molex TM42, TM40 User Manual

Use In TM42, TM40, Base Unit Adapter
Molex Terminator
Description • Operation • Maintenance
DOC No 638500090
Release Date 99/07/01
Revision Date 99/07/01
WARNING
NEVER USE THIS TERMINATOR IN A PRESS WITHOUT GUARDS OR SAFETY DEVICES THAT
ARE INTENDED TO PREVENT INJURY. THE TERMINATOR IS SUPPLIED WITHOUT GUARDS. PLEASE USE GUARDS SUPPLIED WITH THE PRESS. RUNNING THE PRESS WITHOUT GUARDS UNDER ANY CIRCUMSTANCES CAN CAUSE SERIOUS INJURY.
NEVER INSTALL, OPERATE ADJUST, OR SERVICE THIS TERMINATOR WITHOUT PROPER IN-
STRUCTION AND WITHOUT FIRST READING AND UNDERSTANDING THE INSTRUC­TIONS IN THIS MANUAL AND THE TM42 PRESS, TM40 PRESS, OR 3BF WITH BASE UNIT ADAPTER MANUALS.
NEVER INSTALL, REMOVE OR SERVICE TERMINATOR TOOLING WHILE THE FLYWHEEL IS IN
MOTION OR POWER CONNECTED TO THE PRESS.
NEVER INSTALL, REMOVE OR SERVICE THE TERMINATOR TOOLING WITHOUT MANUALLY
CYCLING THE PRESS TO VERIFY THAT THE CLUTCH CONTROL IS IN THE LOCKED PO­SITION PAST TOP DEAD CENTER, BLOCK THE RAM IN THE UP POSITION IF A DEFEC­TIVE CLUTCH IS SUSPECTED.
CAUTION THE PRESS SHOULD ALWAYS BE HAND CYCLED WITH THE TERMINATOR INSTALLED
PRIOR TO RUNNING PRODUCTION. THIS PROCEDURE WILL PREVENT DAMAGE OR REDUCE TOOL WEAR.
WORK SAFELY AT ALL TIMES
FOR SERVICE
CONTACT YOUR LOCAL SALES OFFICE
APPLICATION TOOLING GROUP
1150 DIEHL ROAD,
NAPERVILLE, ILLINOIS 60563
PH: (630) 969-4550
FAX: (630) 505-0049
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Molex Terminator
Table of Contents
Section
1. General Description
2. Installation - Setup - Operation
3. Maintenance
Appendix
A. Terminator Types & T2 Assembly Drawing B. Crimp Definitions C. Statistical Process Control (Summary)
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SECTION 1
General Description
Page
1.1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Technical Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4 Delivery Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.5 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
1.6 Safety & Work Area Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
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Molex Presses and Adapters
For “T” or “T2” Style Terminators
TM42 Press
ISO Metric.
Flexible external light.
Resettable counter.
1.5” Stroke.
TM40 Press
Internal Light.
Non resettable counter.
1.0” Stroke.
Base Unit Adapter
Allows 3BF press to run Terminator style tooling.
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General Description
1.1 Description
The Molex Terminator is an easy to use tool for the termination of a variety of Molex crimp terminals. Production flexibility is obtained through the use of simple interchangeable tooling. The tooling is inexpensive, and unlike a modular applicator, all crimp height and terminal feed adjustments are located in the press. The terminator die can be installed in the TM42, TM40 presses or Base Unit adaptor, and is ideally suited for mid-volume bench operation.
The Molex T2 terminator is the newer version tool that allows for track adjustment. It contains the identical perishable tooling as the Molex FineAdjust applicator. (Center carrier excluded)
1.2 Features
Flexible and inexpensive.
Enhanced crimping productivity.
Simple installation.
Quick release punches.
T2 terminator has standardized tooling with Molex FineAdjust Applicator.
Track Adjustment capabilities in the T2 terminators for improved control of the bellmouth size and cutoff
tab length.
1.3 Technical Specifications Dimensions
Width - 127.0 mm (5.0”) Depth - 44.0 mm (1.8”) Height - 25.0 mm (1”) Weight - 1.4 kg (3.0 lbs)
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1.4 Delivery Check
Terminator 1 Sample crimped terminals 5 Manual 1 Setup & Specification Documents 1
1.5 Tools
The following tools are recommended for setup and adjustments of the terminator tool.
1. Metric Allen Set
2. English Allen Set (for older terminator tools)
3. Large and Small Screwdriver
4. Cresent Wrench
5. Pliers (needle nose)
6. Crimp Micrometer
7. Eye Loop (10x)
8. Wire Stripper/Cutter
Qty
1.6 Safety & Work Area Check
Check that the crimping position is ergonomic for the operator’s size. A bench height of 762 to 813 mm (30 to 32 inches) will provide operator comfort, and allow both feet to rest on the ground. The foot pedal should be positioned for ease of reach.
Check that the press position is located paralleled and approximately 150 mm (6 inches) from the edge of the table. A chair or stool, with adjustable height and backrest should be provided for maximum comfort and back support to the operator. Adjust press light to give appropriate visibility to the work area.
Check that the operators and observers are wearing approved safety goggles when the press is in operation and/or service.
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SECTION 2
Setup And Operation
Page
2.1 Terminator Die Installation and Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Loading the Terminal Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3 Manually Cycling the Press. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.4 Punch and Anvil Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.5 Feed Finger Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.6 Forward and Back Feed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.7 Conductor Crimp Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.8 Insulation Crimp Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.9 Final Check and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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Ram
10-32 x 3/8 Lg. B.H.C.S.
Front Striker
Left Locating Plate
Punch Release Pin
Conductor Punch
Insulation Punch
T2 Terminator Base
M6 x 20 Lg. S.H.C.S.
Right Locating Plate
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Bolster
TERMINATOR INSTALLATION
Fig. 1
Terminator Die Installation & Removal
CAUTION
Always power down the press when installing or removing Molex tooling by pressing the emergency stop button located on the front panel.
STEPS
(Ref. Fig. 1)
1. Remove Press guard. (Ref. Press or Base Unit manual.)
2. Confirm that the Terminator is correct for the specified product. (Ref. Specification sheets supplied with the Terminator.)
3. Make sure all the tooling from a previous setup is removed. (See Step 11.)
4. Load all top tooling first, starting with the rear striker. (See Fig. 16.)
5. Pull on punch release pin to install punches into the punch cavity.
6. Finish with front striker (if specified). Confirm that all components follow assembly drawing sequence.
7. Clean bolster plate of scrap or chips that may interfere with the Terminator base installation.
8. Remove 6 mm S.H.C.S (TM42) and lift the right locating plate from the bolster.
9. Place the Terminator base on the bolster plate and slide to the left. The slot in the base will locate on the left guide block
10. Replace the right locating plate and tighten 6 mm screw.
11. To remove the Terminator reverse the above steps.
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Terminal Strip Feeding
Drag Frame
Drag Cam
Rotate Drag Cam Either Direction to Raise or to Lower Drag Frame
Lift the Feed Finger Up
First Terminal Above Anvils
"T2" Style
Drag Finger / Anti-Back Up Finger
Terminal Strip Feeding
Lift up to Feed Terminal Strip Release to Apply Drag on Terminal Strip
First Terminal Above Anvils
"T" Style
LOADING THE TERMINAL STRIP
Fig. 2
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Loading The Terminal Strip
Note
Terminator Drag mechanism may vary on product selection or Terminator type.
Steps
(Ref. Fig. 2)
1. Confirm terminal part number matches the terminator specification sheet.
2. Install the terminal reel on the press reel holder.
3. Raise the drag plate (T2) and slide the terminal strip under both the cover plate and the drag plate.
4. For other T style Terminators, raise the drag finger and anti backup finger.
5. Ease the terminal strip forward until the first terminal on the strip is sitting on the anvils.
6. If severe resistance is encountered or the terminal strip does not fit, you may need to make a cover plate adjustment.
Removing The Terminal Strip
Steps
1. Raise Terminal Drag plate or T style drag finger and anti backup finger.
2. Lift the Feed Finger from the carrier strip
3. Gently pull on the terminal strip until it has exited the track.
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