MOLEX TERMINALS,
APPLICATORS AND TOOLING.
WORK SAFELY AT ALL TIMES
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For Service, Contact Your
Local Molex Sales Office
Molex Application Tooling Group
2200 Wellington Court
Lisle, Illinois 60532
Tel: 630-969-4550
Fax: 630-505-0049
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TM-3000 and TM-4000 Universal Press
1 General Description
2 Installation
3 Setup - Operation
4 Maintenance and Troubleshooting
5 Parts List, Assembly Drawings, Electrical Schematics
6 EC Declaration of Conformity
A Options
1. Taped Terminal Crimp Module
Table of Contents
SECTION
APPENDIX
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TM-3000 and TM-4000 Universal Press
1.1 Description
1.2 Features
1.3 Technical Specifications
1.4 Delivery Check
1.5 Tools
Section 1
General Description
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TM-3000 and TM-4000 Universal Press
General Description
1.1 Description
The 63801-7200 (120V AC version), the 63801­7300 (240V AC version) TM-3000 Universal Press and the 63801-7600 (240V AC version) TM-4000 Universal Press are economical, electrically­operated, single-cycle and split cycle direct drive presses. They are designed to provide an effective method of applying a wide range of side-feed and rear-feed terminals to a pre-stripped discrete wire or cable. Both the TM-3000 and the TM-4000 are suited to mid-volume semi-automatic operations.
Production flexibility is obtained using interchangeable FineAdjust or Mini-Mac applicators and most Industrial Standard Applicators.
These presses will complete one crimping cycle with each depression of the foot pedal and two depressions for split cycle. Safe operation is provided by an interlock switch that renders the press inoperative if the safety guard is opened or removed.
1.2 Features
 Utilizes both FineAdjust and Mini-Mac
applicators side and rear feed, and most industry standard applicators
 Press is shipped set to Industry shut height of
135.80mm (5.346”)
 Ideal for mid-volume, semi-automatic
applications
 Meets O.S.H.A. safety standards is ANSI-
Z535.2-2002 compliant
 Totally enclosed for operator safety, including a
power interlock switch for the front guard
 Resettable counter for accurate batch counting  Modular solid state controls with an easy plug in
power cord and foot switch.
 “CE” Certified
1.3 Technical Specifications
Dimensions with reel mounted
Height 1210mm (47.60“) Width 648mm (25.50“) Depth 559mm (22.00“) Unpacked weight 100kg (220 lb)
Power Requirements
Voltage: 63801-7200-120V AC 60 Hz Voltage: 63801-7300-240V AC 50 – 60 Hz Voltage: 63801-7600-240V AC 50 – 60 Hz
Note:
If 240V power is not available, then 120V power may be used with an appropriate (1000VA minimum) step-up transformer. Recommended step-up transformer: Allied Electronics #836-0181 (phone: 1-800-433-5700).
Pneumatic Requirements (Air Feed Applicators only)
75 psi min. (366 kN/cm2) min.
1.0 SCFM (28.3 L/min) ¼” NPT inlet 12.7mm (1/2”) supply pipe minimum.
Production Rate
2400 terminations per hour maximum, depending on operator skill and wire length.
Processing Capability
TM-3000 Press output = 4000 lbf (18kN). Copper conductors up to 10 AWG (5.0mm²) in solid or stranded wire.
TM-4000 Press output = 7000 lbf (31kN). Copper conductors up to 4 AWG (21.0mm²) in solid or stranded wire.
Sound Level
Operator will be exposed to less than 85 dBA.
1.4. Delivery Check
After removing the packaging band, the top and sides of the box should lift off easily. The following items are included in this package :
Quantity
Main Press Body 1 Reel Support Assembly 1 “T” wrench for manual cycling 1
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TM-3000 and TM-4000 Universal Press
Carton Contents Quantity
69018-6237 PowerCord (for 63801-7200) 1
OR
62500-1774 Power Cord 220V 10A (for 63801-7300 and 63801-7600) 1 63801-7271 Foot Pedal 1 TM-638007299 Instruction Manual 1
1.5 Tools
The following tools are recommended for setup and adjustments to the applicator in this press
 Metric hex wrench set  Small standard screwdriver  Adjustable wrench  Needle nose pliers  Crimp micrometer  Eye loupe (10x)  Wire stripper/cutter  English hex wrench set for some non-metric
applicators
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TM-3000 and TM-4000 Universal Press
2.1 Lifting/Mounting
2.2 Reel Support
2.3 Foot Pedal and Power Connection
2.4 Pneumatic Supply Hook-up
2.5 Terminal Feed Guide
2.6 Function Test
2.7 Safety and Work Area Check
Section 2
Installation
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TM-3000 and TM-4000 Universal Press
LIFT HOOK
TERMINAL GUIDE
POWER CORD
2.1 Lifting/Mounting
WARNING: This Press weighs over 100 kg (220
lb); it should not attempt to be lifted by one individual. Mechanical lifting devices should be used. A person lifting the press can sustain severe back or other injuries.
A lifting hook is provided on the top of the press. A heavy-duty chain, rope, cable, or belt can be used with loops, links, or rings on each end that can securely attach to the lifting hooks. An electric, hydraulic, or mechanical crane should be used to lift the press. Lift the press up approximately 12mm (.50”) and verify that the press is well balanced. Upon verification, the press can be lifted onto a sturdy workbench. Access to the back of the machine is required for manual cycling. A wooden bench that is a minimum of 25mm (1.00”) thick will offer quiet vibration-free operation. For thinner or sheet metal tops, the TM-3000 can be
MOTOR
REEL SUPPORT ASSEMBLY
WORK LIGHT
PRESS CONTROL
ASSEMBLY
WORK BENCH
OILER ASSEMBLY
FOOT PEDAL
ASSEMBLY
Figure 2-1
attached to the table with two 12mm bolts. Bolts are not supplied by Molex.
2.2 Reel Support
Install the reel support in the hole located on the top of machine frame. For rear feed, rotate the reel support as required. See Figure 2-3. Loosen the M10 set screw that holds the reel support. Pull up from the hole and rotate for the proper feeding orientation. Then slide down back into the hole and tighten the M10 set screw.
2.3 Foot Pedal and Power Connection
Connect the 3-pin plug for the foot pedal in the rear of the press control assembly. Turn the locking ring clockwise until tight. Connect the power cord plug to the socket in the back of the control assembly. Use a grounded electrical outlet as the power source. See Figure 2-2.
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TM-3000 and TM-4000 Universal Press
FOOTSWITCH
CORD
Figure 2-2
POWER
CORD PLUG
2.4 Pneumatic Supply Hook-Up
A compressed air supply is required if air feed or other air powered applicators will be used. The press comes equipped with an air supply system, which consists of filter, regulator, lubricator and a valve to actuate the air feeds at the proper time in the press cycle.
Due to the considerable types of air connection and quick connect fittings available; Molex only supplies the press with a 1/4 NPT female threaded fitting. The customer may attach whatever type of air connections that are commonly used in their plant to this port.
The minimum flexible tube size used to connect the press should be 8mm or 5/16” to assure adequate flow rate.
A filter-regulator-lubricator unit is supplied to properly condition the incoming air. The filter will remove particulate and moisture from the air that can damage or reduce the life of cylinders and valves. This filter and bowl should be serviced on a regular schedule. (See section 4.1) The filter has an automatic drain at the bottom of the bowl that will automatically open and expel fluid when the bowl is getting full. It is recommended that, a 6mm or 1/4” flexible tube, be attached to the drain hose barb and run to a container if the air system contains excessive moisture.
The regulator adjusts the pressure of the incoming air to what the applicators require usually 60-80 PSI (refer to the applicator manual for recommended pressures.) Adjustment is accomplished by pulling up on the knob, rotating it until the gauge indicates the desired pressure, then pushing it down to lock the setting.
A lubricator is supplied for those applicator air feeds that need lubrication. Molex air-feed applicators do not require lubrication. The lubricator is shipped without lubricant in it. To use, fill the lubricator (make sure the main air supply is disconnected or that the slide valve provided is in the off position before adding lubricant) through the fill plug on the top of the unit, with high quality SAE 10 W oil. The lubricator has a graduated dial on top, turn the dial to the 1 or 2 setting.
Caution: Do not over lubricate. Only a very small amount of lubricant is required to assure smooth operation. Excess lubricant is exhausted to the atmosphere.
If lubrication is not required set the dial to 0 to turn off the lubricator.
2.5 Terminal Feed Guide
PULL UP FROM
HOLE, ROTATE AND
SLIDE DOWN INTO
HOLE
REPOSITION
TERMINAL GUIDE
Figure 2-3
Depending on side or rear-feed applications, the terminal guide plate and bracket must be repositioned. The press is set for side-feed applicators when shipped from the factory. When rear-feed applicators are used, the two M6 BHCS from the terminal guide­mounting bracket are to be removed. See Figure 2-3. The guide bracket is rotated 180 degrees and the assembly is then mounted on the two standoffs in the
LOOSEN
M10 SSS IN
FRONT OF
PRESS
REMOVE M6 BHCS
AND REMOVE
TERMINAL GUIDE
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TM-3000 and TM-4000 Universal Press
rear of the press with the two M6 SHCS. See Figure 2-3.
2.6 Function Test
When the press is shipped from the factory, it is set to the industry shut height of 135.80 mm (5.346”) with a calibrated load gauge. The press shut height gauge is spring loaded to give an accurate reading on the press shut height. See Figure 2-4. Molex recommends hand cycling the press each time an applicator is installed. See Section 3-3.
PRESS
SHUT HEIGHT GAUGE
CAUTION: Always manually cycle the press
before restoring power to the machine.
2.6.1 Verification of Press Shut Height
This press comes factory set at an Industry Standard shut height of 135.80mm (5.346”). A label is attached to the front of each press indicating the factory settings. This press has an adjustable shut height, see Section 3.4.3 for crimp height adjustment. Always return the press to the factory setting on the label before installing applicators to avoid tooling
PRESS QUICK CHANGE
MOUNTING PLATE
Figure 2-4
damage. Check the factory setting periodically with a calibrated shut height gage.
Shut height gauges may be purchased from: Artos Eng. 602-581-0070 Komax Corp. 847-537-6640
2.7 Safety and Work Area Check
Check that the crimping position is ergonomic for the operator’s size. A bench height of 762.00 to 813.00mm (30.00 to 32.00”) will provide operator comfort, and allows both feet to rest on the floor. The foot pedal should be placed in a comfortable position. Check that the press position is located approximately 150mm (6“) from the edge of the bench. A chair or stool with adjustable height and backrest should be provided for maximum comfort and back support for the operator.
FUSE HOLDER
CAUTION: Molex recommends that the operator
and observers wear eye protection when the press is in operation or being serviced.
The fuse is located on the control panel. To replace the fuse (10AMP on 110 V models and 5AMP on 220V models), turn the holder in the direction as shown. Turn clockwise to secure holder in place when replaced. See Figure 2-5.
Figure 2-5
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TM-3000 and TM-4000 Universal Press
3.1 Applicator Installation
3.2 Air Feed Applicator Installation
3.3 Manually Cycling the Press
3.4 Operation
Section 3
Setup and Operation
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TM-3000 and TM-4000 Universal Press
3.1 Applicator Installation
Power down the press by turning off the “POWER” switch located on the control panel.
Note: Once the press guard is open the guard interlock switch will disconnect power to the motor.
QUICK
CHANGE
PLATE
LOCATOR
CLAMPS
LOCKING
CLAMP
HEX WRENCH
Figure 3-1
USE 4mm
BASE PLATE
Steps
1. Swing the press guard open.
2. Verify that the applicator is correctly tooled for the terminal being used. (Reference specification sheets supplied with the applicator).
3. Clean the press quick change mounting plate of scrap or chips that may interfere with the applicator installation.
4. Using a 4mm hex wrench, turn the M5 SHCS clockwise until the locking clamp is fully opened.
5. Locate the applicator lug bolt in the press yoke. See Figure 3-1.
6. Align the applicator base plate slots with the locator clamps on the press quick change plate.
7. To lock applicator, turn M5 SHCS counter clockwise until tight.
8. Confirm that the applicator is secured properly.
ENGAGE
PRESS YOKE
LUG BOLT
3.2 Air Feed Applicator Installation
Power down the press by turning off the “POWER” switch, located on the control panel.
Note: Once the press guard is open the guard interlock switch will disconnect power to the motor.
Warning: When using air feed applicators, always use the slide valve supplied to shut-off and vent air pressure to the air feed before servicing. The guard interlock switch DOES NOT remove air pressure. If an air feed is jammed and air pressure is not removed before servicing, the feed could move unexpectedly and cause injury.
SHUT-OFF
SLEEVE
SLIDE LEFT TO
SHUT OFF
TO MAIN
AIR SUPPLY
Figure 3-2
Steps
1. Swing the press guard open.
2. Verify that the applicator is correctly tooled for the terminal being used. (Reference specification sheets supplied with the applicator).
3. Clean the press quick change mounting plate of scrap or chips that may interfere with the applicator installation.
4. Using a 4mm hex wrench, turn the M5 SHCS clockwise until the locking clamp is fully opened.
5. Locate the applicator lug bolt in the press yoke. See Figure 3-1.
6. Align the applicator base plate slots with the locator clamps on the press quick change mounting plate.
FILTER-REG-LUBRICATOR
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TM-3000 and TM-4000 Universal Press
7. To lock applicator, turn M5 SHCS counter clockwise until tight.
8. Confirm that the applicator is secured properly.
9. Disconnect the air supply from the filter-regulator­lubricator supplied with the press, by sliding the shutoff valve sleeve to the left, as shown in Figure 3-2. Remove the plugs from the fittings on the air valve. Do not discard the plugs; when the air applicator is not being used, the fittings should be plugged.
FILTER-REG. LUBRICATOR
RETRACTS
TO MAIN
AIR SUPPLY
PORT ”A”
Figure 3-3
PORT ”B”
ADVANCES
APPLICATOR
Note: When not using an air feed applicator always shutoff the air supply to the filter-regulator-lubricator by sliding the shutoff valve sleeve to the left, the opposite direction of the airflow, as shown in Figure 3-2.
Note: Some applicators feed terminals in the retracted position, for those air tubes must be reversed. In addition, some applicators are air advance and spring return, on these applicators one port will need to be plugged.
10. Insert the “A” port of the air valve with the tube that retracts the feed mechanism of the applicator. See Figure 3-3.
11. Insert the “B” port of the air valve with the tube that advances the feed mechanism of the applicator. See Figure 3-3.
Note: When using the 64016-2000 Crimp Module, set the feed selector on the control panel to “SINGLE” or
AIR-FEED
“DOUBLE”, depending on the spacing of the taped terminals. See Figure 3-5.
12. Connect the main air supply to the filter reg­lubricator. (Custumer supplied fitting)
13. Adjust the regulator to 75-80 PSI (366-390 kN/cm2).
14. Check that the tubing for the applicator is properly connected by dry cycling the press and observing the feed motion.
3.3. Manually Cycling the Press
Turn off the “POWER” switch which is located on the control panel to power down the press.
Note: Once the press guard is open the guard interlock switch will disconnect power to the motor.
Hand cycling the press is necessary to confirm correct tool alignment and terminal feed adjustment. It also gives the setup person the ability to step through the press cycle manually.
Figure 3-4
POWER CORD
Steps
1. Insert the 8mm square socket T-handle wrench through the access hole in the center of the rear cover on the motor and locate it in the shaft motor. See Figure 3-4.
MOTOR
T-HANDLE
WRENCH
TURN
CLOCKWISE
FOOT SWITCH
CORD
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TM-3000 and TM-4000 Universal Press
2. Rotate the wrench clockwise. This turns the motor and moves the ram down and up.
3. Always return the press back to top dead center insuring that the ram is in the start up position.
4. Remove the T-handle wrench.
NOTE: When the T-handle is put into the motor shaft the motor turns off automatically.
3.4. Operation
3.4.1 Full Cycle Operation
CAUTION: Make sure the press guard is in position
and all setup procedures are followed. Follow the safety and work area instructions.
Steps:
1. Push the toggle switch on the control panel to “Full Cycle”. See Figure 3-5.
TOGGLE
SWITCH
TO FULL
CYCLE
POWER
ON
Figure 3-5
2. Turn the “Power “ switch on, the power indicator light will light up.
3. Press the “Motor On” push button, the motor indicator light will light up. After a 5 second delay the press will be ready to cycle.
4. Place the prestripped wire through the slot in the press guard and push until it contacts the wire stop. See Figure 3-6.
FEED
SELECTOR
PUSH
MOTOR ON
5. Press the foot pedal down once. Use a sweeping motion to the right with the crimped wire and remove.
6. Check the crimped wire and confirm that it meets the applicator specifications and visual inspection.
7. Repeat steps 4 and 5 for the next crimp.
GUARD
PRE-STRIPPED
Figure 3-6
WIRE
WIRE STOP
3.4.2 Split Cycle Operation
Desription:
The split cycle is used mostly for closed barrel terminals. This makes it easier to locate the terminal before crimping the wire. The punch/ram will close partially to assist in locating the terminal for the termination. Then the wire can be placed into the terminal and be terminated. To setup the machine for split cycle push the toggle switch on the control panel to “Split Cycle”. See Figure 3-5.
Steps:
1. Depress the foot switch once, the ram will lower partially, positioning the terminal for termination.
2. Place the prestripped wire into the terminal.
3. Depress the foot switch a second time. The ram will complete its downward stroke and return to the top position to complete the cycle of terminating the crimp.
CAUTION: Make sure the press guard is in position and all setup procedures are followed. Follow the safety and work area instructions.
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TM-3000 and TM-4000 Universal Press
Split Cycle Ram Adjustment
When setting up an applicator for split cycle operation it may be necessary to adjust the ram for a partially closed position (1st position), so the terminal will be captivated in the punch and not terminated. For adjustment, the prox sensor located on the left side of the ram cover, needs to be adjusted. See the following steps:
Steps:
1. Depress the foot switch once, with the terminals in the applicator. See where the punch is located in the 1st position of the cycle.
2. If the punch is too high and does not center the terminal so that the prestripped wire can be inserted in the closed barrel or the punch is too low partially crimping the terminal, the prox sensor needs to be adjusted.
3. Open the press guard.
4. Loosen the two M12 jam nuts on the split cycle prox, located on both sides of the prox bracket. Then loosen the M4 jam nut holding the M4 X 25 SHCS. Turn the screw clockwise to raise the prox or counter-clockwise to lower the prox. See Figure 3-7. Raise the prox if the punch is partially crimping the terminal; or lower the prox if the ram is not closing far enough and not centering the terminal punch.
M12 JAM NUT
PROX BRACKET
M4 JAM NUT
PROX SENSOR
1.52mm (.06”)
MAX. GAP
TOGGLE SWITCH
TO SPLIT CYCLE
Figure 3-7
5. Retighten the M4 SHCS and the (2)M12 jam nuts positioning the prox for the 1st position of the split cycle. See Figure 3-7.
6. Close the press guard.
7. Repeat step 1 to check for the correct position of the ram. (Be sure Ram is at Top-Dead-Center first.)
Note: The gap between the prox and the ram should be 1.52mm (.06”) Max. See Figure 3-7.
CAUTION: Always return the ram to the top dead center position or start position of the cycle before recycling the press. This is done by manually cycling the press. See section 3.3.
3.4.3 Crimp Adjustment
See Section 2.6.1 for Industry standard shut height.
Crimp Adjustment Full and Split Cycle
If crimp adjustment is required and cannot be made by the cam adjustment on the applicator, the fine adjustment dial on the press ram can be adjusted by following the steps below.
LOOSEN M6 SHCS
ADJUSTABLE DIAL
Figure 3-8
LOOSEN M6 SHCS
Steps:
1. Open the press guard.
2. Loosen the four M6 SHCSs on the front of the press.
3. Rotate the adjustment dial to the right to raise crimp height or to the left to decrease. Dial indicator lines represent increments of .05mm (.002”). See Figure 3-8.
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TM-3000 and TM-4000 Universal Press
4. When adjustment is complete, retighten the four M6 SHCSs.
5. Close the guard.
6. Place a prestripped wire into the terminal and terminate under power. Examine the quality of the crimp.
7. Repeat steps 1 thru 6 if the desired crimp is not achieved.
Use caution adjusting the ram downward. Over adjustment in this direction may cause tooling damage or breakage.
Always return the adjustment to the factory setting before installing another applicator, or recalibrating shut height. See Section 2.6.1.
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Molex Taped Terminal Crimp Module
4.1 Maintenance
4.2 Oiler
4.3 Troubleshooting
Section 4
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TM-3000 and TM-4000 Universal Press
4.1 Maintenance
Power down the press by pressing the power button to off “O” located on the control panel.
For efficient operation the press should be cleaned daily with a soft bristle brush to remove any carrier strip debris and terminal plating dust from the tooling area.
Maintenance Schedule
The following is offered as a general guideline for maintenance. Tool life can be increased with good maintenance practices or decrease with lack of maintenance.
Item
Air Filter 100,000 Weekly
Air
Lubricator
Ram 25,000 Daily
Main Bearing 25,000 Daily
Cleaning 25,000 Daily
Frequency
Cycles
100,000 Weekly
Frequency
Time
Materials
Clean bowl and sintered
filter with denatured alcohol
SAE 10W oil. Check and
refill if used
SAE 10W oil
Oil Cup (Top of ram)
Grease fitting right side of
Press bearing lube
Use soft bristle brush on
Applicator mounting plate
4.2. Oiler
LID
Description
The wick action oiler is included with the press. The oiler applies a thin coat of lubricant to the terminals, which
TUBE
helps with feeding and better release from termination punches. The oiler is primarily used for terminals with gold plating. To avoid contamination when shipped and
WICK
(PKG OF 25
#638900727)
during setup, the oiler is shipped from the factory with no lubricant oil. The oiler should only be used on applicators that require lubrication for smooth trouble­free operation.
Oiler Position
Adjust the position of the oiler unit using the mounting screw that attaches the oiler to the quick change mounting plate. Simply loosen the screw, slide the unit to the desired position, and tighten the screw. The unit can be removed and placed on the rear side of the quick change mounting plate for rear-feed applications.
OIL CUP
Figure 4-8
Figure 4-9 OILER ASSEMBLY
GREASE FITTING
(OIL RESERVOIR)
MOUNTING
BRACKET
JAR
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TM-3000 and TM-4000 Universal Press
Oiler Wick
Adjust the height of the oiler wick by pulling up or pushing down on the wick to the appropriate height. The wick can be moved using pliers or simply grab it with your fingers.
Filling the Reservoir
While firmly holding the lid, screw the jar (oil reservoir) counter clockwise until it is removed. Fill the jar with the desired lubricant oil and replace the lid.
Replacing the Wick
While firmly holding the lid, screw the jar oil reservoir) counter clockwise until it is removed. Feed a new wick up into the tube until it protrudes from the top end of the tube and replace the lid.
Package of 25 Wicks: Molex Order No: 63890-0727
Lubricant Oil
Recommended oil: Transdraw B-19
Vendor: Sure Lubricants Inc.
356 South Lively Boulevard Elk Grove Village, IL 60007-2010 Phone: 888-787-3582 Fax: 847-956-6655 E-mail: surelub@aol.com
4.3 Troubleshooting
Symptom  Cause Solution
 Power/Power cord failure Check supply  Loose connection Refer to control schematic  Guard interlock switch disengaged Re-Install guard  Fuse blown Replace
Motor will not run
Press will not cycle
Press partially cycles  Toggle switch set to split cycle Reset the toggle switch to full cycle
 On/Off switch failure Replace  Motor failure Replace  T-wrench not removed from motor Removed T-wrench from motor  Control PCB not working Replace  Solid state relay not working Replace  Control board for motor Repair or replace  Guard interlock switch disengaged Re-Install guard  Faulty footswitch Check Connection. Repair or replace  Control PCB not working Replace  Fuse blown Replace
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TM-3000 and TM-4000 Universal Press
5.1 Parts List
5.2 Assembly Drawings
5.3 Electrical and Pnuematic Schematics
Section 5
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TM-3000 and TM-4000 Universal Press
5.1. Parts List
Item No. Order No. Ref. No. Description Quantity
1 63801-7200 FE-2TC (110VAC) 2 63801-7300 FE-2TC (220VAC) 3 63801-7201 4 63801-7202 5 63801-7203 6 63801-7204 7 63801-7205 8 63801-7206
9 63801-7207 10 63801-7208 11 63801-7209 12 63801-7210 13 63801-7211 14 63801-7212 15 63801-7213 16 63801-7214 17 63801-7215 18 63801-7216 19 63801-7217 20 63801-7218 21 63801-7219 A007-NA6911 Front Bearing 1 22 64016-2501 23 64016-2502 24 64016-2503 25 63801-7281 26 63801-7222 27 63801-7283 28 63801-7224 29 63801-7284 30 63801-7285 31 63801-7286 32 63801-7287 33 63801-7288 34 63801-7631 35 63801-7232 36 63801-7233 37 63801-7234 38 63801-7235 39 63801-7236 40 63700-3845 41 63801-7237 42 63801-7238 43 63801-7239 44 63801-7240 45 63801-7241 46 63801-7242 47 63801-7243 48 63801-7244 49 63801-7245
A021-R80 Shaft E-Ring 1
TM-3000 Main Assembly (Figure 5-1 and 5-2)
Universal Press (110VAC) See Notes Below
Universal Press (220VAC) See Notes Below A01 Press Frame 1 A02 Ram 1 A03 Follower 1 A04 Front Cap 1 A05 Press Face Plate 1 A06 Switch-TDC 1 F05 Flag Pickup 1 A08 Access Cover 1 F17 Oil Fill Cap 1 A10 Flag-Position 1
(M) B01 Split Cycle Prox 1 (M) B03 Guard Handle 1
B02 Yoke Adapter 1 B03 Mounting Block Cover 1 B04 Mounting Block 1
(M) A01 Press Yoke 1
B01 Press Shaft 1
--- Guard Slide 2
--- Guard Front 1
--- Front Guard Insert 1
(M) Rear Guard 1
(M) A02 Quick Change Plate 1
(M) Side Guard 1 (M) Name Plate (Universal Press) 1 (M) Hinge Mounting Bracket 1 (M) Guard Hinge 2
(M) A06 Guard Sensor Bracket 1
(M) Guard Bracket 1 (M) Stand-off, Guard Side 3
--- Control Panel 1 F12 Eye Bolt 1 C04 Stand off 2 C01 Terminal Guide 1 C03 Guide 2 C02 Terminal Guide Bracket 1
(M) Rotor Magnet 1 F06 Press Lamp 1 E05 Lamp Mounting Bracket 1
(M) B02 Guard Switch Prox 1
(M) Oiler Assembly (Figure 5-3) 1
F07A
F07B (M) A03 Alignment Block 2 (M) A04 Locking Clamp 1 (M) A05 Clamp Retainer 1
∗∗∗∗Bulb-110 VAC
∗∗∗∗∗∗∗∗Bulb-220 VAC
1 1
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TM-3000 and TM-4000 Universal Press
Item No. Order No. Ref. No. Description Quantity
50 63801-7246 51 63801-7247 A007-A6909ZZ Rear Bearing 2
52
53 63801-7249 54 63801-7250 55 63801-7251 56 63801-7252 57 63801-7253 58 63801-7254 59 63801-7256 60 63801-7257 61 63801-7258 62 63801-7259 63 63801-7260 64 63801-7261 65 63801-7262 66 63801-7263 67 63801-7269 68 63801-7270 69 63801-7271 70 69018-6237 71 62500-1774 72 63801-7272 73 63801-7273 74 63801-7274 75 63801-7275 76 63801-7276 77 63801-7277 78 63801-7278 79 63801-7279 80 63801-7600
63801-7248 63801-7648
A021-R68 E-Ring 2
A021-S45 Small E-Ring 1
Note:
1. For TM-3000 Press 220VAC use assembly no. 63801-7300.
2. For TM-4000 Press (220VAC only) use assembly no. 63801-7600.
3. All parts for both 63801-7200 and 63801-7300 Presses unless otherwise specified.
4. ∗∗∗ Indicates parts for 63801-7200 (110VAC) Press only.
5. ∗∗∗ ∗∗∗∗ Indicates parts for 63801-7300 (220VAC) Press only.
6. ∗∗∗ ∗∗∗∗∗∗∗∗ Indicates parts for 63801-7600 (220VAC) Press only.
TM-3000 Main Assembly (Figure 5-1 and 5-2)
(M) F01 Motor with Gear Reducer 1 (M) F01
F02
F02A
F03 Relay - Motor On 1 F04 Transformer (18V) 1
(M) E04 PCB-Machine 1
E03 Sensor Flag -Motor 1 F08 Motor Shutoff Prox 1 E02 Prox Motor Shutoff Bracket 1 A09 Rear Cover 1 D01 Reel Support 1 D02 Reel Boss 2 D03 Reel Disc 2 D04 Reel-Spring 1
(M) Filter-Regulator-Lubricator 1 (M) Air Valve-3 Way 1 (M) Foot switch with cord 1
---
--­(M) Slide Valve 1 (M) Label (Lightning Bolt) 1-1/2” Triangle 1 (M) Label (Eye-Glasses) 1 (M) Label (Caution) 2 (M) Plug (1/4” Tube) 2 (M) Elbow Male (1/4” Tube) for Filter-Reg.-Lubricator (M) Elbow Male (1/4” Tube) for 3-Way Valve 3 (M) Terminal Guide Standoff 4
--- Universal Press (220VAC) See Notes Below
∗∗∗∗∗∗∗∗∗∗∗∗ Motor with Gear Reducer
∗∗∗∗ Motor Controller 110VAC
∗∗∗∗∗∗∗∗ Motor Controller 220 VAC
∗∗∗∗ Power Cord (110VAC) 20 AMP
∗∗∗∗∗∗∗∗ Power Cord (220VAC) 10 AMP
1
1 1
1 1
1
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TM-3000 and TM-4000 Universal Press
27
5.2. Assembly
35
(3)
43
(2)
72
67
44
68
77
28
76
78
75
33
(3)
13
25
34
31
M12
JAM NUT (2)
(REF)
29
26
40
79
Figure 5-1
(4)
32
24
30
(2)
22
23
74
14
(2)
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TM-3000 and TM-4000 Universal Press
5.2 Assembly (Continued)
(2)
4
5
47
56
110V
220V
110V
220V
11
7
6
16
26
48
15
17
18
49
41
45
46
42
29
REF
54
55
64
20
12
(2)
10
58
(2)
19
8
57
65
21
Figure 5-2
66
73
63
70
71
37
110V
220V
53
59
38
(2)
52
60
61
69
36
(2)
39
3
51
9
(2)
(2)
50
62
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TM-3000 and TM-4000 Universal Press
Assembly (continued)
Item No. Description Quantity
3
6
5
3
2
1
4
Figure 5-3
Oiler Assembly
Item No. 43 (63801-7240)
1 Oiler Wick 1 2 Oiler Lamp Tube 1 3 Oiler Lamp Tube Nut 2 4 Wide Mouth Glass Jar 1 5 Oiler Glass Jar Lid 1 6 Oiler Bracket 1
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TM-3000 and TM-4000 Universal Press
5.3. Electrical Schematic
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TM-3000 and TM-4000 Universal Press
5.3. Pnuematic Schematic
Americas Headquarters
Lisle, Illinois 60532 U.S.A. 1-800-78MOLEX amerinfo@molex.com
Far East North Headquarters
Yamato, Kanagawa, Japan 81-462-65-2324 feninfo@molex.com
Figure 5-5
Far East South Headquarters
Jurong, Singapore 65-6-268-6868 fesinfo@molex.com
Visit our Web site at http://www.molex.com
European Headquarters
Munich, Germany 49-89-413092-0 eurinfo@molex.com
Corporate Headquarters
2222 Wellington Ct. Lisle, IL 60532 U.S.A. 630-969-4550 Fax: 630-969-1352
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TM-3000 and TM-4000 Universal Press
6.1 EC Declaration of Conformity
Section 6
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TM-3000 and TM-4000 Universal Press
6.1 EC Declaration of Conformity
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TM-3000 and TM-4000 Universal Press
For more information use the Quality Crimping Handbook
And Industrial Crimping Handbook
There is no charge for these books, they can be found on the Molex Website (www.molex.com) or contact you
local Molex sales engineer
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TM-3000 and TM-4000 Universal Press
1. Taped Terminal Crimp Module
APPENDIX A
OPTIONS
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TM-3000 and TM-4000 Universal Press
TAPED TERMINAL CRIMP MODULE
Description Operation Maintenance
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Order Number 64016-2000
Instruction Manual
Page 33
TM-3000 and TM-4000 Universal Press
WARNING
NEVER USE THIS CRIMP MODULE IN A PRESS WITHOUT GUARDS OR SAFETY DEVICES THAT ARE
INTENDED TO PREVENT HANDS FROM REMAINING IN THE DIE SPACE.
NEVER OPERATE, SERVICE, INSTALL, OR ADJUST THIS CRIMP MODULE WITHOUT PROPER
INSTRUCTION AND WITHOUT FIRST READING AND UNDERSTANDING THE INSTRUCTIONS IN THIS MANUAL AND ALL APPLICABLE PRESS MANUALS.
NEVER INSTALL OR SERVICE THIS CRIMP MODULE WHILE CONNECTED TO ANY ELECTRICAL
POWER SOURCE. DISCONNECT POWER BY UNPLUGGING THE PRESS FROM ITS POWER SOURCE.
CAUTION THE MOLEX CRIMP MODULE IS DESIGNED TO OPERATE ONLY IN THE MOLEX TM-3000 OR
TM-4000 PRESSES. INSTALLATION IN OTHER CRIMP PRESSES CAN CAUSE SEVERE TOOL DAMAGE. IT IS ADVISABLE THAT BEFORE INSTALLATION, A CHECK OF THE PRESS SHUT HEIGHT BE PERFORMED. MOLEX WILL NOT BE LIABLE FOR ANY DAMAGES AS A RESULT OF INSTALLATION IN A PRESS WITH AN IMPROPERLY SET SHUT HEIGHT.
CAUTION MOLEX CRIMP SPECIFICATIONS ARE VALID ONLY WHEN USED WITH MOLEX TERMINALS
AND MOLEX APPLICATION TOOLING.
WORK SAFELY AT ALL TIMES
For Service, Contact Your
Local Molex Sales Office
Molex Application Tooling Group
2200 Wellington Court
Lisle, IL 60532
Tel: (630) 969-4550
Fax: (630) 505-0049
Visit our Web site at http://www.molex.com
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TM-3000 and TM-4000 Universal Press
Table of Contents
SECTION
1 General Description
2 Setup, Adjustments, and Operation
3 Maintenance
4 Parts List, Assembly Drawings, Troubleshooting, and Guard upgrade
APPENDIX
A Pull Force Testing
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1.1 Description
1.2 Features
1.3 Technical Specifications
1.4 Delivery Check
1.5 Tools
1.6 Specification Sheets
Section 1
General Description
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TM-3000 and TM-4000 Universal Press
AND P
RESS YOKE
Principal Mechanical Parts of the Taped Terminal Crimp Module
PRESS YOKE
PUNCH HOLDER
ATP-301
CARRYING
HANDLE
TAPE GUIDE
COVER
Figure 1-1
RAM
WIRE STOP/
STRIPPER UNIT
ANVIL MOUNT
STORAGE FOR
PUNCH HOLDER
FEED
CYLINDER
STORAGE
FOR
WIRE STOP/
STRIPPER
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TM-3000 and TM-4000 Universal Press
General Description
Description
The taped terminal crimp module provides an effective method of applying a wide range of side feed tape-mounted terminals to pre­stripped discrete wire(s) from 4 to 30 AWG.
The crimp module and press combination replaces the Molex ATP-301 Press (19228-
0030) and the Molex ATP-201 Press (19047-
0001).
This crimp module operates only in the Molex TM-3000 and TM-4000 Universal Presses. The crimp module uses quick-change modular tooling, requires little or no adjustments, and is intended for mid-volume to high-volume, semi­automatic operations.
Molex offers the following crimp presses for operating the crimp module:
TM-3000 Universal Press 120V 50-60 Hz.
63801-7200
TM-3000 Universal Press 240V 50-60 Hz.
63801-7300
The TM-3000 should be used for 10-30 AWG terminals.
TM-4000 Universal Press 240V 50-60 Hz.
63801-7600
The TM-4000 should be used for 4-30 AWG terminals.
General Features
Independent adjustment of insulation crimp height. Tooling is accessed from the front of the module,
simplifying change over. No track adjustment is required. Compatible with the Molex TM-3000 and TM-4000
Universal Presses only. It does NOT fit into
Molex TM-40, TM-42, or TM-2000 presses. No terminal feed adjustment is required.
Uses crimp tooling from existing Molex ATP-201 and
ATP-301 crimp presses.
Technical Specification
Dimensions
Crimp Module Only Width: 140mm (5.5") Depth: 136mm (5.3") Height: 175mm (6.9")
(ram down)
Weight 4.1kg (9lb)
Guarding
The crimp module is intended to be used with the guards supplied on the TM-3000 or TM­4000 Universal Press. A special retrofit guard kit is available when the crimp module is installed on earlier TM-3000 press models. See Section 4.3.
Caution: DO NOT operate the crimp module without press guards in place.
Delivery Check
Carefully remove the crimp module from its shipping container and determine that the following items are included in the package.
Crimp Module 1
Air line Kit 1
Press Guard Kit (if required) 1
Instruction Manual 1
NOTE: Terminal crimp tooling is not included with the crimp module and must be ordered separately.
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TM-3000 and TM-4000 Universal Press
Tools
The following tools are recommended for setup and adjustments to the crimp module:
1. Metric standard hex wrench set
2. Inch standard hex wrench set
3. Wire stripper / cutter
4. Crimp Micrometer or caliper
Specification Sheets
Specification sheets are available for all crimp tooling. The specification sheet contains the following:
Applicable terminal numbers Wire AWG ranges Insulation diameter ranges Pull Force specification Strip lengths Slug height specification Tooling parts lists and assembly drawings
The specification sheet is available on the Molex website (www.molex.com).
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TM-3000 and TM-4000 Universal Press
Set-Up and Operation
2.1 Shut Height
2.2 Setup
2.3 Crimp Height Adjustments
2.4 Crimp Tooling Installation and Removal
2.5 Specific Crimp Module Adjustments
2.6 Operation
Section 2
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Figure 2
-2
Read the following instructions before attempting to operate the crimp module.
2.1. Shut Height
The Molex Taped Terminal Crimp Module operates only in the TM-3000 and TM-4000 presses with standard shut height of 135.80mm (5.346"). Installation in crimp presses with other than standard shut heights can cause severe tool damage. Before installing the crimp module, the press shut height must be verified. The correct shut height is required for proper crimping without causing tool damage.
The shut height of the TM-3000 and the TM-4000 presses are preset at the factory and labeled on the front of the press. Over time, however, the press may wear causing a change in the 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.
PRESS
SHUT HEIGHT GAUGE
Measuring Press Shut Height
1. Disconnect the power supply from the press. Remove the machine guards if necessary.
PRESS QUICK CHANGE
MOUNTING PLATE
Figure 2-1
2. Remove the applicator from the press. Make sure that the bottom of the press ram and quick change mounting plate are free of 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 full down stroke position. (See the TM-3000 press instructions on manually cycling the press.)
5. Read the shut height measurement from the front of the gauge. Follow gauge manufacturer’s instructions; usually the gauge reads “0” at the correct shut height.
6. If shut height adjustment is necessary:
LOOSEN M6 SHCS
ADJUSTABLE DIAL
LOOSEN M6 SHCS
a. Loosen the four M6 SHCS on the front of the
press.
b. Rotate the adjustment dial to the right to raise
shut height or to the left to decrease. Dial indicator lines represent increments of .05mm (.002”). See Figure 2-2.
c. When adjustment is complete, retighten the four
M6 SHCS.
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
The principal mechanical parts of the crimp module are illustrated in the assembly drawings (Section 4-1).
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Crimp Module Installation and Removal
1. Turn off the press and disconnect the power. Open the press guard.
2. Clean the quick-change mounting plate of scrap or chips that may interfere with the crimp module installation.
3. Using a 3mm hex wrench, loosen the set screw holding the press yoke. Pull the press yoke straight down and remove it from the press. (Note: a storage hole is provided on right side of the crimp module frame to keep the press yoke)
4. Install the press yoke furnished with the crimp module in the press ram. Tighten the set screw securely.
5. Using a 4mm hex wrench, turn the M5 SHCS clockwise until the locking clamp is fully opened.
6. Visually align the crimp module’s base plate slots with the location clamps on the press quick-change mounting plate.
PRESS YOKE
LOCATOR
CLAMPS
RAM
ADAPTER
QUICK
CHANGE
PLATE
LOCKING
CLAMP
Figure 2-2
M5
SHCS
BASE PLATE
7. Slide the crimp module 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 ram adapter into the press yoke. See Figure 2-2.
8. To lock the crimp module, turn the M5 SHCS counterclockwise until tight.
9. Connect the air lines from the feed cylinder to the press air valve. The cylinder port closest to the module frame must be connected to the “normally
open” valve port. The other cylinder port (with the flow control valve) must be connected to the “normally closed” valve port.
10. Close the press guard.
11. Remove the crimp module by reversing the previous steps. When storing the crimp module, always leave a strip of terminals in the module on the anvils to prevent damage to the tooling. See Section 3.5 Storage.
Punch and Anvil Alignments
Note: Always clean mounting surfaces of crimp tooling
and tooling holders prior to alignment.
1. Disconnect power from the press and open the machine guard.
2. Using a 5/32” hex wrench, slightly loosen the anvil mounting screw. See Figure 2-3.
3. Slowly hand-cycle the ram of the press to bottom of its stroke. With the punches engaging the anvils, securely tighten the anvil mounting screw to ensure alignment of punches and anvils.
4. Hand cycle the press ram to its up position.
5. Close the machine guard and restore power to the press.
ANVIL
LOOSEN THE
#10 SHCS
Figure 2-3
2.3. Crimp Height Adjustments
Conductor Crimp Height Adjustment
1. Obtain a piece of solder, approximately 40mm (1.5”) long and approximately 0.5mm (.02”) larger in diameter than the crimped slug height. If the solder
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diameter is too large the crimped slug will have large extrusions, making it difficult to measure the overall slug height.
2. With no terminals in the applicator, lay the solder across the anvils and cycle the press (by hand or under power).
3. Using a crimp micrometer or dial caliper, measure the solder slug height and compare to specification.
4. If adjustments are necessary, turn off the press and open the machine guard.
5. The conductor crimp height is based on the conductor punch contacting the conductor anvil. If the press shut height was correctly set prior to crimp module installation (see section 2.1) there should be no need to adjust conductor crimp height. However, some of the larger terminal crimps may cause minor press frame deflection which can be compensated by adjusting the press shut height. See section 2.1 for shut height adjustment.
NOTE: Crimp height adjustments for closed-barrel industrial terminals are always based on solder slug heights, not terminal crimp heights.
1. Load the terminals, close the machine guard, and crimp several wires under power.
2. Perform a pull test on the conductor crimp to verify the mechanical integrity of the crimp. See Appendix A-Pull Force Test.
Insulation Crimp Height
1. Place a stripped length of the appropriate wire into the terminal and crimp under power.
2. Observe quality of insulation crimp.
3. If adjustments are necessary, turn off the press. Open the machine guard.
4. Using a 5/32” hex wrench, loosen the #10 SHCS holding the punches.
5. Rotate the insulation adjusting cam to achieve the desired insulation height. There are three cam positions (marked L, M, and S) for large, medium, and small diameter wires. The cam must be in one of the three positions; do not adjust it between positions. See Figure 2-4.
6. While holding the punches up against the punch holder, securely tighten the #10 SHCS.
7. Close the machine guards, restore power, and crimp a wire under power. Inspect the insulation crimp and make further adjustments if needed.
INSULATION CAM
LOOSEN THE
#10 SHCS
PUNCHES
Figure 2-4
Note: Due to the large variety of insulation wall
thickness, materials, and durometers, Molex does not specify insulation crimp height.
2.4. Crimp Tooling Removal and Installation
Caution: Always disconnect power before installing or
removing tooling.
Removal and Installation of ATP-301 Style Punches
NOTE: Always clean mounting surfaces of crimp tooling
and tooling holders prior to installation.
PUNCH HOLDER
O-RING
PUNCHES
#10 SHCS
Figure 2-5
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TM-3000 and TM-4000 Universal Press
1. Disconnect power from the press. Open the machine guard.
2. If the ram is down, move it manually to the full up position.
3. To remove the punches, use a 5/32” hex wrench to remove the #10 SHCS holding the punches to the punch holder. See Figure 2-5.
4. Remove the screw, punches, and O-ring together. Some tool kits may include a spacer plate (behind the conductor punch).
5. To install, place the punches with the spacer (if used) and O-ring against the punch holder and securely tighten the #10 SHCS. The conductor punch (“E2”) goes against the punch holder and the insulation punch (“I2”) is stacked on the conductor punch. Make sure the etched “E2” or “I2” on each punch faces outward.
Note: The press should be hand-cycled after installing punches to insure a free fit between punch and anvil. If excessive resistance is felt, check for an incorrectly installed punch and/or anvil misalignment.
Removal and Installation of ATP-301 Style Anvils
ANVIL MOUNT
O-RING
ANVILS
NOTE THE SIDE
PLATE POSITION
Figure 2-6
#10 SHCS
NOTE: Always clean mounting surfaces of crimp tooling
and tooling holders prior to installation.
1. Disconnect power from the press. Open the machine guard.
2. If the ram is down, move it manually to the full up position.
3. To remove the anvils, use a 5/32” hex wrench to remove the #10 SHCS holding the anvils to the anvil mount. See Figure 2-6.
4. Remove the screw, anvils, and O-ring together. Some tool kits may include a spacer plate (behind the conductor anvil).
5. To install, place the anvils with the spacer (if used) and O-ring against the anvil mount, leaving the mounting screw slightly loose. The conductor anvil (“E1”) is installed first and the insulation anvil (“I1”) is stacked onto it. Make sure the etched “E1” or “I1”on each anvil face outward.
WARNING: Use the mounting screws that are furnished with the ATP tool kit. The feed mechanism may become damage when using screws that are too long.
6. The side plates must be a close fit to the width of the anvils. For the ATP-301 style anvils, the step on the side plates must be toward the outside. If it is not, loosen the M4 SHCS and reverse the side plate.
7. The anvils must be aligned to the punches before tightening the screws. See section 2.2 (Set Up; Punch and Anvil Alignments).
Removal and Installation of ATP-201 Style Punches
RAM
SET SCREW
VISIBLE IN
THE HOLE
RAM IN THE
FULL UP
POSITION
ATP-201
PUNCH
Figure 2-7
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TM-3000 and TM-4000 Universal Press
1. Disconnect power from the press. Open the machine guard.
2. If the ram is down, move it manually to the full up position.
3. To remove the punch assembly, use a 3mm hex wrench to loosen the set screw on the front of the ram. This screw is accessible through the module’s front cover. See Figure 2-7.
4. With the set screw loosened, pull the punch assembly straight down.
5. To install the punch assembly, orient the assembly so the flat on the round stub faces forward. Put the stub into the hole in the bottom of the ram and push the punch assembly up against the bottom of the ram. See Figure 2-8.
RAM
FLAT FACE
OF THE ATP-201
PUNCH FACING
FORWARD
Figure 2-8
6. With the punch assembly in the ram, tighten the set screw securely.
Note: The press should be hand-cycled after installing the punch assembly to insure a free fit between punch and anvil. If excessive resistance is felt, check for an incorrectly installed punch and/or anvil misalignment.
Removal and Installation of ATP-201 Style Anvils
NOTE: Always clean mounting surfaces of crimp tooling
and tooling holders prior to installation.
1. Disconnect power from the press. Open the machine guard.
2. If the ram is down, move it manually to the full up position.
3. To remove the anvils, use a 5/32” hex wrench to remove the #10 SHCS holding the anvils to the anvil mount. See Figure 2-9.
ANVIL MOUNT
O-RING
ANVIL
NOTE THE SIDE
PLATE POSITION
Figure 2-9
#10 SHCS
4. Remove the screw, anvil(s), and O-ring together.
5. To install, place the anvil(s) and O-ring against the anvil mount, leaving the mounting screw slightly loose. The conductor anvil (“E1”) is installed first and the insulation anvil (“I1”) is stacked onto it. Make sure the etched “E1” or “I1”on each anvil face outward.
WARNING: Use the mounting screws that are furnished with the ATP tool kit. Screws that are to long may damage the feed mechanism.
6. The side plates must be a close fit to the width of the anvils. For the ATP-201 style anvils, the step on the side plates must be toward the inside. If it is not, loosen the M4 SHCS and reverse the side plate.
7. The anvils must be aligned to the punches before tightening the screws. See section 2.2 (Set Up; Punch and Anvil Alignments).
2.5. Crimp Module Adjustments
Terminal Feed Adjustments
The tape feed mechanism is a ratcheting wheel and has no adjustable features.
Order No: TM-638017299 Release Date: 06-06-05 UNCONTROLLED COPY Page 44 of 47 Revision: D Revision Date: 12-0-02-09
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TM-3000 and TM-4000 Universal Press
Feed Speed Adjustments
Terminal feed speed is controlled by the flow control valve on the feed cylinder. Loosen the locking ring, then turn the adjustment knob clockwise (CW) to reduce the feed speed or counterclockwise (CCW) to increase the feed speed. See Figure 2-10. Adjustments to the feed speed should be made gradually. When adjustment is complete, turn the locking ring until it is finger-tight.
KNOB
LOCKING
RING
Figure 2-10
FEED
CYLINDER
Terminal Stripper Adjustment
ADJUST
M5 SHCS
M5 SHCS
Figure 2-11
ADJUST
Some terminals have a tendency to stick in the conductor punch after being crimped. The terminal stripper is used to shed the terminal away from the retracting punches.
1. Disconnect power from the press. Open the machine guard.
2. If the ram is down, move it manually to the full up position.
3. To adjust the stripper in and out, use a 4mm hex wrench to loosen the M5 SHCS on the side of the stripper. Move the stripper toward the punches, but not too close or it could interfere with the ram stroke. See Figure 2-11. Tighten the M5 SHCS when adjustment is complete.
4. To adjust the stripper up and down, use a 4mm hex wrench to loosen the M5 SHCS on the front of the stripper. Move the stripper down until it is just above the taped terminal on the anvils. See Figure 2-11. Tighten the M5 SHCS when adjustment is complete. NOTE: If the stripper is adjusted down too far it may interfere with the terminal feed motion.
Wire Stop Adjustment
The wire stop is used when the terminal being crimped does not have an internal wire stop tab. Some larger ring terminals fall into this category.
M5 SHCS
ADJUST
WIRE STOP
TERMINAL
Figure 2-12
Order No: TM-638017299 Release Date: 06-06-05 UNCONTROLLED COPY Page 45 of 47 Revision: D Revision Date: 12-0-02-09
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TM-3000 and TM-4000 Universal Press
ON ANVIL
1. Disconnect power from the press. Open the machine guard.
2. If the ram is down, move it manually to the full up position.
3. To adjust the wire stop, loosen the M5 SHCS on the side of the stripper. Move the wire stop in or out until it is near the end of the terminal barrel. See Figure 2-12. Tighten the M5 SHCS when adjustment is complete.
NOTE: Since they are mounted to the same block, adjustments to the wire stop will also influence the terminal stripper. To achieve full adjustment of the wire stop, the stripping tool may need to be removed from the block.
2.6 Operation
Loading and Unloading Tape
1. Applicable terminals are listed on the Crimp Tooling
Specification Sheet. Do not crimp terminals that are not listed on the Specification Sheet.
2. Disconnect power from the press. Open the machine
guard.
3. The tape will be easier to “start” in the track if the
corner of the tape is trimmed as shown in Figure 2-13.
4. Open the tape track cover by pulling out the spring-
loaded knob and lifting the cover up. A hole is provided in the module frame for the knob’s pin to enter to hold the track cover open. See Figure 2-14.
5. Load the taped terminal strip from the front of the
module, engaging the slots in the tape with the teeth on the feed wheel. Make sure the terminal is also centered above the crimp anvils. See Figure 2-15.
TRIM THE CORNER
OF THE TAPE
Figure 2-13
HOLE
TRACK COVER
LIFT KNOB UP
TRACK
COVER CLOSED
PULL KNOB OUT
Figure 2-14
6. Pull out the spring-loaded knob and lower the track cover, allowing the pin to engage the lower hole.
7. Unloading the tape is the reverse process.
TAPE SLOT
TERMINAL
Figure 2-15
Tape De-Reeling Information
The tape reel should be mounted on the reel arm of the press, with the printed side of the reel facing the operator. The tape de-reels counterclockwise (CCW).
To prevent tape feed jams, the tape should enter the press guard below the bottom horizontal bar. If the tape is threaded between the bars, a terminal may become snagged on the bar during feeding. See Figure 2-16.
TERMINAL
Order No: TM-638017299 Release Date: 06-06-05 UNCONTROLLED COPY Page 46 of 47 Revision: D Revision Date: 12-0-02-09
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TM-3000 and TM-4000 Universal Press
While operating the crimp module, the tape entering the press should not become taut. The operator should occasionally turn the terminal reel to maintain a slack loop.
The scrap tape exits below the press guard.
Removal of Crimped Terminals from Tape
After being crimped, the tape feed will advance the terminal one position to the right. It is the operator’s responsibility to remove the crimped terminal from the tape.
If crimped wires are allowed to accumulate on the tape they will eventually cause a tape feed jam.
To prevent tape damage, the terminal should be pulled off the tape towards the operator’s right. This sideways action makes it easier for the terminal to break free from the adhesive holding it to the tape.
TAPE REEL
TAPE ENTERS
BELOW GUARD
TAPE EXIT
Figure 2-16
Order No: TM-638017299 Release Date: 06-06-05 UNCONTROLLED COPY Page 47 of 47 Revision: D Revision Date: 12-0-02-09
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