Molex 63801-8500 User manual

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638018500 - T2 & TERMINATOR CRIMP MODULE

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Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638018500 - T2 & TERMINATOR CRIMP MODULE

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

2 / 40

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638018500 - T2 & TERMINATOR CRIMP MODULE

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

3 / 40

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638018500 - T2 & TERMINATOR CRIMP MODULE

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

4 / 40

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638018500 - T2 & TERMINATOR CRIMP MODULE

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

Always

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

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

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.

5 / 40

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638018500 - T2 & TERMINATOR CRIMP MODULE

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

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: +1 (630) 969-4550

Fax:+1 (630) 505-0049

Visit our Web site at http://www.molex.com

6 / 40

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638018500 - T2 & TERMINATOR CRIMP MODULE

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

7 / 40

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638018500 - T2 & TERMINATOR CRIMP MODULE

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:

8 / 40

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638018500 - T2 & TERMINATOR CRIMP MODULE

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

ΕΕ

Ε Terminal numbers

ΕΕ

Ε Wire AWG ranges

ΕΕ

Ε Insulation diameter ranges

ΕΕ

Ε Strip lengths

ΕΕ

Ε ull force

ΕΕ

Ε Crimp heights

ΕΕ

Ε Bell mouth

ΕΕ

Ε Bend, twist, and roll limits

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.

9 / 40

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638018500 - T2 & TERMINATOR CRIMP MODULE

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.

10 / 40

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638018500 - T2 & TERMINATOR CRIMP MODULE

T2 and Terminator Crimp Module

Doc. No: TM-638018500 Release Date: 11-26-12 UNCONTROLLED COPY age 10 of 39

Revision: A Revision Date: 11-26-12

Figure 2-2

FOOT SWITCH

CORD

MOTOR

TURN

CLOCKWISE

HANDLE

WRENCH

POWER CORD

2.2 How to Manually Cycle the Press

Always turn off and disconnect the power supply to the press.

Always hand cycle the Crimp Module in the press to ensure the tooling is properly aligned.

Note: When the press guard is open make sure the power is disconnected from the motor (MOTOR ON light is not

illuminated)

Hand cycling the press is necessary to confirm correct tool

alignment and terminal feed adjustment. It also allows setup

personnel to observe the crimping cycle in slow-motion.

Manually Cycling the TM3000 and TM4000 Presses

1. Insert the hand-cycle T wrench (furnished with the

press) through the access hole in the center of the

motor’s rear cover and locate it on the motor shaft.

See Figure 2-2.

2. Rotate the wrench clockwise. This turns the motor

and moves the ram down and up.

3. Always return the press ram back to top dead center to

ensure that the ram is in the startup position.

4. Remove the T-handle wrench.

NOTE: When the T-handle wrench is inserted onto

the motor shaft the power is automatically disconnected from the motor. ress the green MOTOR ON button to

restore power to the motor.

2.3 Crimp Module Installation and Removal

Always turn off and disconnect the power to the press.

Installation

1 Open the press guard door.

2 Clean the quick change mounting plate of scrap or chips that may interfere with the Crimp Module installation.

Molex recommends a soft brush; do not use compressed air to clean the equipment. The forces created by

compressed air can force debris into the tool.

3 To install the Crimp Module, follow the procedure below:

a. Using a 4mm hex wrench, turn the M5 socket head cap screw clockwise until the locking clamp is fully opened.

b. Slide the Module’s lug bolt into the press ram yoke.

c. ull the Crimp Module’s frame down until the Module’s base plate rests on the quick change mounting plate.

d. Visually align the Crimp Module’s base plate notches on the left with the location clamps on the press quick-change

mounting plate.

e. Slide the Crimp Module to the left until the two notches in the base plate engage against the location clamps. See

Figure 2.3.

f. To lock applicator, turn the M5 socket head cap screw counterclockwise until tight.

11 / 40

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638018500 - T2 & TERMINATOR CRIMP MODULE

T2 and Terminator Crimp Module

Doc. No: TM-638018500 Release Date: 11-26-12 UNCONTROLLED COPY age 11 of 39

Revision: A Revision Date: 11-26-12

PRESS

RAM Y

OKE

CRIMP MODULE

BASE PLATE

M5 SHCS

LOCKING

CLAMP

QUICK CHANGE

MOUNTING PLATE

LOCATION

CLAMPS

Figure 2-3

LUG BOLT

4 Close the press guard door.

5 Hand cycle the press. See Section 2.2 ow to Manually Cycling the Press.

6 Reconnect power and press the green MOTOR ON button.

Removal

Remove the Crimp Module by reversing the previous steps. When storing the Module, always leave a strip of terminals in the

Module’s track to prevent damage to the tooling. See Section 5.5 Storage.

2.4 Tool Set Removal and Installation

Power must be disconnected from the press. Manual press cycling (hand cycling) is absolutely required

for safety and preventing equipment damage. Always hand cycle when trouble shooting or changing

adjustments, tooling, terminal reel, crimp module, or accessories.

Tool Set Removal

1. Disconnect power and open the guard door.

2. Set both the conductor and insulation cams to their highest (loosest) setting.

For the conductor cam, loosen the COND LOCK set screw on the ram face plate. Turn the conductor adjusting knob

counterclockwise until it stops.

For the insulation cam, slide it all the way to the left.

3. Remove the M6 button head cap screw and remove the right locating plate.

4. Lift the feed finger clear and slide the terminator die out of the Crimp Module.

5. Remove the punches, nose hold-down, rear striker, and center carrier cutoff tooling from the ram.

6. The terminator tooling is best stored in its original container.

Tool Set Installation

Make sure the proper crimp tooling is used for the terminal. Find the terminal part number on the terminal reel label

and compare it to the Application Tooling Specification sheet for the tooling. All Molex crimp tooling has an

Application Tooling Specification sheet.

Before any die is installed make sure the cover alignment procedure and the track adjustment procedure, (when applicable)

have been completed. See the specific terminator die instruction manual for these procedures.

12 / 40

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638018500 - T2 & TERMINATOR CRIMP MODULE

T2 and Terminator Crimp Module

Doc. No: TM-638018500 Release Date: 11-26-12 UNCONTROLLED COPY age 12 of 39

Revision: A Revision Date: 11-26-12

DRAG

CAM

DRAG FRAME

TERMINAL CENTERED

ABOVE ANVILS

TERMINAL STRIP

LIFT THE FEED

FINGER UP

ROTATE

Figure 2

“T2” Style

1. ower down the press and open the guard door.

2. Some crimp tools may have nose hold down, rear strikers, or center carrier cutoff tooling. If these items are used,

attachment points are located behind the punches either in the front or on the bottom of the Crimp Module’s ram. Refer to

the Specification sheet supplied with each individual terminator die for parts supplied with that terminator.

3. Fit the (2) punches in the opening on the underside of the ram. The conductor punch is positioned in the rear. See

Figure 6-5. A click will be heard when the punch retaining/release pin engages the slots in the punches

4. Set both the conductor and insulation cams to their highest (loosest) setting.

5. The front plunger striker mounts in front of the insulation crimp punch and is attached with a #10-32 set screw and hex nut

through the hole in the ram’s face plate. The set screw is adjusted to minimize punch float.

6. Clean the Crimp Module’s base plate of debris or chips that may interfere with the tool set installation.

7. Remove the right locating plate from the bolster plate by removing the M6 button head cap screw.

8. Lift the feed finger clear and slide the terminator track notch onto the left locating plate.

9. Attach the right locating plate against the anvils and tighten the M6 button head cap screw.

Always hand cycle the Crimp Module after installing tooling to ensure proper tool alignment.

Loading and Unloading the Terminal Strip

1. The specified terminals are printed on the specification sheet for the Terminator. Only use the Molex terminals on the

specification sheet which is supplied with the Terminator.

Always turn off and disconnect the power supply to the press when loading or unloading terminals

2. Install the terminal reel on the press reel arm and unwind about 400mm (15 in.) of terminals off the reel.

CAUTION: Terminals and terminal carrier strips may have sharp edges. Use caution while handling terminals.

“T2” STYLE TOOLING

1. If using a T2 Terminator, rotate the drag cam until the drag frame is in the upright position. This will allow the terminal to slide

easily through the terminal track. See Figure 2-4.

2. ush the terminal strip through the track until the first terminal comes to rest centered above the crimp anvils.

3. If severe resistance is encountered or the terminal strip does not fit, a rear cover adjustment may be needed. See Section 4.3

4. Rotate the drag cam to engage the terminal drag frame.

5. Cycle the press by hand so that the feed finger transfers the next terminal to a centered position over the crimp

anvils. Check that all other parts slide and engage without any interference. The press should be hand cycled several

times.

6. When unloading the terminal strip, make sure the power is turned off and disconnected from the press.

13 / 40

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638018500 - T2 & TERMINATOR CRIMP MODULE

T2 and Terminator Crimp Module

Doc. No: TM-638018500 Release Date: 11-26-12 UNCONTROLLED COPY age 13 of 39

Revision: A Revision Date: 11-26-12

DRA

G FINGER

TERMINAL

CENTERED ABOVE ANVILS

TERMINAL

STRIP

LIFT THE FEED

FINGER UP

Figure 2

“T” Style

ANTI

BACK

UP FINGER

DRAG AND ANTI

BACK

UP PINS

7. Rotate the drag cam until the drag frame is in the upright position.

8. Raise feed finger and pull terminal strip backwards until disengaged from applicator track. See Figure 2-4. If

preferred, cut the terminal carrier strip and pull it forward through the applicator track with needle nose pliers.

9. Close the guard door and restore power to the press.

“T” (TERMINATOR) STYLE TOOLING

1. If using a “T” style Terminator, push both the drag and anti-backup pins located on the front of the terminator die. This will allow

the terminals to slide freely through the terminal track. See Figure 2-5.

2. ush the terminal strip through the track until the first terminal is centered above the crimp anvils. If severe resistance is

encountered or the terminal strip does not fit, a rear cover adjustment may be needed. See Section 4.3.

3. Release the terminal drag and anti-backup pins to engage the terminal drag frame on the track.

4. Hand-cycle the press so the feed finger transfers the next terminal to a centered position over the crimp anvils.

5. Check that all other parts slide and engage without any interference. The press should be hand cycled several times.

6. When unloading the terminal strip, make sure the power is turned off and disconnected from the press.

7. Raise terminal drag finger and anti-backup finger from the carrier strip.

8. Lift the feed finger and pull terminal strip backwards until disengaged from terminator track. If preferred, cut the terminal carrier

strip and pull it forward through the terminator track with needle nose pliers.

9. Close the guard door and restore power to the press.

2.5 A Quick Checklist Prior To The First Crimp

The T2 and Terminator tooling is modular and can be installed and immediately operated, however preventive measures should

be practiced to assure safe operation and prevent accidental tooling damage.

In many cases, T2 and terminator tooling can crimp various Molex terminals. The terminal tested and shipped with

the tooling may not be the actual terminal (or the actual wire) the customer is using. This may require some minor

adjustments BEFORE crimping under press power.

1. The Crimp Module must be hand-cycled to verify there is no mechanical interference.

2. Verify mechanical function

 Terminal cutoff, single terminal feed, and crimped terminal is ejected.

3. Never operate the Crimp Module if there is a feed problem. Correct this first and proceed with setup.

 Verify the Crimp Module feeds terminals perfectly to the anvil center.

 Fine tuning of the terminal feed may be required depending on the application.

4. Inspect the crimps according to the Application Tooling Specification sheet.

5. Adjust conductor and insulation crimp heights accordingly. See Section 2.6 and 2.7.

14 / 40

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638018500 - T2 & TERMINATOR CRIMP MODULE

T2 and Terminator Crimp Module

Doc. No: TM-638018500 Release Date: 11-26-12 UNCONTROLLED COPY age 14 of 39

Revision: A Revision Date: 11-26-12

CONDUCTOR

ADJUSTING KNOB

INSULATION

ADJUSTING CAM

CONDUCTOR

LOCK SCREW

Figure 2

2.6 Conductor Crimp Height Adjustment

1. With the guard door closed, place a stripped length of suitable wire into the terminal and crimp the wire under power.

Strip length for the wire can be found in the Application Tooling Specification shipped with the tooling, or downloaded

from the Molex website.

2. Inspect the quality of conductor crimp and measure the crimp height. A crimp micrometer should be used (order no.

63800-2820); refer to the Crimp Quality Manual (document no. TM-638000029), Section 7. If adjustments are

necessary, disconnect the power from the press. Open the guard door. The desired crimp height can be achieved by

loosening the COND LOCK screw and turning the turning conductor cam adjusting knob clockwise to lower the crimp

height or counterclockwise to raise the crimp height. Tighten the COND LOCK screw to prevent the conductor crimp

adjustment from moving. See figure 2-6. The conductor adjusting knob should be adjusted in one-turn increments.

3. Close the guard door and repeat steps 1 – 3 until the desired crimp height is obtained. See the Crimp Quality Manual

(document no. TM-638000029), Section 7 for more information.

4. erform a pull test on conductor crimp to verify the mechanical integrity of the crimp. Refer to the Molex ull Force Tester

(order nos. 63801-9100 and 63801-9700) Application Tooling Specification Sheets or the Crimp Quality Manual for basic

pull force instructions.

2.7 Insulation Crimp Height Adjustment

1. lace a stripped length of the appropriate wire into the terminal and crimp under power.

2. Observe the quality of the insulation crimp and measure the crimp height. See the Crimp Quality Manual for more

information.

3. If adjustments are necessary, always turn off and disconnect the power supply from the press. Open the guard door.

4. Slide the insulation-adjusting cam and observe the number in the window below INS SET to achieve the desired insulation

height.

Each increment represents approximately 0.23mm (.009") for a total adjustment of .60mm (0.063"). The " " setting

is for the loosest (tallest) crimp height and the "8" setting the tightest (smallest) crimp height. It is recommended that

the customer start with the loosest setting which is “1”, and make test crimps until the proper insulation crimp height is

achieved.

5. Repeat the steps 1 – 3 until the desired insulation crimp height is obtained.

Note: Due to the large variety of insulation wall thickness, materials, and hardness, insulation crimp height is not typically

specified. For each different wire type, the insulation crimp height can be measured, recorded, and inspected as a quality

indicator.

Different applicator options are available, listed on molex.com, to better achieve optimal crimps for various wire

insulation types

15 / 40

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638018500 - T2 & TERMINATOR CRIMP MODULE

T2 and Terminator Crimp Module

Doc. No: TM-638018500 Release Date: 11-26-12 UNCONTROLLED COPY age 15 of 39

Revision: A Revision Date: 11-26-12

Section 3

Troubleshooting

Symptom

Cause

ection

Solution

Terminals

not feeding



Terminal strip bent or damaged

Replace terminals



Feed finger worn or not properly adjusted

4.5

Check proper finger setting

 Drag plate not holding terminal strip

Check compression springs

and

close the drag.



Feed finger not moving back enough to pick

up the terminal (pitch) 4.8 Set terminal feed backstroke.



Terminal jammed under cover plate

Clear and re

load

terminal

strip

Excessive

Bell mouth



Conductor punch worn

4.9

Replace

unch

 Track out of position 4.4

Adjust base and track for proper

alignment with the punches and anvil.

Cut-off plunger

does

not return to

original position



Cut

off

plunger

retainer

screws

over

tightened

Reduce tigh

tening torque on screws



Cut

off plunger spring damaged or broken

Replace spring

per specification sheet



Cut edges worn or damaged

 lunger, retainer, and insulation anvil 4.9

Remove scoring marks. If problem not

solved, replace with new tooling.

Conductor crimp

is too loose



Wrong tooling

4.9

Replace

per specification sheet



Tooling worn or damaged

4.9

Replace per specification sheet



Wrong cam setting

Measure crimp height and adjust accordingly



ress shut height too high

2.1

Adjust

press

shut height

to 135.8mm

Conductor crimp

Is too tight



Wrong tooling

4.9

Replace per specification sheet



Cam out of adjustment

2.6

Measure crimp height and adjust accordingly



ress shut height is too low

2.1

Adjust

press shut height

to 135.8mm

Insulation crimp

Is too tight



Cam out of adjustment

2.7

Readjust insulation cam



Wrong tooling

4.9

Replace per specification sheet



ress shut height is too low

2.1

Adjust

press shut height

to 135.8mm

Terminal sticks

during crimping



Wrong tooling

4.9

Replace

per specification sheet



Tooling worn or damaged

4.9

Replace per specification sheet



rimp height to

low

Measure crimp height and adjust accordingly



Gold plating and/or some high tensile materials

Appendix

Install a terminal oiler.

Terminals bent

up or down



See

causes for

“terminals sticking”



rack

set too far in or too far out

4.4

Adjust track.

 Nose hold down misadjusted or missing.

Refer to specification sheet

(if applicable)

Crimp extrusion)



See

causes for

“conductor crimp too tigh

t”



Gold plating and/or some high tensile materials

Appendix

Install a terminal oiler.



Wrong tooling

4.9

Replace per specification sheet



Tooling worn or damaged

4.9

Replace per specification sheet

Wire brush

inconsistent



Wire stop out of adju

stment

4.2

Adjust accordingly



Wire stop missing

1.7

Replace per specification sheet



Operator applying too much force against

wire stop

Adjust method of presenting wire into

the machine.

Insulation crimps

do not

provide strain relief

(I C- A620)

 Verify wire insulation diameter is within

the range of the terminal (specification sheet) 2.7 Adjust accordingly or see if alternate tooling

Is available at molex.com.

16 / 40

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638018500 - T2 & TERMINATOR CRIMP MODULE

T2 and Terminator Crimp Module

Doc. No: TM-638018500 Release Date: 11-26-12 UNCONTROLLED COPY age 16 of 39

Revision: A Revision Date: 11-26-12

Section 4

Adjustments

There are many adjustments on the Crimp Module. Be aware of what adjustments are made to the Module, as making one

adjustment can sometimes influence another. For example, moving the track for a bell mouth adjustment may require the feed

finger to be realigned. It is best practice to have frequent five minute preventive maintenance checks and cleanings before and

after each use. Regular cleaning, lubrication, spot checks for tooling wear, and alignment can prevent production problems and

allow time for replacement parts to be delivered if needed.

4. . Punch and Anvil Alignment

Note: Always clean mounting surfaces of crimp tooling and tooling holders prior to alignment.

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.

1. Disconnect the power supply from the press. Open the guard door.

2. With a terminal centered over the anvils, slightly release anvil mounting screw. See Figures 4-1 and 4-2.

3. lace the hand cycling wrench through the access hole in the press motor’s rear cover.

4. Slowly lower the press ram until it is in the fully down position. With the terminal resting on the anvils the punch will align the

bottom tooling.

5. While the ram is fully down, tighten the anvil mounting screws to ensure exact alignment of punches and anvils. Tighten

center carrier cut-off tooling if applicable.

6. Use the hand cycle wrench to bring the ram back to top dead center.

7. Close the guard door and restore power to the press.

4.2. Wire Stop Adjustment

The wire stop is used to control the amount of conductor brush beyond the conductor crimp grip.

For automatic wire processing machines, the wire stop can be moved back and used to assist in the stripping of the terminal from

the crimp punches. However, in certain circumstances the wire stop may need to be completely removed when running on an

automated machine.

1. Check the Application Tooling Specification sheet to obtain the correct wire strip length.

2. lace the correct wire gauge that is properly stripped into the terminal and crimp the wire under power. rior to crimping

under power make sure the tooling has been hand-cycled. See Section 2-1 ow to Manually Cycle the Press.

3. Observe quality of crimp and the wire insulation and brush position.

M4 SHCS (2)

Figure 4

“T2” STYLE

PLUNGER

RETAINER

Figure 4

“T” STYLE

# 0

32 SHCS

PLUNGER

RETAINER

17 / 40

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638018500 - T2 & TERMINATOR CRIMP MODULE

T2 and Terminator Crimp Module

Doc. No: TM-638018500 Release Date: 11-26-12 UNCONTROLLED COPY age 17 of 39

Revision: A Revision Date: 11-26-12

Figure 4

TERMINAL

M4 X 2mm BHCS (2)

REAR COVER

DRAG RELEASE

UP POSITION

TRACK

POINT

REAR COVER FRONT EDGE

POINT 2

PUSH REAR COVER

Figure 4

WIRE STOP

MOUNTING SCREW

WIRE

M5 SHCS

FOR WIRE STOP

WIRE STOP

WIRE

4. If adjustments are necessary, turn off the press. Open the guard door.

5. Hand cycle the press to lower the ram.

6. On the T2 tooling, use a 4mm hex wrench to loosen the M5 socket head cap screw located on the side of the anvil mount.

See Figure 4-3.

7. For some T2s andTerminator (“T” style) tooling, the wire stop mounting screw may be located on top of the anvil mount.

8. Adjust the position of the wire stop by moving the wire stop towards the operator to decrease the brush length and towards

the press to increase it.

9. Feeler gauge or shim stock can be used to create a gap between the back of the conductor punch and front of the wire stop.

The amount of shim used here is directly related to the amount of wire brush.

10. Tighten the M5 socket head cap screw.

11. Hand cycle the press to ensure the conductor punch does not hit the wire stop. Then crimp a terminal under power and

observe the quality of the termination.

4.3 Rear Cover Adjustments

Always turn off and disconnect the power supply to the press before making adjustments.

1. Disconnect the power from the press. Open the guard door.

2. Remove the terminator from the Crimp Module. See Section 2.3, Crimp Module Installation and Removal

3. For the T2 style tooling, rotate the drag cam until the drag frame is in the upright position.

4. With an 8-10” long strip of terminals installed in the track, push the rear cover towards the front of the track to eliminate any

excessive play between points 1 and 2. See Figure 4-4.

5. Slide the strip of terminals forward and back while lightly pushing the rear cover towards the front of the track. The goal is to

have minimal movement between points 1 and 2, but still allow the strip of terminals to slide freely.

18 / 40

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638018500 - T2 & TERMINATOR CRIMP MODULE

T2 and Terminator Crimp Module

Doc. No: TM-638018500 Release Date: 11-26-12 UNCONTROLLED COPY age 18 of 39

Revision: A Revision Date: 11-26-12

6. After the correct position is achieved, tighten the two M4 button head cap screw (T2) or #8 button head cap screw (“T” style) and

remove the strip of terminals.

7. Re-install the terminator in the Crimp Module. See Section 2.3, Crimp Module Installation and Removal

4.4 Track Position Adjustment (T2 tools only)

Disconnect the power supply to the press.

1. Open the guard door.

2. Depending on the amount of movement, the feed finger mount may need to be loosened and readjusted. See Section 4.5

Feed Finger Alignment.

3. Determine which way the track needs to move. To decrease front cut-off tab or to increase bell mouth, the track should be

adjusted toward the operator. The track is usually adjusted toward the press to decrease bell mouth or to help straighten a

bend-up condition.

4. Remove the Crimp Module from the press. See Section 2.3.

5. To position the terminal track in or out, use a 4mm hex wrench to loosen the M5 lock screw located on the underside of the

track. This screw can be accessed through a slot in the Crimp Module’s base plate. See Figure 4-5.

6. Slide the track in or out to the desired position.

7. To lock the track in position, tighten the M5 lock screw.

8. Slide a length of terminal strip through the track and make sure it feeds freely into the cutoff plunger(s).

9. If the feed finger mount was loosened during the track positioning, remember to tighten its mounting screw.

10. The wire stop may need to be re-adjusted for insulation and brush position.

See Section 4.2 Wire Stop Adjustment.

11. Hand cycle the press to ensure the terminal is positioned properly on the anvils and does not have an excessive cutoff tab.

See Section 4.6 Terminal Position Adjustment. Also, verify the terminal feed operation.

12. Close the guard door and remove the hand-cycle wrench from the motor.

13. Restore power to the press, crimp a terminal under power, and observe the quality of the termination.

14. Repeat the above steps until the desired terminal position is obtained.

4.5 Feed Finger Alignment

Never operate the Crimp Module if there is a feed problem. Tooling damage can result. Adjust the

insulation and conductor adjusting cams to create a loose crimp while solving feed problems. (Move the

insulation cam to to the #1 position and turn the conductor adjusting screw CCW until the conductor cam stops.)

ACCESS SLOT FOR

TRACK ADJUSTMENT

Figure 4

BASE PLATE

19 / 40

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638018500 - T2 & TERMINATOR CRIMP MODULE

T2 and Terminator Crimp Module

Doc. No: TM-638018500 Release Date: 11-26-12 UNCONTROLLED COPY age 19 of 39

Revision: A Revision Date: 11-26-12

CENTER OF CARRIER

STRIP PILOT HOLE

FEED

FINGER

Figure 4-6

FEED GUIDE

1. Typically, terminals are fed by the carrier strip pilot hole. In this case, position the feed finger to align to the center of the

carrier strip pilot hole. See Figure 4-6.

2. Disconnect power from the press. Open the guard door.

3. Using a 2.5mm hex wrench, loosen the M3 socket head cap screw located on the slotted hole of the feed finger mount.

While raising the feed finger slightly, slide the feed finger to the desired position. See Figure 4-7.

4. If the feed finger mount cannot be moved far enough, remove the M3 socket head cap screw completely and install it in the

next tapped hole in the feed lever.

5. Tighten the M3 socket head cap screw to lock the feed finger in position.

6. Hand cycle the press to verify proper feed operation.

7. Close the guard door, remove the hand-cycle wrench from the motor, and restore press power.

4.6 Feed Finger Spring Tension

The feed finger is held against the terminal strip by force created from a torsion spring. If the force is too low, the feed finger

may “skip” over the terminal strip and result in no feeding or partial feeding.

1. Disconnect power from the press. Open the

guard door.

2. Use a small regular screwdriver in the slot of

the feed finger pivot shaft to keep the torsion

spring from unwinding. See Figure 4-8.

3. Using a 2.5mm hex wrench, loosen the M3

socket head cap screw holding the pivot

shaft.

4. Turn the screwdriver clockwise to increase

the tension of the torsion spring or

counterclockwise to decrease it. Turn in small

increments (30°) to avoid damaging the

spring.

5. While holding the pivot shaft from turning,

tighten the M3 socket head cap screw.

6. Since the pivot shaft can move axially when

loosened, check the feed finger alignment

and adjust if necessary.

7. Hand cycle the press to verify proper feed operation.

8. Close the guard door, remove the hand-cycle wrench from the motor, and restore press power.

M3 SHCS

FEED

FINGER MOUNT

FEED FINGER

PIVOT SHAFT

TORSION

SPRING

SLOT IN PIVOT SHAFT

Figure 4

M3 SHCS

FEED

FINGER

MOUNT

FEED FINGER

Figu

re 4

20 / 40

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