molex TM-3000, TM-4000 Instruction Manual
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
Order No.63801-7299
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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Revision: D Revision Date: 12-0-02-09
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
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
Order No: TM-638017299 Release Date: 06-06-05 UNCONTROLLED COPY Page 3 of 47
Revision: D Revision Date: 12-0-02-09
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
Order No: TM-638017299 Release Date: 06-06-05 UNCONTROLLED COPY Page 4 of 47
Revision: D Revision Date: 12-0-02-09
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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Revision: D Revision Date: 12-0-02-09
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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Revision: D Revision Date: 12-0-02-09
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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Revision: D Revision Date: 12-0-02-09
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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Revision: D Revision Date: 12-0-02-09
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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Revision: D Revision Date: 12-0-02-09
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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Revision: D Revision Date: 12-0-02-09
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
Order No: TM-638017299 Release Date: 06-06-05 UNCONTROLLED COPY Page 11 of 47
Revision: D Revision Date: 12-0-02-09
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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Revision: D Revision Date: 12-0-02-09
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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Revision: D Revision Date: 12-0-02-09
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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Revision: D Revision Date: 12-0-02-09
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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Revision: D Revision Date: 12-0-02-09
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