molex 63801-8500 User manual

Distributor of Molex Connector Corporation: Excellent Integrated System Limited
Datasheet of 0638018500 - T2 & TERMINATOR CRIMP MODULE
Contact us: [email protected] Website: www.integrated-circuit.com
Excellent Integrated System Limited
Excellent Integrated System Limited
Stocking Distributor
Stocking Distributor
Click to view price, real time Inventory, Delivery & Lifecycle Information:
Click to view price, real time Inventory, Delivery & Lifecycle Information:
Molex Connector Corporation
Molex Connector Corporation
0638018500
0638018500
For any questions, you can email us directly:
For any questions, you can email us directly:
[email protected]
[email protected]
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Distributor of Molex Connector Corporation: Excellent Integrated System Limited
Datasheet of 0638018500 - T2 & TERMINATOR CRIMP MODULE
Contact us: [email protected] Website: www.integrated-circuit.com
T2 and Terminator Crimp Module
Doc. No: TM-638018500 Release Date: 11-26-12 UNCONTROLLED COPY age 1 of 39
Revision: A Revision Date: 11-26-12
T2™ and Terminator Crimp Module
6380 -8500
Instruction Manual
 Description
 Operation
 Maintenance
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Distributor of Molex Connector Corporation: Excellent Integrated System Limited
Datasheet of 0638018500 - T2 & TERMINATOR CRIMP MODULE
Contact us: [email protected] Website: www.integrated-circuit.com
T2 and Terminator Crimp Module
Doc. No: TM-638018500 Release Date: 11-26-12 UNCONTROLLED COPY age 2 of 39
Revision: A Revision Date: 11-26-12
Table of Contents
Contents
T2™ and Terminator Crimp Module ......................................................................................................................................................... 1
Safety Warnings and Information.............................................................................................................................................................. 4
Tooling Technical Assistance ................................................................................................................................................................... 5
rincipal Mechanical arts of the Crimp Module ...................................................................................................................................... 6
Section 1 ............................................................................................................................................................................................... 7
General Description ......................................................................................................................................................................... 7
1.1 ....... Description .......................................................................................................................................................................... 7
1.2 ....... Features .............................................................................................................................................................................. 7
1.3 ....... Technical Specification ....................................................................................................................................................... 7
1.4 ....... Delivery Check .................................................................................................................................................................... 7
1.5 ....... Crimp Tooling Accessories (optional) ................................................................................................................................. 7
1.6 ....... Tools ................................................................................................................................................................................... 7
1.7 ....... Application Tooling Specification Sheets ............................................................................................................................ 7
Section 2 ............................................................................................................................................................................................... 9
Set-Up and Operation ...................................................................................................................................................................... 9
2.1 ....... Shut Height ......................................................................................................................................................................... 9
2.2 ....... How to Manually Cycle the ress ..................................................................................................................................... 10
2.3 ....... Crimp Module Installation and Removal ........................................................................................................................... 10
2.4 ....... Tool Set Removal and Installation .................................................................................................................................... 11
2.5 ....... A Quick Checklist rior To The First Crimp ...................................................................................................................... 13
2.6 ....... Conductor Crimp Height Adjustment ................................................................................................................................. 14
2.7 ....... Insulation Crimp Height Adjustment .................................................................................................................................. 14
Section 3 ............................................................................................................................................................................................. 15
Troubleshooting ............................................................................................................................................................................. 15
Section 4 ............................................................................................................................................................................................. 16
Adjustments ................................................................................................................................................................................... 16
4.1. ...... unch and Anvil Alignment ............................................................................................................................................... 16
4.2. ...... Wire Stop Adjustment ....................................................................................................................................................... 16
4.3 ....... Rear Cover Adjustments ................................................................................................................................................... 17
4.4 ....... Track osition Adjustment (T2 tools only) ......................................................................................................................... 18
4.5 ....... Feed Finger Alignment ...................................................................................................................................................... 18
4.7 ....... Terminal Forward Feed Adjustment (Centering the Terminal to the Anvils) ..................................................................... 20
4.8 ....... Back Stroke Feed Adjustments (Terminal pitch or spacing on the strip) ........................................................................... 20
4.9 ....... Crimp Tooling Installation and Removal ........................................................................................................................... 21
Section 5 ............................................................................................................................................................................................. 23
Maintenance .................................................................................................................................................................................. 23
5.1 ....... Cleaning ............................................................................................................................................................................ 23
5.2 ....... Lubrication ........................................................................................................................................................................ 23
5.3 ....... Spare arts ....................................................................................................................................................................... 24
5.4 ....... erishable arts ................................................................................................................................................................ 24
5.5 ....... Crimp Module Storage ...................................................................................................................................................... 25
Section 6 ............................................................................................................................................................................................. 26
6.1 ....... Main arts List .................................................................................................................................................................. 26
6.2 ....... Frame Assembly ............................................................................................................................................................... 28
6.2 ....... Feed Assembly ................................................................................................................................................................. 29
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Distributor of Molex Connector Corporation: Excellent Integrated System Limited
Datasheet of 0638018500 - T2 & TERMINATOR CRIMP MODULE
Contact us: [email protected] Website: www.integrated-circuit.com
T2 and Terminator Crimp Module
Doc. No: TM-638018500 Release Date: 11-26-12 UNCONTROLLED COPY age 3 of 39
Revision: A Revision Date: 11-26-12
6.2 ....... Ram Assembly .................................................................................................................................................................. 30
6.3 ....... Terminator Set-up ............................................................................................................................................................. 31
Typical T2 Tool Set – Front Carrier (Figure 6-5) ........................................................................................................................... 31
Typical T2 Tool Set – Dual Carrier (Figure 6-6) ............................................................................................................................. 32
Typical T2 Tool Set – Rear Carrier (Figure 6-7) ............................................................................................................................. 33
Typical Terminator Tool Set – Front Carrier (Figure 6-8) ............................................................................................................... 34
Typical Terminator Tool Set – Rear Carrier (Figure 6-9) ............................................................................................................... 35
Typical Terminator Tool Set – Dual Carrier (Figure 6-10) .............................................................................................................. 36
Typical Terminator Tool Set – Center Carrier (Figure 6- 11).......................................................................................................... 37
“T” Micro Terminal (Figure 6-12) .................................................................................................................................................... 38
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Distributor of Molex Connector Corporation: Excellent Integrated System Limited
Datasheet of 0638018500 - T2 & TERMINATOR CRIMP MODULE
Contact us: [email protected] Website: www.integrated-circuit.com
T2 and Terminator Crimp Module
Doc. No: TM-638018500 Release Date: 11-26-12 UNCONTROLLED COPY age 4 of 39
Revision: A Revision Date: 11-26-12
Safety Warnings and Information
Read and understand all of the instructions and safety information in this
manual before operating or servicing this equipment.
Keep this manual available when using this equipment.
Replacement manuals are available for download at www.molex.com.
SAFETY ALERT SYMBOL
This symbol is used to call your attention to hazards or unsafe practices which could result in an injury
or property damage. The signal word, defined below, indicates the severity of the hazard. The message
after the signal word provides information for preventing or avoiding the hazard.
DANGER
DANGER:
Indicates an imminently hazardous situation which, if not avoided, could result in death or serious injury.
WARNING
WARNING:
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
CAUTION:
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
CAUTION may also be used to alert against unsafe practices associated with events that could lead
to personal injury.
WARNING
WARNING
Always
we
ar proper eye protection when
Operating or servicing this equipment.
Failure to wear eye protection could result
in serious eye injury from flying debris.
Excessive noise levels.
Always wear proper ear protection when
Operating or servicing this equipment.
WARNING
WARNING
Never wear clothing or jewelery that is loose or
that could potentially enter the equipment
and get caught.
Failure to observe this warning could result in
severe injury or death.
Never
install or service the press
while
connected to any electrical power source.
Disconnect power by unplugging the press
from its power source.
Failure to observe this warning could result
In severe injury or death.
WARNING
WARNING
Never operate, service, install, or adjust this
equipment without proper instruction or without
first reading and understanding the instructions
in this manual and all applicable press manuals.
Always
hand cycle the
module
in the
press
to ensure the tooling is properly aligned.
Failure to observe these precautions may result
In injury or property damage.
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Distributor of Molex Connector Corporation: Excellent Integrated System Limited
Datasheet of 0638018500 - T2 & TERMINATOR CRIMP MODULE
Contact us: [email protected] Website: www.integrated-circuit.com
T2 and Terminator Crimp Module
Doc. No: TM-638018500 Release Date: 11-26-12 UNCONTROLLED COPY age 5 of 39
Revision: A Revision Date: 11-26-12
WARNING
WARNING
Never
use this
equipment
in a press or wire processing
machine without guards or safety devices that are
intended to prevent hands from remaining in the die space.
This equipment is supplied with no guards and is intended
to be used with the guards the press and/or
the wire processor.
Failure to observe this warning could result in severe
injury or death.
Do not use compressed air to clean
the equipment.
The forces created by compressed
air can force debris into the tool.
Failure to observe these precautions may
result in injury or property damage.
CAUTION
The Molex
Crimp Module is
designed to operate
ONLY in the TM
-
3000 and TM
-
4000 press
with standard shut height
at 135.80mm (5.346”).
Installation in crimp presses with other than standard shut heights can cause severe tool damage. Check the shut height of the
crimp press before operating the Crimp Module. Molex will not be liable for any damages as a result of installation in a crimp
press with nonstandard or improperly set shut height.
Failure to observe these precautions may result in injury or property damage.
CAUTION
Never
perform any service or maintenance other than as described in this manual.
Never modify, alter or misuse the equipment
Molex crimp specifications are valid only when used with Molex terminals, applicators and tooling.
Failure to observe this precaution may result in injury and property damage.
Tooling Technical Assistance
Molex offers tooling technical assistance for customers who may need some guidance for tooling adjustments. This support
can be obtained by calling either of the two numbers listed below and asking for the Molex Tooling Group.
Call Toll Free 1-800-786-6539 (US) 1-630-969-4550 (Global).
This assistance is limited to the operation and set-up of Molex application tools. Questions with regard to Molex connector
products or how to identify the proper tooling and/ or tooling documentation should be directed to your local Molex personnel
or Customer Service Representative.
When calling for service on the applicator it is recommended to have the following: a copy of the Tooling Manual, the specific
Application Tooling Specification and a person familiar with the application tool should be present. The following information
is also recommended to supply:
1. Customer name
2. Customer address
3. erson to contact such as (name, title, e-mail, and telephone number)
4. order number (Lease number also if applicable)
5. Serial number (Lease number also if applicable)
6. Molex Connector product order number
7. Urgency of request
8. Nature of problem
Molex Application Tooling Group
2200 Wellington Court
Lisle, IL 60532, USA
Tel: [phone]
Fax:[phone]
Visit our Web site at http://www.molex.com
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Distributor of Molex Connector Corporation: Excellent Integrated System Limited
Datasheet of 0638018500 - T2 & TERMINATOR CRIMP MODULE
Contact us: [email protected] Website: www.integrated-circuit.com
T2 and Terminator Crimp Module
Doc. No: TM-638018500 Release Date: 11-26-12 UNCONTROLLED COPY age 6 of 39
Revision: A Revision Date: 11-26-12
Figure
-
FEED
LOCKING SCREW
ADJUSTING
SCREW
INSULA
TION
ADJUSTING CAM
RAM
GREASE
FITTING
FRAME
GUIDE
BLOCK
FEED
FINGER
CONDUCTOR
ADJUSTING KNOB
BASE PLATE
PUNCH LOCK
TERMINAL POSITION
ADJUSTING
KNOB
LOCATING PLATE
Principal Mechanical Parts of the Crimp Module
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Distributor of Molex Connector Corporation: Excellent Integrated System Limited
Datasheet of 0638018500 - T2 & TERMINATOR CRIMP MODULE
Contact us: [email protected] Website: www.integrated-circuit.com
T2 and Terminator Crimp Module
Doc. No: TM-638018500 Release Date: 11-26-12 UNCONTROLLED COPY age 7 of 39
Revision: A Revision Date: 11-26-12
Section
General Description
. Description
The Molex T2™and Terminator Crimp Module provides an
effective method of transitioning T2 or Terminator tooling
from the TM-40 or TM-42 press or Base Unit into the TM-
3000 or TM-4000 press
This Crimp Module is installed ONLY in the Molex TM-3000
and TM-4000 Universal resses. This unit will not work in
other industry-standard presses. The Crimp Module
features minimal setup time without the need for shimming,
is versatile, reliable, easy to install, and is designed for mid-
volume to high-volume, semi or fully automatic operations.
Molex offers the following presses for operating the Crimp
Module:
 TM-3000 ress 120 V 60 Hz. 6380 -7200
 TM-3000 ress 240 V 50 Hz. 6380 -7300
 TM-4000 ress 240 V 60 Hz. 6380 -7600
.2 Features


 Fine adjustment allows users to achieve crimp height
target by adjusting a wedge (0.74 mm total adjustment)
for conductor crimp height and an 8-step cam (0.23mm
per step) for insulation crimp height.


 Independent adjustment cams allow users to quickly
adjust the conductor or insulation crimp height
independently.


 Quick crimp punch removal.


 Compatible ONLY with the Molex TM-3000 and TM-
4000 Universal resses


 Automatic terminal feed (on ram upstroke only).


 Quiet operation; low maintenance and easy to keep
clean.


 Accepts any Molex T2 or Terminator tooling.
.3 Technical Specification
Dimensions
(Crimp Module Only)
Width: 190mm (7.5")
Depth: 121mm (4.8")
Height: 146mm (5.7")
Weight (Crimp Module Only)
4.1kg (9lbs)
Guarding
The Crimp Module is supplied with no guards and is
intended to be used with the guards installed on the
TM-3000 or TM-4000 press.
Do not operate the Crimp Module
without press guards installed.
.4 Delivery Check
Carefully remove the Crimp Module from its shipping
container; note that the following items are also
included in the package:
TM-638018500 Operation Manual 1
Crimp Module with serial tag 1
.5 Crimp Tooling Accessories (optional)
Molex Order No. 63801-7240 Terminal Oiler
(Appendix C)
Molex Order No. 63800-2820 Digital Crimp Micrometer
Molex Order No. 63817-0000 Hand Held Wire strippers
Molex Order No. 63801-9200 neumatic Bench Top
Wire Strip Machine
Molex Order No. 63801-9250 Metric Bench Top Wire
Strip Machine
Molex Order No. 63801-9100 ull Force Tester Bench
Top
Molex Order No. 63801-9700 ull Force Tester Hand
Held
Molex Order No. 63800-2810 Eye loupe
.6 Tools
The following tools are recommended for setup and
adjustments to the applicator:
1. Metric and English hex wrench sets
2. Adjustable wrench
3. Wire stripper / cutter
4. Feeler gages/ shim stock
5. Eye loupe (5X)
.7 Application Tooling Specification Sheets
Molex ships specification sheets with all T2 or
Terminator tooling. The specification sheet contains
the following:
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Distributor of Molex Connector Corporation: Excellent Integrated System Limited
Datasheet of 0638018500 - T2 & TERMINATOR CRIMP MODULE
Contact us: [email protected] Website: www.integrated-circuit.com
T2 and Terminator Crimp Module
Doc. No: TM-638018500 Release Date: 11-26-12 UNCONTROLLED COPY age 8 of 39
Revision: A Revision Date: 11-26-12
Ε
ΕΕ
Ε Terminal numbers
Ε
ΕΕ
Ε Wire AWG ranges
Ε
ΕΕ
Ε Insulation diameter ranges
Ε
ΕΕ
Ε Strip lengths
Ε
ΕΕ
Ε ull force
Ε
ΕΕ
Ε Crimp heights
Ε
ΕΕ
Ε Bell mouth
Ε
ΕΕ
Ε Bend, twist, and roll limits
Ε
ΕΕ
Ε Tooling parts list and assembly
The specification sheets contain all the critical information on tooling replacement part numbers and inspection
characteristics. Copies should be kept on hand and made available.
Application Tooling Specification and other Molex tooling documentation is available for download on the Molex website
(www.molex.com).
To find Application Tooling Specification sheets, go to Molex.com. Using the “Search Box” on the main page, enter the
desired tooling order number. When the tooling page comes up, go to the “Specifications & Other Documents” section and
click on the “Application Tooling Specification“ link.
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Distributor of Molex Connector Corporation: Excellent Integrated System Limited
Datasheet of 0638018500 - T2 & TERMINATOR CRIMP MODULE
Contact us: [email protected] Website: www.integrated-circuit.com
T2 and Terminator Crimp Module
Doc. No: TM-638018500 Release Date: 11-26-12 UNCONTROLLED COPY age 9 of 39
Revision: A Revision Date: 11-26-12
Figure 2
-
PRESS
PRESS QUICK CHANGE
MOUNTING PLATE
SHUT HEIGHT
GAUGE
Section 2
Set-Up and Operation
Read the following instructions before attempting to operate the Crimp Module.
2. Shut Height
The shut height for the Crimp Module is 135.80mm (5.346"). The shut height for the crimp press is calibrated using a Shut Height
Gauge. See Figure 2-1. The gauge is designed to apply the proper load at 135.80mm (5.346") shut height. Molex offers an
industry standard shut height gauge (order number 63800-7900) that will fit in the TM-3000 and TM-4000 crimp presses. It is
recommended that the crimp press shut height be checked regularly.
The Crimp Module is designed to operate in the TM-3000 and TM-4000 crimp presses with standard shut height of 135.80mm
(5.346"). Installation in crimp presses with non-standard shut heights or ram strokes greater than 30mm can cause severe tool
damage. It is recommended before installation, a check of the shut height be performed. The correct shut height is required to
prevent the punches from hitting the anvils and the cut-off tooling from crashing. Calibrated presses also allow various T2 and
Terminator tools to be installed with minimal adjustment to the Crimp Module.
Measuring Press Shut Height
Always turn off and disconnect the power supply to the press.
1. Open the guard door.
2. Remove the applicator or Crimp Module from the press. See Section 2.3 Module Installation and Removal for additional
information. Clean the bottom of the press ram and top of the quick change mounting plate.
3. lace the shut height gauge onto the press quick change mounting plate. Align the gauge to the ram as shown in
Figure 2-1.
4. Manually cycle the press to the down stroke position. See Section 2.2, ow to Manually Cycle the Press, or follow the
TM-3000 Operation Manual (order number TM638017299) Section 3.3 Manually Cycling the Press.
5. Read the shut height measurement from the front of the gauge. Follow the gauge manufacturers’ instruction; usually the
gauge reads “0” when shut height is 135.80mm (5.346").
6. If adjustments are necessary, refer to the TM-3000 press manual for adjustment of the press shut height.
7. Repeat the above steps until the correct shut height is obtained.
8. Shut height gauges must be calibrated on a regular basis.
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