molex TM-3000 User manual

TM-3000 and TM-4000 Universal Press
Doc. No: TM-638017299 Release Date: 06-06-05 UNCONTROLLED COPY Page 1 of 36
Revision: F Revision Date: 11-27-18
TM-3000 Universal Press
TM-4000 Universal Press
Operation Manual
Press Model Numbers
63801-7200, 63801-7300, 63801-7600
Original Instructions

TM-3000 and TM-4000 Universal Press
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Revision: F Revision Date: 11-27-18
Safety Warnings and Information
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 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 wear proper eye protection when operating or
servicing this equipment.
Failure to wear eye protection could result in serious
eye injury from flying debris.
Heavy Object
To avoid muscle strain or back injury, use lifting aids
and proper lifting techniques when moving this press.
Failure to observe these precautions may result in
injury or property damage.
WARNING
WARNING
Never wear clothing or jewelry that is loose or that
could potentially snag in the press and get caught.
Failure to observe this warning could result in severe
injury or death.
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
WARNING
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.
Always hand cycle the applicator in the press to
ensure that the tooling is properly aligned.
Failure to observe these precautions may result
in injury or property damage.
Read and understand all of the 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 no charge at www.molex.com

TM-3000 and TM-4000 Universal Press
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Revision: F Revision Date: 11-27-18
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 the number listed below and asking for the Molex Tooling Group.
This assistance is limited to the operation and setup of a customer’s Molex press. Questions with regard to Molex connector
products or how to identify the proper tooling or tooling documentation should be directed to your local Molex personnel or
customer service representative.
When calling for service on the press, a copy of the Tooling Manual and specific applicator Tooling Specification Sheet
should be present, and a person who is familiar with the applicator should be present. Be sure the following information is
supplied:
1. Customer name
2. Customer address
3. Person to contact (e.g., name, title, e-mail, and telephone number)
4. Applicator order number (Lease number, if applicable)
5. Serial number (Lease number, if applicable)
6. Molex Connector product order number
7. Urgency of request
8. Nature of problem
Application Tooling Support
Phone: (402) 458-TOOL (8665)
E-Mail: [e-mail]
Website: www.molex.com/applicationtooling
WARNING
WARNING
Never use this 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.
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.
WARNING
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 in crimp presses with other-than-standard shut heights can cause severe tool or applicator damage. It is advisable that before
installation, a check of the shut height be performed. Molex will not be liable for any damages as a result of installation in a crimp press with a
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.

TM-3000 and TM-4000 Universal Press
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Revision: F Revision Date: 11-27-18
Table of Contents
Contents
TM-3000 Universal Press ..................................................................................................................................................................1
TM-4000 Universal Press ..................................................................................................................................................................1
Safety Warnings and Information ........................................................................................................................................................2
Table of Contents ................................................................................................................................................................................4
Section 1 5
General Description....................................................................................................................................................................5
1.1 Description.....................................................................................................................................................................6
1.2 Features.........................................................................................................................................................................6
1.3 Technical Specifications ................................................................................................................................................6
1.4 Delivery Check...............................................................................................................................................................7
1.5 Tools..............................................................................................................................................................................8
Section 2 9
Installation...................................................................................................................................................................................9
2.1 Lifting/Mounting ...........................................................................................................................................................10
2.2 Foot Pedal and Power Connection ..............................................................................................................................10
2.3 Reel Support................................................................................................................................................................10
2.4 Pneumatic Supply Connection (See Figures 3-2 and 3-3)...........................................................................................11
2.5 Terminal Feed Guide ...................................................................................................................................................12
2.6 Shut Height..................................................................................................................................................................12
2.7 Safety and Work Area Check.......................................................................................................................................13
2.8 Guards.........................................................................................................................................................................13
Section 3 16
Setup and Operation.................................................................................................................................................................16
3.1 Applicator Installation...................................................................................................................................................17
3.2 Air Feed Applicator Installation ....................................................................................................................................17
3.3. Manually Cycling the Press..........................................................................................................................................19
3.4. Operation.....................................................................................................................................................................19
Section 4 22
4.1 Maintenance ................................................................................................................................................................23
4.2. Oiler .............................................................................................................................................................................23
4.3 Troubleshooting...........................................................................................................................................................24
Section 5 25
5.1. Main Parts List.............................................................................................................................................................26
5.2. Main Assembly ............................................................................................................................................................28
5.2 Main Assembly (Continued).........................................................................................................................................29
5.3. Electrical Schematic ....................................................................................................................................................34
5.3. Pnuematic Schematic ..................................................................................................................................................35

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Revision: F Revision Date: 11-27-18
Section 1
General Description
1.1 Description
1.2 Features
1.3 Technical Specifications
1.4 Delivery Check
1.5 Tools

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Revision: F Revision Date: 11-27-18
General Description
1.1 Description
The 63801-7200/63801-7300 TM-3000 Universal Press and the 63801-7600 TM-4000 Universal Press are economical,
electrically-operated, single-cycle and split cycle direct drive presses. They are designed to provide an effective method of
applying a wide range of side-feed and rear-feed terminals to a pre-stripped discrete wire or cable. Both the TM-3000 and the
TM-4000 are suited to mid-volume semi-automatic operations.
Production flexibility is obtained using interchangeable FineAdjust, Mini-Mac or FA2 applicators and most industry-standard
applicators.
These presses will complete one crimping cycle with each actuation of the foot pedal (two foot pedal actuations for split cycle).
Safe operation is provided by a sensor that prevents press operation if the safety guard is opened or removed.
These presses also have a secondary sensor in the back of the motor (where the hand cycle wrench is used) to prevent the
press from operating if the hand cycle wrench is accidently left in the motor.
1.2 Features
Utilizes FineAdjust, Mini-Mac and FA2 applicators (side and rear feed), and most industry-standard applicators
Press is calibrated to 135.80mm (5.346”) industry shut height
Ideal for mid-volume, semi-automatic applications
Guarding for operator safety, including sensors for guard closed and the hand cycle wrench removed
Resettable counter for accurate batch counting
1.3 Technical Specifications
Dimensions with reel mounted
Height 1,210mm (47.60“)
Width 648mm (25.50“)
Depth 559mm (22.00“)
Unpacked weight 113.4kg (250 lb)
Shipping weight 140.61kg (310 lb)
Press Stroke
TM-3000 30mm (1.125”)
TM-4000 30mm (1.125”)
Power Requirements
Voltage: 63801-7200 TM-3000 –100-120VAC 50-60 Hz, 4A, single phase, grounded supply
Voltage: 63801-7300 TM-3000 –200-240VAC 50-60 Hz, 2A, single phase, grounded supply
Voltage: 63801-7600 TM-4000 –200-240VAC 50-60 Hz, 2A, single phase, grounded supply
Note: If 200-240VAC power is not available, then 100-120VAC power may be used with Molex step-up transformer 62500-
2992.
Operating Environment Requirements
Temperature: -10°C to 40°C (14°F to 104°F)
Humidity: Less than 90% relative humidity, non-condensing/non-freezing
Atmospheric Pressure: 86-106KPa (12.5-15.4 psi)
Altitude: 1,000m (3,280 ft.) maximum

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Revision: F Revision Date: 11-27-18
Transport/Storage Environment Requirements
Temperature: -20°C to 60°C (-4°F to 140°F); 70°C (158°F) allowed for less than 24 hours
Humidity: Less than 90% relative humidity, non-condensing
Atmospheric Pressure: 86-106KPa (12.5-15.4 psi)
The TM-3000 and TM-40000 press systems require only electrical power, however these press systems include an air valve
for air feed applicators where air is required (Mylar Tape Applicators for example).
Pneumatic Requirements (Air Feed Applicators Only)
5 bar (72 psi) minimum, 10 bar (145 psi) maximum
1.7 m³/h (1 SCFM) minimum flow
Included: ¼” NPT inlet with push-in fitting for ¼” OD tube.
Production Rate
TM-3000: 2,400 terminations per hour maximum, depending on operator skill, terminal and wire length.
TM-4000 press has a slightly slower cycle rate due to gear reduction to meet force capability.
Processing Capability
TM-3000 press output = 4,000 lbs. (18kN).
Copper conductors up to 10 AWG (5.0mm²) in stranded wire.
TM-4000 Press output = 7,000 lbs. (31kN).
Copper conductors up to 4 AWG (21.0mm²) in stranded wire, insulated or un-insulated connector products.
Copper conductors up to 2 AWG (34.0mm²) in stranded wire, un-insulated connector products only.
Sound Level
Operator will be exposed to less than 70 dBA.
1.4 Delivery Check
After removing the packaging band, lift off the top and sides of the box. The following items are included in this package:
Quantity
Press Assembly 1
63801-7290 Reel Support Assembly 1
63801-7264 Hand Cycle Wrench 1
63801-7271 Foot Pedal 1
TM-638007299 Operation Manual 1
Carton Contents Quantity
69018-6237 Power Cord 110V with 110V NEMA 5-15P plug
(for 63801-7200) 1
(for 200-240VAC presses)
62500-1774 Power Cord with 220V NEMA 6-15P plug 1
Power Cord with CEE-V7 Euro plug 1
Power Cord with BS 1363 plug 1

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Revision: F Revision Date: 11-27-18
1.5 Tools
The following tools are recommended for setup and adjustments to the applicator and the press:
Metric hex wrench set
Small standard screwdriver
Adjustable wrench
Needle nose pliers
Crimp micrometer (Molex part no. 63800-2850)
Eye loupe (10x) (Molex part no. 63800-2810)
Wire stripper/cutter
English hex wrench set for some non-metric
applicators

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Revision: F Revision Date: 11-27-18
Section 2
Installation
2.1 Lifting/Mounting
2.2 Reel Support
2.3 Foot Pedal and Power Connection
2.4 Pneumatic Supply Connection
2.5 Terminal Feed Guide
2.6 Function Test
2.7 Safety and Work Area Check

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Revision: F Revision Date: 11-27-18
FOOT PEDAL
ASSEMBLY
PRESS CONTROL
ASSEMBLY
Figure 2-1
OILER
ASSEMBLY
MOTOR
REEL SUPPORT
ASSEMBLY
TERMINAL GUIDE
POWER CORD
WORKBENCH
LIFT HOOK
WORK LIGHT
2.1 Lifting/Mounting
WARNING: This press weighs over 100 kg (220 lb.); it should not be lifted by one individual. Mechanical lifting
devices should be used. A person lifting the press can sustain severe back or other injuries.
A lifting hook is provided on top of the press. A heavy-duty chain, rope, cable or belt can be used with loops, links or rings on
each end that can securely attach to the lifting hooks. An electric, hydraulic or mechanical crane with a 230kg (500 lb.)
minimum liftin capacity should be used to lift the press. Lift the press up approximately 12mm (.50”) and verify that the
press is well balanced. Upon verification, the press can be lifted onto a sturdy workbench. Access to the back of the
machine is required for manual hand cycling. A wooden workbench that is a minimum of 25mm (1.0”) thick will offer quiet,
vibration-free operation. The TM-3000 and TM-4000 can be attached to the table with two 12mm (.50”) bolts. Bolts are not
supplied by Molex; however, bolting the press to the workbench is required
for all bench placements.
2.2 Foot Pedal and Power Connection
Connect the 3-pin plug of the foot pedal cord in the rear of the press. Turn
the locking ring clockwise until tight. Connect the power cord plug to the rear
of the press. Use a grounded power source. See Figure 2-2.
2.3Reel Support
Install the reel support in the hole located on the top of the machine frame. For rear feed, rotate the reel support as required.
See Figure 2-4. Loosen the M10 set screw that holds the reel support. Pull up from the hole and rotate for the proper feeding
orientation. Then, slide down back into the hole and tighten the M10 set screw.
To set up the reel support assembly:
1Place one reel boss (order number 63801-7261) onto the reel support (order number 63801-7260).
2Align the back of the reel support over the rear location of where the applicator is installed in the press.
3Securely tighten the wing screw on the reel boss.
4Next, place the reel spring (order number 63801-7263) onto the reel support.
5Slide one reel disc (order number 63801-7262) onto the reel support.
POWER
CORD PLUG
Figure 2-2
FOOT
PEDAL CORD

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Revision: F Revision Date: 11-27-18
Figure 2-3
REEL SUPPORT ASSEMBLY 63801-7290
REEL BOSS
63801-7261
REEL BOSS
63801-7261
REEL OF TERMINALS
REFERENCE
REEL DISC
63801-7262
REEL SUPPORT
63801-7260
WING SCREW
69907-3612 (2)
REEL DISC
63801-7262
REEL SPRING
63801-7263
6Place the reel of terminals onto the reel support.
7Install the second reel disc (order number 63801-7262) onto the reel support.
8Slide the second reel boss onto the reel support with slight pressure against the back disc pushing on the spring,
and securely tighten the wing screw. See Figure 2-3.
Note: The reel bosses can be adjusted as needed to align the terminal strip to the applicator track.
2.4 Pneumatic Supply Connection (See Figures 3-2 and 3-3)
A compressed air supply is required if air feed applicators will be used. The press is equipped with a compressed air filter,
regulator, lubricator and a solenoid valve to actuate the air feed at the proper time in the press cycle.
Due to the many types of air connection and quick connect air fittings available, the press is supplied with a 1/4 NPT female
threaded fitting. Customers may attach their preferred air connections that are commonly used in their plants to this fitting.
The minimum supply line inside diameter should be 8mm (5/16”) to assure adequate compressed air flow.
A filter-regulator-lubricator unit is furnished to properly condition the supply air. The filter will remove particulates and
moisture from the air that can damage or reduce the life of air cylinders and valves. This filter and bowl should be serviced
on a regular schedule (See Section 4.1). The filter has an automatic drain at the bottom of the bowl that will automatically
open and expel fluid when the bowl becomes full. It is recommended that a 6mm (1/4”) flexible tube be attached to the drain
hose barb and run to a container to drain excessive moisture.
The regulator provides consistent air pressure to the air feed applicator. A typical air feed applicator requires 400-500kPa
(60-80 psi) (refer to applicator instructions for recommended pressures.) Adjustment is accomplished by pulling up on the
knob, rotating it (clockwise to increase and counterclockwise to decrease pressure) until the gauge indicates the desired
pressure and then pushing it down to lock the setting.
A lubricator is supplied for air feed applicators that need lubrication. Molex air feed applicators do not require lubrication.
The lubricator is shipped without lubricant in it. Fill the lubricator (make sure the main air supply is disconnected or the slide
valve is in the off position before adding lubricant) through the fill plug on the top of the unit with SAE 10W air tool oil, such
as Ingersoll-Rand 10Z4 (SDS link). The lubricator has a graduated dial on top. Turn the dial to the “1”or “2”setting.
Caution: Do not over lubricate. Only a very small amount of lubricant is required to assure smooth operation.
Excess lubricant is exhausted to the atmosphere.
If lubrication is not required, set the dial to “0”to turn off the lubricator.

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SHUT HEIGHT GAUGE
PRESS QUICK CHANGE
MOUNTING PLATE
Figure 2-5
PRESS
PULL UP FROM HOLE, ROTATE
AND SLIDE DOWN INTO HOLE
REPOSITION
TERMINAL GUIDE
Figure 2-4
REMOVE M6 SCREWS AND
REMOVE
TERMINAL GUIDE
LOOSEN THE
M10 SET SCREW
IN FRONT OF PRESS
2.5 Terminal Feed Guide
Depending on side or rear-feed applications, the terminal guide
plate and bracket must be repositioned.
The press is set for rear-feed applicators when shipped from the
factory. When rear-feed applicators are used, the two M6 screws
from the terminal guide mounting bracket are removed. The guide
bracket is rotated 90 degrees, and the assembly is then mounted
on the side of the press with the two M6 socket head screws.
Figure 2-4 shows conversion between side-feed and rear-feed
terminal guides.
2.6 Shut Height
As shipped from the factory, the press is set to the industry-
standard shut height of 135.80mm (5.346”) with a calibrated
gauge. Molex offers an industry-standard shut height gauge
(order number 63800-7900). It is recommended that the crimp
press shut height be checked regularly. See Figure 2-5 and
Section 3-3.
CAUTION: Always manually cycle the press after adjusting the shut height before restoring power to the machine.
Verification of Press Shut Height
In case the press shut height is inadvertently changed, a label is attached to the front of
each press indicating the original factory settings. See Section 3.4 for shut height
adjustment. Always reset the press to the factory setting on the label before installing
applicators to avoid tooling damage. Check the factory setting periodically with a calibrated
shut height gage.

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Revision: F Revision Date: 11-27-18
Figure 2-6
FUSE
HOLDER
Figure 2-7
Figure 2-8
2.7 Safety and Work Area Check
The press position should be ergonomic for the operator’s size. A bench height of 762-
813mm (30.0-32.0”) will provide operator comfort and allows both feet to rest on the floor.
The foot pedal should be placed in a comfortable position. The press should be located
approximately 150mm (6.0”) from the edge of the bench. A chair or stool with adjustable
height and backrest should be provided for maximum comfort and back support for the
operator.
CAUTION: Molex recommends wearing eye protection when the press is in
operation or being serviced.
To prevent fatigue, operators should be encouraged to take a short break every few hours.
The fuse is located on the control panel. To replace the fuse (10AMP on 100-120V models
and 7AMP or 10AMP on 200-240V models), turn the holder counterclockwise. Turn the
holder clockwise install the fuse. See Figure 2-6.
2.8 Guards
Upgrade Kit Safety Guard for Old Styles of the TM-3000 and TM-4000 Guards
For existing TM-3000 and TM-4000 presses with older guards (see Figure 2-7), the 64016-2595 safety guard upgrade kit is
available. See document ATS-640162595. Applicable press order numbers: 63801-7200, 63801-7300 and 63801-7600.
New Safety Guard
Starting in 2012, all new presses will have the 64016-2590 Safety Guard Assembly
factory installed (see Figure 2-8). If the Safety Guard needs to be installed, follow
the steps below.
Installation
Before installing the safety guard, turn off and disconnect the power
supply to the press.

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Revision: F Revision Date: 11-27-18
NEW ANGLE
GUARD
64016-2581
PRESS LAMP
ASSEMBLY
EXISTING HOLES
IN PRESS FRAME
EXISTING
HARDWARE
USE 4MM HEX WRENCH
Figure 2-9
SPACER PLATE
64016-2579
INSTALL WITH A
3MM HEX WRENCH
M4 x 16 Long SHCS
WITH WASHERS
GUARD
MOUNTING
FRAME
USE THESE HOLES TO
REINSTALL THE GUARD
MOUNTING FRAME ONLY IF
THE DOOR ALIGNMENT
NEEDS ADJUSTMENT.
Figure 2-10
Tools
To install the 64016-2595 safety guard assembly, the following tools will be needed:
#3 Phillips Screw Driver 10mm Combination Wrench 3mm Hex Wrench 4mm Hex Wrench
1. Install the angle guard behind the existing lamp bracket. See Figure 2-9.
NOTE: The angle guard (64016-2581) must be installed to ensure operator safety.
2. Install the spacer plate (64016-2579) and guard mounting frame on the press. The spacer plate should be aligned so its
rear-most set of holes aligns to the threaded holes in the press frame.
3. Place the guard mounting frame over the spacer plate. Align the front set of holes in the guard mounting frame with the
threaded holes in the press frame. Use M4 screws and washers to fasten the guard mounting frame and spacer plate to the
press frame.
NOTE: If there are alignment problems with the guard door after installation, the rear set of holes in the guard mounting
frame can be aligned with the threaded holes in the press frame. This will move the guard door forward. See Figure 2-10.

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Revision: F Revision Date: 11-27-18
USE A #3 PHILLIPS HEAD
SCREWDRIVER AND A 10MM
COMBINATION WRENCH
FOR GUARD HINGE
GUARD HINGE
REAR GUARD
64016-2586
SAFETY GUARD
EXISTING HARDWARE
USE A 4MM
HEX WRENCH
Figure 2-11
M4 X 8 LG.
BHCS (2)
REFERENCE ONLY
TERMINALGUDIE
63801-7234 NOT
INCLUDED
WITH 64016-2590
LOWER TERMINAL
GUIDE 64016-2522
Figure 2-12
4. Install the guard mounting frame. Use the left (front) mounting holes that the guard mounting frame originally used.
5. Install the rear guard and the new front door assembly to the hinges. See Figure 2-11.
6. Install the lower terminal guide (64016-2522) into the terminal guide (63801-7234) with (2) M4 x 8mm BHCS. See
Figure 2-12.
Note: Clearance holes may need to be drilled into the existing terminal guide on some older TM-3000 presses.

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Revision: F Revision Date: 11-27-18
Section 3
Setup and Operation
3.1 Applicator Installation
3.2 Air Feed Applicator Installation
3.3 Manually Cycling the Press
3.4 Operation

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Revision: F Revision Date: 11-27-18
QUICK
CHANGE
PLATE
LOCATOR
CLAMPS
LOCKING
CLAMP
USE 4mm
HEX WRENCH
ENGAGE
PRESS YOKE
BASE
PLATE
LUG BOLT
PRESS
YOKE
RAM
SPACER
Figure 3-1
3.1 Applicator Installation
Always turn off and disconnect the power supply to the press. Turn off the “POWER” switch located on the control
panel.
Note: Once the press guard is open, the guard sensor will disconnect power to the motor.
Steps
1. Swing the press guard open.
2. Verify that the applicator is correctly tooled for the
terminal being used. (Refer to specification sheets
supplied with the applicator).
3. Clean the press quick change mounting plate of
scrap or chips that may interfere with the applicator
installation. Use a soft brush, not compressed air.
4. Using a 4mm hex wrench, turn the M5 socket head
screw clockwise until the locking clamp is fully
opened.
5. Slide the applicator lug bolt in the press yoke. See
Figure 3-1.
6. Pull down on the applicator base plate slots with the
locator clamps on the press quick change plate.
7. To lock applicator, turn M5 socket head screw
counterclockwise until tight.
8. Confirm that the applicator is secured properly.
9. Remove the ram spacer prior to hand cycling the
press.
Note: A ram spacer should be used when storing or transporting your applicator. Remove ram spacer proir to hand cycling
the press and replace it before removing the applicator from the press to avoid potenial damage to the tooling.
3.2 Air Feed Applicator Installation
Always turn off and disconnect the power supply to the press. Turn off the “POWER” switch located on the control
panel.
Note: Once the press guard is open, the guard sensor will disconnect power to the motor.
Warning: When using air feed applicators, always use the slide valve to shut off and vent air pressure before
servicing. The guard interlock switch DOES NOT remove air pressure. If an air feed is jammed and air pressure is
not removed before servicing, the feed could move unexpectedly and cause injury.
Steps
1. Open the press guard door.
2. Verify that the applicator is correctly tooled for the terminal being used. (Refer to specification sheets supplied with the
applicator).
3. Clean the press quick change mounting plate of scrap or chips that may interfere with the applicator installation. Use a
soft brush, not compressed air.
4. Using a 4mm hex wrench, turn the M5 socket head screw clockwise until the locking clamp is fully opened.
5. Slide the applicator lug bolt in the press yoke. See Figure 3-1.
6. Pull down on the the applicator base plate slots with the locator clamps on the press quick change mounting plate.
7. To lock the applicator, turn the M5 socket head screw counterclockwise until tight.

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Revision: F Revision Date: 11-27-18
PORT “B”
Figure 3-3
AIR-FEED
APPLICATOR
PORT “A”
ADVANCES
RETRACTS
FILTER-REG. LUBRICATOR
TO MAIN
AIR SUPPLY
8. Confirm that the applicator is secured properly.
9. Remove ram spacer before hand cycling the press.
Note: A ram spacer should be used when storing or transporting an applicator. Remove ram spacer prior to hand cycling the
press, and replace it before removing the applicator from the press to avoid potential damage to the tooling.
10. Disconnect the air supply to the filter-regulator-lubricator by sliding the shutoff valve sleeve toward the back of the press,
as shown in Figure 3-2. Remove the plugs from the fittings on the air valve. Do not discard the plugs; when the air
applicator is not being used, the fittings should be plugged.
Note: If not using an air feed applicator, always shut off
the air supply to the filter-regulator-lubricator by sliding
the shutoff valve sleeve away from the press, as shown
in Figure 3-2.
Note: Some applicators feed terminals in the retracted
position; for those, air tubes must be reversed. In
addition, some applicators are air advance and spring
return; on those applicators, one valve port will need to
be plugged.
11. Insert port “A” of the air valve with the tube that retracts the
feed mechanism of the applicator. See Figure 3-3.
12. Insert port “B” of the air valve with the tube that advances
the feed mechanism of the applicator. See Figure 3-3.
Note: When using the 64016-2000 crimp module, set the feed selector on the control panel to “SINGLE” or “DOUBLE”,
depending on the spacing of the taped terminals. See Figure 3-5.
13. Connect the main air supply to the filter reg-
lubricator by sliding the sleeve toward the
press.
14. Adjust the regulator to the recommended
pressure for the applicator.
15. Check that the tubing for the applicator is
properly connected by dry cycling the press
and observing the feed motion. The terminals
should feed while the press ram is going up.
If the feed motion is incorrect, reverse the
tubing at the valve and check again.
Note: The air valve will not operate if the press is being hand cycled. The air valve operates only during normal press cycles
with motor power.
TO MAIN
AIR SUPPLY
SHUTOFF
SLIDE VALVE
SLEEVE
Figure 3-2
FILTER-REG-LUBRICATOR
SLIDE
LEFT
TO SHUT
OFF

TM-3000 and TM-4000 Universal Press
Doc. No: TM-638017299 Release Date: 06-06-05 UNCONTROLLED COPY Page 19 of 36
Revision: F Revision Date: 11-27-18
Figure 3-4
MOTOR
TURN
CLOCKWISE
HAND CYCLE
WRENCH
TOGGLE SWITCH
SET TO
FULL CYCLE
PUSH
MOTOR ON
Figure 3-5
POWER ON
FEED
SELECTOR
3.3. Manually Cycling the Press
Always turn off and disconnect the power supply to the
press.
Always hand cycle the applicator in the press to ensure
the tooling is properly aligned.
Note: Once the hand cycle wrench is inserted into the back of the
motor, the wrench sensor will disconnect power to the motor.
Hand cycling the press is necessary to confirm correct tool
alignment and terminal feed adjustment. It also gives the
setup person the ability to step through the press cycle
manually. With no terminal or wire in the applicator, there
should be no resistance. If there is any resistance, stop. Put
the ram back to the starting cycling position and evaluate
where the resistance is coming from. It could be tool
misalignment, incorrect shut height or another problem with
the applicator.
Steps
1. Insert the hand cycle wrench (order number 63801-7264) through the access hole in the center of the motor rear cover.
Rotate the wrench to engage the motor shaft. See Figure 3-4.
2. Rotate the wrench (clockwise or counterclockwise). This turns the motor and moves the ram down and up.
3. Always return the ram back to the top so that the ram is in the start position.
4. Remove the hand cycle wrench.
3.4. Operation
Full Cycle Operation
CAUTION: Make sure the press guard is in position and all
setup procedures are followed. Follow the safety and work
area instructions.
Steps
1. Set the toggle switch on the control panel to “Full Cycle.” See
Figure 3-5.
2. Turn the “Power “ switch on. The power indicator light will
illuminate.
3. Press the “Motor On” push button. The motor indicator light
will illuminate. After a 5-second delay, the press will be ready
to cycle.
4. Place the pre-stripped wire through the slot in the press guard
and push until it contacts the applicator’s wire stop. See Figure 3-6.
5. Press and release the foot pedal. Use a sweeping motion to the right to remove the crimped terminal.
6. Check the crimped terminal and confirm that it meets the specifications and visual inspection.
7. Make sure the applicator properly fed the next terminal into position.
8. Repeat steps 4 and 5 for the next crimp.
9. During press operation, remember to turn the terminal reel occasionally to keep a slack loop of terminals going into the
applicator.
Note: If the press is idle for more than 10 minutes, the motor power will disconnect. Restore power by pressing “MOTOR ON.”

TM-3000 and TM-4000 Universal Press
Doc. No: TM-638017299 Release Date: 06-06-05 UNCONTROLLED COPY Page 20 of 36
Revision: F Revision Date: 11-27-18
1.5mm (.06”)
MAX. GAP
M4 JAM NUT
Figure 3-7
SENSOR
M12 JAM NUT
SENSOR BRACKET
TOGGLE SWITCH
TO SPLIT CYCLE
WIRE STOP
PRE-STRIPPED
WIRE
Figure 3-6
GUARD
Split Cycle Operation
Description
Split cycle is only used for closed barrel terminals and helps locate the
terminal before crimping. The ram will close partially to assist in
locating the terminal. With the terminal located, the wire can be placed
into the terminal barrel and crimped. To set up the machine for split
cycle, flip the toggle switch on the control panel to “Split Cycle.” See
Figure 3-5.
Steps
1. Press and release the foot pedal.Tthe ram will lower partially,
positioning the terminal for termination.
2. Place the pre-stripped wire into the terminal barrel.
3. Press and release the foot switch a second time. The ram will
complete its downward stroke and return to the top position to complete the cycle.
CAUTION: Make sure the press guard is in position and all setup procedures are followed. Follow the safety and work
area instructions.
Split Cycle Ram Adjustment
When setting up an applicator for split cycle operation, it may be necessary to adjust the split position of the ram (first
position) so the terminal will be captured by the punch but not crimped. To change the split position, the sensor located on
the left side of the ram cover must be adjusted. See the following steps:
Steps
1. With the terminals in the applicator,
depress the foot pedal once. See
where the crimp punch stops in the
split position.
2. If the punch is too high and does
not hold the terminal or the punch
is too low and partially crimps the
terminal, the sensor needs to be
adjusted.
3. Open the press guard.
4. Loosen the two M12 jam nuts on
the split cycle sensor, located on
both sides of the sensor bracket.
Then, loosen the M4 jam nut holding the M4 socket head screw. Turn the M4 screw clockwise to raise (or counterclockwise
to lower) the sensor. See Figure 3-7. Raise the sensor if the punch is partially crimping the terminal, or lower the sensor if
the ram is not closing far enough to hold the terminal.
5. Tighten the M4 jam nut and the two M12 jam nuts positioning the sensor for the split cycle position. See Figure 3-7.
6. Close the press guard and press the “MOTOR ON” button. Press and release the foot pedal one more time to finish the
cycle from step 1.
7. Repeat step 1 to check for the correct position of the ram.