molex 57030-3000 Operation and maintenance manual

INSTRUCTION FOR OPERATION AND ADJUSTMENT OF
MODULAR CRIMP DIE
1980, JAN 1.
2015,May 25
A
INSTRUCTION SHEET NO.
IS-0006E
ISSUED DATE
REVISED DATE
REV
JM
××××
A
57×××－3000
MODEL NO.
MODEL NO.57030-3000

--*For the Safety Operation *--
Do not start your Modular Crimp Die until you have read and
acquainted yourself with these instruction!
Safety cover should be mounted in proper manner for
crimping operation.

CONTENTS
1.DESCRIPTION -------------------------------------------------------------------------------------- 2.
2. MECHANISM AND ADJUSTMENT -------------------------------------------------------------- 2.
2-1. CONDUCTOR CRIMP HEIGHT ADJUSTMENT MECHANISM -------------------------- 2.
2-2. INSULATION CRIMP HEIGHT ADJUSTMENT MECHANISM -------------------------- 2.
2-3. FEED LENGTH ADJUSTMENT MECHANISM -------------------------------------- 3.
2-4. FEED PAWL FINGER LOCATION ADJUSTMENT MECHANISM -------------- 5.
2-5. BELL MOUTH,CUT-OFF TAB ADJUSTMENT MECHANISM -------------------------- 5.
3. TO MOUNT MODULAR CRIMP DIE TO CRIMPING MACHINE Ml5A -------------- 7.
4. REPLACEMENT OR MOUNTING PROCEDURE FOR PERISHABLE PARTS -- 8.
5. MATTERS To BE ATTENDED TO ------------------------------------------------------------ 10.
6. DAILY MAINTENANCE ------------------------------------------------------------------------ 11
7. TRQURLE SHQQTING ------------------------------------------------------------------------ 12.
8. CRIMPING PROCEDURE FOR THE SAME SERIES TERMINAL ------------------------ 12.
9. ASSEMBLY DIAGRAM OF MODULAR CRIMP DIE AND PARTS LIST ------------ 13.

l. Description.
Molex Japan Modular Crimp Die is designed and developed to save time,
Money and man-hour for crimping operation as well as to make precise
termination.
It is very easy to mount on/or remove from the Crimping Machine M15A,
Therefore versatile Crimping are possible to possess several Modular Dies.
It has may special features to save time as undermentioned.
(See photo l.)
1—1. One-touch selection mechanism for conductor crimp height.
1—2. One-touch selection mechanism for insulation crimp height.
1—3. Easy adjustment for feed length.
1—4. Easy adjustment for feed finger location.
We are confident that Molex Modular Crimp Dies have
made major contributions to our Customers’ cost reduction efforts.
2. Mechanism and Adjustment
2—l. Conductor crimp height adjustment mechanism.
Conductor crimp height is able to select for wire size to be used
by "one-touch" under the conditions of Crimping machine shut
height is adjusted to specified height.
Procedure: (gee illustration l.)
l—Confirm wire size to be used.
2—Select suitable crimp height in the mark of A, B, C, or D.
(Crimp height specifications are shown in Name plate, Parts list
or Crimping Specifications.)
—2—
[PHOTO-1]

3 —Push Adjust Rod ⑫by a screw driver until Pin (61) Provided on
Adjust Rod is come off from Identification Plate ⑪
4—Turn Adjust Rod to the mark selected by paragraph 2 and release
it so Adjust Rod is pushed back by Spring (58) to seat pin (61) in the
selected mark position, Then selected crimp height is to obtained.
5—Confirm pin (61) is in the selected mark position.
Constituent Components
MODEL NO.
DESCRIPTION
ITEM NO.
J5877-***
J5870-003
J5876-***
J5870-004
J5822-021
J5811-014
WIRE CRIMP HIGHT ADJUST ROD
HOLDER BLOCK
IDENTIFICATION PLATE
COVER PLATE
COMPRESSION SPRING
SPRING PIN
(12)
(7)
(11)
(8)
(58)
(61)
2—2. Insulation Crimp Height Adjustment Mechanism.
This mechanism is designed to obtain crimp heights in eight (8) steps.
Procedure: (See Illustration 2.)
1—Pul1 Insulation Crimp Height Adjust Rod (13) by fingers until it is
come off from cavity of the Rem (3).
—3—
(58)
(8)
(12)
(61)
(7)
(11)

2—Turn Adjust Rod (13) to align selected number to Indication mark
(See illustration 2) and release it.
3—Adjust Rod (13) is pulled back by Compression Spring (57) , and fallen
into cavity of Ram. Then selected insulation crimp height is to be obtained,
4—Confirm Adjust Rod is properly fallen into the cavity of Ram.
Normal position is known as the front surface of Adjust Rod and
the surface of Identification plate are approximately aligned.
Constituent Components:
MODEL NO.
DESCRIPTION
ITEM NO.
J5880-***
INS. CRIMP HIGHT ADJUST ROD
(13)
J5870-005
RAM
(9)
J5822-020
COMPRESSION SPRING
(57)
2—3. Feed Length Adjustment Mechanism.
This Mechanism is designed to adjust the feed length easily
according to the terminal types having different feed length.
Procedure: (See photo 2.)
1—Adjustment should be performed by manual operation, after
modular die is mounted on the crimping machine. Fine adjustment
may be performed in the automatic operation, after completion of
manual adjustment.
2—loosen Lock Bolt (80) so that feed length Adjust Rod (39) is able to
turn by a screw driver. Turn Adjust Rod (39) clockwise, then feed
finger (55) is shifted to left with feed length is increased. In the
opposite direction, turn it counter-clockwise, then feed length is
decreased.
—4—
(57)
(9)
(13)

3—Performing this adjustment, feed finger location may be shifted,
therefore adjustment of feed finger location should be performed
afterwards. After completion of adjustment, tighten Lock Bolt (80).
4—Confirm feed length by 2—3 times manual operation.
Note: For the manner by manual operation, please refer to Manual
Operation Procedure described in Crimping Machine
instructions.
5—Confirm feed length by 2-5 times automatic operation.
2—4. Feed pawl finger location adjustment mechanism.
This mechanism is designed to locate terminal properly in the
center of the anvil.
Procedure: (See photo 3.)
1—Loosed Lock Nut (92)
2—Turn Adjust Screw (68) counter-clockwise, then feed finger (55) is
shifted to left, and turn it clockwise, then feed finger is shifted to
right.
3—Turn Adjust Screw (68) so that the center of terminal is located at
the center of Anvil (4) properly.
Tighten Lock Nut (82) after completion of adjustment.
4—Confirm terminal is fed in the correct location by 2-3 times
manual operation. Fine adjustment may be performed by 2-5
times automatic operation.
2—5. Bell Mouth, Cut-off Tab Adjustment Mechanism.
Length of bell mouth and cut-off cab are adjusted by this
mechanism at the same time.
—5—
(68)
(68)
(68)
(82)
(55)

Procedure: (See illustration?)
1—Loosen Lock Bolt (88) provided on the Block (26).
2—Turn Adjust Rod (28) provided on the Block (26). Then terminal strip
guide assembly is shifted back and forth.
TURN TO
LENGTH OF
BELL MOUTH
LENGTH OF
CUT-OFF
TERMINAL
SHIFTED TO
CLOCKWISE
INCREASE
DECREASE
BACK SIDE
COUNTOR-
CLOCKWISE
DECREASE
INCREASE
FRONT SIDE
3—Turn Adjust Rod (28) so that length of bell mouth and cut-off tab
are in the specified dimensions described in the crimping
specifications.
4—Tighten Lock Bolt lightly. (so that adjust rod is able to turn by a
screw driver.)
5—Mount Modular crimp die on crimping machine, (power switch
should be turned off.)
6—As a test, crimp wire onto terminal by manual operation.
7—If the length of bell mouth and cut-off tab are adjusted properly,
remove modular die from crimping machine, and tighten lock bolt
(88) securely.
8—Mount modular die on crimping machine again, and crimp terminal
2—3 times for the final confirmation.
At the paragraph 7, if it is not adjusted properly, turn adjust rod
(28) again for readjustment.
Note: In this case, if the Lock Bolt (88) is over-tightened, adjust rod is
not able to turn. Then modular die has to be removed from
crimping machine to tighten lock bolt again according to
paragraph 4.
—6—
(88)
(28)
(25)

3. To mount Modular Crimp Die to Crimping Machine M15A
Modular dies are designed to mount on/or remove from crimping machine
M15A very easily.
Procedure;
1—A hanging hook is provided on the ram of crimping machine, Hang
Holder Block of Modular crimp die on this hook.
2—Pull down Modular Die toward Bolster. Gear Base Plate Groove of
Modular die to Locator Block.
3—Tighten Clamp Bolt with pushing Modular die toward Locator Block.
4—Confirm Modular die is held securely by Clamp Plate.
After mounting, crimping machine may be operated 2—3 times by
manual operation for checking abnormal operation of modular die.
*Mounting Procedure, in case of the Bolster is removed from the base of
crimping machine.
1—Adjust the Ram position of crimping machine so that ram shut
height is in the highest position.
2—Mount Modular crimp die mounted on bolster on the bed of
crimping machine.
3—Place nodular crimp die mounted on bolster on the bed of crimping
machine. And Hang Holder Block of modular die on the Hook provided
on Ram of crimping machine.
4—Move modular die mounted on bolster so that Holder block is
located in the center of Hook in all directions.
5—Tighten Clamp Plate Bolt to fix Bolster to Bed of crimping machine.
—7—

*Conductor crimp height adjustment
This adjustment may be applied in case of modular die is replaced, of
specified crimp height is not obtained on normal crimping operation.
1—Select proper conductor crimp height mark [A, B, C or D] for
wire size to be used.
2—Check interference between punch and anvil by manual operation.
3—Feed terminal, to be crimped, on the anvil of Modular crimp die by
manual operation.
5—Adjust conductor crimp adjusting mechanism provided on crimping
machine so that conductor crimp height is in the specified value.
6—Confirm crimp height by 2-3times automatic crimping operation.
Note: For the adjusting method of conductor crimp height by
crimping machine, please refer to instruction manual for
Crimping Machine M15A.
4. Replacement or Mounting Procedure for Perishable Parts.
*For the Perishable Parts of Modular Crimp Die, please refer to Parts List.
*Replacement of the perishable Parts should be performed after Modular Die
is removed from the crimping machine.
4—l. Replacement of Anvil
1—Remove Mounting Bolt (88) for Anvil (4) located under Base Plate,
then Anvil (4) is to be removed.
2—Clean up inside of a groove where the anvil is set into.
3—Replace with new anvil with tightening mounting bolt (88).
Note: Do not make mistake for front and back side of Anvil.
4—Confirm interference between punch and anvil to move down ram
slowly.
—8—

4—2. Replacement of conductor punch of insulation punch.
l—Pu1l out Ram assembly. —Take off tip of feed finger from the hole
of the carrier, and pull fully to anvil direction. Then Ram
assembly is able to remove from body very easily.
2—Remove mounting volt (77) to remove punches.
3—Remove with new punches, —In order to prevent mismounting of
conductor punch, a dent is provided on it to mate should be
mounted in the regular order.
4—Tighten mounting bolt lightly.
5—Put Ram into the body Follow paragraph 1, so it easy to put
Ram into the body.
6—Place a sheet of paper (0.1 mm thick, approximate 1 cm X 1 cm)
on the anvil.
7—Move Ram down slowly by manual operation until ram is stopped
so that the paper is put between punch and anvil. Tighten
mounting bolt (77) with pushing ram lightly. In this manner, center of punch
and anvil are property aligned, and punches are mounted without
a gap on ram.
8—Move Ram 2 —3 times up and down and check if it is moved
smoothly for confirmation.
－9－

4－3. Replacement of Floating Shear and Holder.
1—A pair of mounting bolt (74) are placed under the base plate.
Remove these bolts, then Holder (6) is to remove together with
Floating Shear (5) and Spring. (In order to replace Floating Shear
only, loosen the bolt provided on Holder).
2—Replace with new parts.
3—Mount Floating Shear, Holder and Spring. Holder is tightened by
Mounting bolts (74) lightly, and then pushed tightly toward anvil for
the final mounting to tighten bolts securely.
4—Confirmation-Push Floating Shear down by fingers and release.
Confirm if it is pushed back by spring. If not, holder may be
pushed too much toward anvil direction, therefore try again to
mount holder.
(Note 1) If the Floating Shear is mounted as a gap is existed. between
anvil, then crimped terminal if it has excessive burr or not.
(Note 2) For the replacement of parts, please clean up parts and
Mounting surfaces before mounting.
(Note 3) Please keep and maintain Perishable Parts with applying a rust
preventive oil. And take great care in handling parts to prevent
from making a crack on them.
5. Matters to be attended to.
1—Adjustment or Replacement should be performed with the press
Motor power turned off condition for safety.
2—Please keep and maintain an extra set of Perishable Parts for
modular die in your factory.
－10－

3—It' it is need to use special with, Please contact our Field Service
department on details.
4—Please keep and maintain Modular Dies removed from the crimping
machine with inserting applicable terminal between punch and anvil,
for preventing from interference between punch and anvil.
5—Please Clean out any grit, dirt or foreign matter from the parts and
area where parts may be mounted, in case of replacement of
perishable parts.
6. Daily maintenance.
6—1. Check worn-out, broken, rusty or cracked parts before starting
crimping operation.
6—2. Lubricate all moving parts with superior grease or machine oil.
Note: D0 not attach oil or grease to the terminal in lubrication.
6—3. Check loosen bolt on the followings.
1—Anvil mounting bolt (83)
2—Holder mounting bolt (74)
3—Feed finger mounting bolt (75)
4—Punches mounting bolt (77)
5—Lock Bolt (80) for feed length adjust rod.
6—Wire stopper mounting bolt (88)
6—4. Clean out any grit or dirt
6—5. Check and confirm conductor crimp height and wire size before
crimping operation.
—11—

7. Trouble Shooting.
Trouble
Check point
Measures
1.Irregular Feeding
1.Feed finger mounting bolt
To tighten securely
2.Lock Bolt for feed length
adjust-rod.
To tighten securely
2. Terminals are not able to
feed
1.Top of feed finger is off from
hole of carrier.
To correct
2.Feed finger does not move
To contact Molex-Japan Field
Service Department
3.Worn-our Spring
To replace
8. Crimping procedure for the same series terminal.
Molex Japan Modular Crimp Die is applicable to crimp the same series
terminal with replacing applicable parts.
For the applicable parts, please refer to the Parts List on each modular
die respectively please refer to the following paragraphs for replacement
procedure.
*Conductor crimp height adjusting mechanism.
(Parts to be replaced—J5877—***)
*Insulation crimp height adjusting mechanism.
(Parts to be replaced—J588O—***)
*Perishable Parts replacement procedure.
(Parts to be replaced—Perishable parts.)
*For mounting method on full automatic crimping machine, Please contact
Molex Japan Application Tooling. (Tel.[phone])
—12—

If you have any further questions
on Molex Japan Modular Crimp Die,
please contact our Field Service.
ISSUED BY : ENGINEERING
DEPT.
MOLEX-JAPAN
1995. 5.
？

Molex Japan LLC
1-5-4 Fukami-Higashi
Yamato, Kanagawa
Japan 242-8585
Direct +81.46.265.2322
Fax [phone]