molex FA2 Operating instructions

FA2 Applicator
Doc. No: TM-638080200 Release Date: 02-08-18 UNCONTROLLED COPY Page 1 of 33
Revision: B2 Revision Date: 05-04-18
FA2 CRIMP APPLICATOR
General Description, Setup and Operating Instructions
Document No. 63808-0200
Start-Up Guide
Page 10

FA2 Applicator
Doc. No: TM-638080200 Release Date: 02-08-18 UNCONTROLLED COPY Page 2 of 33
Revision: B2 Revision Date: 05-04-18

FA2 Applicator
Doc. No: TM-638080200 Release Date: 02-08-18 UNCONTROLLED COPY Page 3 of 33
Revision: B2 Revision Date: 05-04-18
Safety Warnings and Information
Read and understand all instructions and safety information in this manual before
operating or servicing this tool.
Keep this manual available when using this tool.
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 that could result in an injury or property damage.
The signal word, defined below, indicates severity of hazard. The message following the signal word provides information for
prevention or avoidance of the hazard.
DANGER
DANGER:
Indicates an imminently hazardous situation that, if not avoided, could result in death or serious
injury
WARNING
WARNING:
Indicates a potentially hazardous situation that, if not avoided, could result in death or serious
injury
CAUTION
CAUTION:
Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate
injury
May also be used to alert against unsafe practices associated with events that could lead to
personal injury
DANGER
Never install or service this machine 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 a press or wire processing machine without guards or safety devices that are intended to
prevent hands from remaining in the die space.
Failure to observe this warning could result in severe injury or death.
WARNING
Never wear clothing or jewelery that is loose or that could potentially hang into the equipement and get
caught.
Failure to observe this warning could result in severe injury or death.
WARNING
Always wear proper eye protection when operating or servicing this equipment.
Failure to wear eye protection could result in serious eye injury from flying debris.

FA2 Applicator
Doc. No: TM-638080200 Release Date: 02-08-18 UNCONTROLLED COPY Page 4 of 33
Revision: B2 Revision Date: 05-04-18
CAUTION
CAUTION
Do not use compressed air to clean this
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.
Always hand-cycle the applicator in the
equipment to ensure tooling is properly aligned.
Failure to observe these precautions may result
in injury or property damage.
CAUTION
CAUTION
Heavy Object
To avoid muscle strain or back injury, use
lifting aids and proper lifting techniques when
removing or replacing.
Failure to observe these precautions may
result in injury or property damage.
Never operate, service, install or adjust this
machine without proper instruction and without
first reading and understanding the instructions
in this manual and all applicable press or wire
processing machine manuals.
CAUTION
Always wear proper ear protection when operating or servicing this applicator.
CAUTION
Molex applicators are designed to operate in presses with standard shut heights of 135.80mm (5.346”).
Installation of crimp presses with other-than-standard shut heights can cause tool breakage. It is advisable to
perform a check of the shut height before installation. Molex will not be liable for any damages as a result of
applicator installation in a crimp press with an incorrectly 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.

FA2 Applicator
Doc. No: TM-638080200 Release Date: 02-08-18 UNCONTROLLED COPY Page 5 of 33
Revision: B2 Revision Date: 05-04-18
Table of Contents
Safety Warnings and Information ..................................................................................................................................3
Section 1 –General Description....................................................................................................................................6
1.1 Description.................................................................................................................................................6
1.2 Features ....................................................................................................................................................6
1.3 General Applicator Parts Identification (Mechanical Feed)........................................................................7
1.4 General Applicator Parts Identification (Air Feed)......................................................................................8
1.5 Applicator Tooling Identification.................................................................................................................9
Section 2 –Start-Up Guide..........................................................................................................................................10
Section 3 –Troubleshooting........................................................................................................................................12
3.1 Applicator Troubleshooting......................................................................................................................12
3.2 Crimp Troubleshooting ............................................................................................................................12
Section 4 –Setup and Operation.................................................................................................................................14
4.0 Press Shut Height....................................................................................................................................14
4.1 Applicator Installation and Removal ........................................................................................................14
4.2 How to Make a Crimp ..............................................................................................................................15
4.3 Crimp Height Adjustments.......................................................................................................................15
4.4 Track Guide Setup and Adjustment.........................................................................................................16
4.5 Loading and Unloading Terminals in the Applicator Track.......................................................................18
4.6 Terminal Feed Adjustments.....................................................................................................................19
4.7 Terminal Track Position Adjustment ........................................................................................................22
4.8 Crimp Tooling Installation and Removal ..................................................................................................23
4.9 Wire Stop Setup and Adjustment.............................................................................................................25
4.10 Wire Processing Setup and Feed Cam Orientation .................................................................................27
4.11 Bend Adjust Dial......................................................................................................................................28
Section 5 –Maintenance .............................................................................................................................................29
5.1 Cleaning ..................................................................................................................................................29
5.2 Lubrication...............................................................................................................................................29
5.3 Storage....................................................................................................................................................29
Section 6 –Service Parts ............................................................................................................................................30
6.1 Feed Pawl Spring Replacement ..............................................................................................................31
6.2 Accessories .............................................................................................................................................32
6.3 Contact Us...............................................................................................................................................32
Section 7 –Crimp Quality............................................................................................................................................33

FA2 Applicator
Doc. No: TM-638080200 Release Date: 02-08-18 UNCONTROLLED COPY Page 6 of 33
Revision: B2 Revision Date: 05-04-18
Section 1 –General Description
1.1 Description
The FA2 applicator fits in the Molex TM-2000, TM-3000 and TM-4000 Universal Presses and in most industry-standard crimp
presses with 135.8mm (5.346”) shut height and 3-point base plate mounting to the press bolster.
Molex currently offers the following crimp presses for operating the FA2 applicator:
Description
Order Number
TM-3000 Press 120 V 50/60 Hz
63801-7200
TM-3000 Press 240 V 50/60 Hz
63801-7300
TM-4000 Press 240 V 50/60 Hz
63801-7600
1.2 Features
Fine adjustment allows users to achieve target with little effort by adjusting in increments of 0.015mm (.0006”) for
conductor crimp height and in increments of .025mm (.001”) for insulation crimp height.
Independent adjustment cams allow users to quickly adjust conductor or insulation crimp height without affecting each
other.
The track position for bellmouth and cut-off tab can be adjusted while the applicator is in the press.
This applicator does NOT fit in the Molex TM-40 or TM-42 presses.
Directly adapts to most automatic wire processing machines.
Compatible with 30mm and 40mm stroke presses; no changes necessary in applicator.
Quick setup time; crimp heights, track position, and feed adjustments can be adjusted while the applicator is in the press.
This applicator is designed to industry-standard 3-point mounting and 135.80mm (5.346”) shut height.
Press Stroke Compatibility
28.6mm (1 1/8”) minimum
41.3mm (1 5/8”) maximum
Applicator Mounting in Press
oThis applicator uses the industry-standard 3-point base plate mounting to the press bolster and T-shape industry-
standard ram mounting.
Guarding
This applicator is supplied without guards and is intended to be used with guards supplied by the press manufacturer.
Caution: DO NOT operate the applicator without guards.

FA2 Applicator
Doc. No: TM-638080200 Release Date: 02-08-18 UNCONTROLLED COPY Page 7 of 33
Revision: B2 Revision Date: 05-04-18
1.3 General Applicator Parts Identification (Mechanical Feed)
Indicates manual page number for more information
LUG BOLT
FEED CAM
RAM
POSITION
ADJUSTING KNOB
PUNCH COVER
14
27
23
20
17
TRACK
23
19
18
22
19
FEED PAWL
SCRAP CHUTE
TERMINAL GUIDE
TRACK
LOCKING SCREW
22
17
18
TRACK ADJUSTING
SCREW
22
DRAG BRAKE KNOB
18
DRAG BRAKE
29
16
RAM STORAGE SCREW
INSULATION
ADJUSTING CAM
15
14
15
CONDUCTOR
ADJUSTING CAM
29
GREASE FITTING
* CYCLE COUNTER
(NON-RESETTABLE)
25
WIRE STOP ASSEMBLY
BACK FRAME
16
MOUNTING DATUM
24
BASE PLATE
*Depending on conditions during applicator assembly and setup, the counter reading may vary on new applicators.

FA2 Applicator
Doc. No: TM-638080200 Release Date: 02-08-18 UNCONTROLLED COPY Page 8 of 33
Revision: B2 Revision Date: 05-04-18
1.4 General Applicator Parts Identification (Air Feed)
14
RAM STORAGE SCREW
15
INSULATION
ADJUSTING CAM
15
CONDUCTOR
ADJUSTING CAM
29
29
16
25
WIRE STOP ASSEMBLY
BACK FRAME
16
9
24
MOUNTING DATUM
GREASE FITTING
*CYCLE COUNTER
(NON-RESETTABLE)
BASE PLATE
Indicates manual page number for more information
LUG BOLT
PUNCH COVER
14
SPEED CONTROL
(FORWARD STROKE)
20
23
SPEED CONTROL
(BACK STROKE)
21
20
ADJUSTING SCREW
(BACK STROKE)
15
15
23
17
TRACK
FEED PAWL
20
18
POSITION
ADJUSTING KNOB
22
RAM
SCRAP CHUTE
TERMINAL GUIDE
DRAG BRAKE KNOB
22
18
17
19
20
22
TRACK ADJUSTING
SCREW
TRACK
LOCKING SCREW
DRAG BRAKE
18
* Depending on conditions during applicator assembly and setup, the counter reading may vary on new applicators.

FA2 Applicator
Doc. No: TM-638080200 Release Date: 02-08-18 UNCONTROLLED COPY Page 9 of 33
Revision: B2 Revision Date: 05-04-18
1.5 Applicator Tooling Identification
Note: The above is a generic illustration. Please refer to the Application Tooling Specification (ATS) document
for your specific applicator to identify replacement parts and part numbers.
Tooling component used on some applicators
CONDUCTOR PUNCH
INSULATION PUNCH
FEED CAM
(NOT USED ON
AIR FEED APPLICATORS)
TERMINAL HOLD DOWN
CONDUCTOR STUFFER
BLADE AND SPRING
INSULATION STUFFER
AND SPRING
FRONT PLUNGER
STRIKER
TERMINAL GUIDE
COARSE/FINE
SPACERS
HEIGHT SPACER
CONDUCTOR ANVIL
FRONT PLUNGER
RETAINER
PUNCH
COVER
SCRAP
CHUTE
FRONT CUT-OFF
PLUNGER AND
SPRING
INSULATION ANVIL

FA2 Applicator
Doc. No: TM-638080200 Release Date: 02-08-18 UNCONTROLLED COPY Page 10 of 33
Revision: B2 Revision Date: 05-04-18
Section 2 –Start-Up Guide
Step
Instruction
Page
1
Verify Press Compatibility
oPress stroke is between 26.8-41.2mm (1 1/8-1 5/8”)
oPress shut height is 135.8mm (5.346”)
o3-point universal base plate mounting
oT-shape universal ram mounting
5, 12
2
Confirm Terminal, Wire and Tool
Use the applicator’s ATS document to confirm the applicator is compatible with Molex terminal part number
and selected wire (conductor size and insulation diameter).
ATS
3
Set Up Applicator for Wire Processing (If Applicable)
oAs shipped, Molex applicators are set up for bench crimping.
oFor wire processing applications, please review section 4.10.
25
Test Fit Terminal Strip in the Track
oMake adjustments to the guide cover if terminals are too tight or loose.
4
Install Applicator in Press
oRemove ram storage screw.
oInstall the applicator into the press and engage the lock.
oConnect the air lines (air feed applicators only) to the air valve.
12-13
5
Install Terminal Reel and Load Terminals in Track
oTerminal strip must slide freely in track without excessive play.
oCenter the first terminal above the anvils.
oMake sure the drag brake is ON before operating the press.
16-20
6
Hand-Cycle/Slow-Cycle the Press
oRecord the insulation adjusting cam and conductor adjusting cam factory settings.
oTo prevent tool damage, move the insulation adjusting cam to setting 1and the
conductor adjusting cam to setting A.
oVerify back feed pawl position engages the terminal strip carrier hole.
oStop the press if there is any tightness or binding.
oStop the hand-cycle/slow-cycle when the press ram is at the top of its stroke.
oVerify the forward feed position (terminal centered over anvils).
oHand-cycle/slow-cycle several times to crimp terminals and evaluate the feed and cut-off tab.
13-14,
18-19
7
Crimp with Wire (Production Speed)
oVerify that terminals feed properly before crimping under power.
oClose the guards and turn on press power.
oCrimp a pre-stripped wire and evaluate. Crimps will be loose because the insulation
adjusting cam and conductor adjusting cam are at their loosest settings.
oMove the insulation adjusting cam and conductor adjusting cam halfway to the factory
settings and crimp again.
oBegin measuring the crimp heights and compare to ATS specifications.
oIncrementally increase the insulation adjusting cam and conductor adjusting cam settings over several
crimps until ATS crimp specifications are met.
13-14,
17-19
RAM STORAGE
SCREW