molex TM-3000 User manual

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TM-3000UniversalPress
OrderNo63801-7299 ReleaseDate:06-06--05 UNCONTROLLED COPY Page1of29
Revision:A RevisionDate:06-06-05
TM-3000 UNIVERSAL PRESS
UsewithMolexFineAdjustorMini-MacApplicators
Instruction Manual
§Description
§Operation
§Maintenance

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Revision:A RevisionDate:06-06-05
WARNING
NEVER USETHISMACHINEWITHOUTTHEGUARDSORSAFETYDEVICESTHATAREINTENDEDTO PREVENTHANDSFROM
REMAININGINTHEDIESPACE. RUNNINGTHISMACHINEWITHOUTGUARDS,UNDERANYCIRCUMSTANCES,CANCAUSE
SERIOUSINJURY.
NEVER LIFTTHISPRESSWITHOUTTHEAIDOFMECHANICALLIFTINGDEVICES.
NEVER OPERATE,SERVICE,OR ADJUSTTHIS MACHINEORINSTALLAPPLICATORDIESWITHOUTPROPERINSTRUCTIONAND
WITHOUTFIRSTREADINGANDUNDERSTANDINGTHEINSTRUCTIONSINTHISMANUAL.
NEVER SERVICETHISMACHINEWHILEITISCONNECTEDTOANYELECTRICALPOWERSOURCE.DISCONNECTPOWERBY
UNPLUGGINGTHEPRESSFROMITSPOWERSOURCEANDFROMTHECOMPRESSEDAIRSUPPLY.
NEVER INSTALLORREMOVEAPPLICATORDIESWITHTHE MOTORRUNNING,ORAIRSUPPLYCONNECTED.
CAUTION THETM-3000PRESSISSHIPPEDFROMTHEFACTORYATASHUTHEIGHTOF135.80mm(5.346”). FAILURETOHAND
CYCLETHEPRESSWHENINSTALLINGAPPLICATORSCANCAUSESEVEREDAMAGETOTHETOOLINGAND/ORPRESS.
CAUTION MOLEXCRIMPSPECIFICATIONSAREVALIDONLYWHENUSEDWITHMOLEXTERMINALS,APPLICATORSANDTOOLING.
WORK SAFELY AT ALL TIMES
For Service, Contact Your
Local Molex Sales Office
Molex Application Tooling Group
1150E.DiehlRoad
Naperville,Illinois60532
Tel:[phone]
Fax:[phone]

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Table of Contents
SECTION
1GeneralDescription
2Installation
3Setup-Operation
4MaintenanceandTroubleshooting
5PartsList,AssemblyDrawings,ElectricalSchematics
APPENDIX
AOptions

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Section 1
General Description
1.1 Description
1.2 Features
1.3 TechnicalSpecifications
1.4 DeliveryCheck
1.5 Tools

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General Description
1.1 Description
The63801-7200(120VACversion)andthe63801-7300
(240VACversion)TM-3000UniversalPressisaneconomical,
electrically-operated,single-cycleandsplit cycledirect drive
press. Itisdesignedtoprovideaneffectivemethodofapplying
awide rangeofside-feedandrear-feedterminalstoapre-
strippeddiscretewire orcable. TheTM-3000issuitedtomid-
volumesemi-automaticoperations.
Productionflexibilityisobtainedthroughtheuseof
interchangeableFineAdjustorMini-Macapplicators andmost
IndusrtyStandardApplicators..
TheTM-3000willcompleteonecrimpingcyclewitheach
depressionofthefootpedalandtwodepressionsforsplitcycle.
Safeoperation isprovided byan interlockswitch thatrenders
thepressinoperativeifthesafetyguardisopenedorremoved.
1.2 Features
§UtilizesbothFineAdjustandMini-Macapplicatorssideandrear
feed,andmostindustrystandardapplicators
§PressisshippedsettoIndustryshutheightof135.80mm
(5.346”)
§Idealformid-volume,semi-automaticapplications
§MeetsO.S.H.A.safetystandardsisANSI-Z535.2-2002compliant
§Totallyenclosedforoperatorsafety, includingapowerinterlock
switchforthefrontguard
§Resettablecounterforaccuratebatchcounting
§Modularsolid statecontrolswithan easypluginpowercord
andfootswitch.
1.3 Technical Specifications
Dimensions with reel mounted
Height 1210.00mm(47.60“)
Width 648.00mm (25.50“)
Depth 559.00mm (22.00“)
Unpackedweight 100kg (220lbs)
Power Requirements
Voltage:63801-7200-120VAC60HZ
Voltage:63801-7300-240VAC60HZ
1/4NPTinlet12.7mm(1/2”)Supplypipemin.
Production Rate
2400terminationsperhourmaximum,dependingonoperatorskill
andwirelength.
Processing Capability
Upto 10AWG(5.0mm²)ofcopper conductorinsolidor stranded
wire. (2TonPress)
Sound Level
Operatorwillbeexposedtolessthan85DBA.
1.4 Delivery Check
Afterremovingthepackagingband,thetopandsidesofthebox
shouldliftoffeasily.Thefollowingitemsareincludedinthispackage:
Quantity
MainPressBody 1
ReelSupportAssembly 1
“T”wrenchformanualcycling 1
Carton Contents Quantity
69018-6237PowerCord
(for63801-7200) 1
OR
62500-1774PowerCord220V10A.
(for63801-7300) 1
63801-7271FootPedal 1
63800-7299-TM-3000InstructionManual 1
1.5 Tools
Thefollowingtoolsarerecommendedforsetupand
adjustmentstotheapplicatorinthispress
üMetrichexwrenchset
üSmallstandardscrewdriver
üAdjustablewrench
üNeedlenosepliers
üCrimpmicrometer
üEyeloupe(10x)
üWirestripper/cutter
üEnglishhexwrenchsetforsomenon-metricapplicators
Pneumatic:RequiredforAirFeedApplicatorsonly.
75PSImin.(366KGf/cm2)min.
1.0 SCFM(28.3L/min.

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Revision:A RevisionDate:06-06-05
Section 2
Installation
2.1 Lifting/Mounting
2.2 ReelSupport
2.3 FootPedalandPowerConnection
2.4 PneumaticSupplyHook-up
2.5 TerminalFeedGuide
2.6 FunctionTest
2.7 SafetyandWorkAreaCheck

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Revision:A RevisionDate:06-06-05
2.1 Lifting/Mounting
WARNING:TheTM-3000Pressweighs over100kg(220
lbs);itshouldnotattempttobeliftedbyoneindividual.
Mechanicalliftingdevicesshouldbeused. Apersonlifting
thepresscansustainseverebackorotherinjuries.
Aliftinghookisprovidedonthetopofthe press. A
heavy-dutychain,rope,cable,orbeltcanbeusedwith
loops,links,orringsoneachend thatcansecurelyattach
totheliftinghooks. An electric,hydraulic,ormechanical
craneshouldbe usedto liftthepress. Lift thepress up
approximately12.00mm(.50”)andverifythatthepress
iswell balanced. Upon verification, thepresscan be
liftedontoasturdyworkbench. Accessto theback ofthe
machineis requiredfor manualcycling. A woodenbench
thatisaminimumof25.00mm(1.00”)thickwilloffer
quietvibration-freeoperation. Forthinnerorsheetmetal
tops,theTM-3000canbeattachedtothetablewithtwo
12mmbolts. BoltsarenotsuppliedbyMolex.
2.2 Reel Support
Installthereelsupportintheholelocatedonthetopof
machineframe. Forrearfeed,rotatethereelsupportas
required. SeeFigure2-3. LoosentheM10setscrewthatholds
thereelsupport. Pull upfrom theholeand rotatefor the
properfeedingorientation. Thenslidedownbackintothehole
andtightentheM10setscrew.
2.3 Foot Pedal and Power Connection
Connectthe3-pinplugforthefootpedalintherear ofthe
presscontrolassembly.Turnthelockingring clockwiseuntil
tight. Connectthepowercordplugtothesocketintheback
ofthecontrolassembly. Useagroundedelectrical outletas
thepowersource.SeeFigure2-2.
FOOT PEDAL
ASSEMBLY
PRESS CONTROL
ASSEMBLY
Figure 2-1
OILER ASSEMBLY
MOTOR
REEL SUPPORT
ASSEMBLY
TERMINAL GUIDE
POWER CORD
WORK BENCH
LIFT HOOK WORK LIGHT

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POWER
CORD PLUG
Figure 2-2
FOOTSWITCH
CORD
PULL UP FROM
HOLE, ROTATE AND
SLIDE DOWN INTO
HOLE
REPOSITION
TERMINAL GUIDE
Figure 2-3
REMOVE M6 BHCS
AND REMOVE
TERMINAL GUIDE
LOOSEN
M10 SSS IN
FRONT OF
PRESS
2.4 Pneumatic Supply Hook-Up
Acompressedairsupplyis requiredifairfeedorotherair
poweredapplicatorswillbe used. TheTM3000presscomes
equippedwithanair supplysystem,whichconsists offilter,
regulator,lubricatorand avalve toactuate theairfeedsatthe
propertime inthe presscycle.
Duetotheconsiderabletypesofairconnectionandquick
connectfittingsavailable;Molex onlysuppliesthe TM3000press
witha1/4NPTfemalethreadedfitting. Thecustomermay
attachwhatevertypeofairconnectionsthatare commonlyused
intheirplanttothisport.
Theminimumflexibletubesizeusedtoconnectthepressshould
be8mmor5/16”toassureadequateflowrate.
Afilter-regulator-lubricatorunit issuppliedtoproperlycondition
theincoming air. Thefilter will remove particulate and moisture
fromtheairthatcandamageorreducethelife ofcylindersand
valves. Thisfilterandbowlshould beservicedonaregular
schedule. (Seesection 4.1) Thefilter has anautomatic drainat
thebottomofthebowlthatwillautomaticallyopenandexpel
fluidwhenthebowlisgettingfull. Itisrecommendedthat, a
6mmor1/4”flexibletube,beattachedtothedrainhosebarb
andruntoacontaineriftheairsystem containsexcessive
moisture.
Theregulatoradjuststhepressureof theincomingair towhat
theapplicatorsrequireusually60-80PSI(refertotheapplicator
manualforrecommended pressures.) Adjustmentis
accomplishedbypullingupontheknob,rotatingituntilthe
gaugeindicatesthedesiredpressure,thenpushingitdownto
lockthesetting.
Alubricatorissuppliedforthoseapplicatorairfeedsthatneed
lubrication. Molexair-feedapplicatorsdonot require
lubrication.Thelubricatorisshippedwithoutlubricantinit. To
use,fillthelubricator(makesurethemainairsupplyis
disconnectedorthattheslidevalveprovidedisintheoffposition
beforeaddinglubricant)throughthe fillplugonthetopofthe
unit,withahighqualitySAE10Woil. Thelubricatorhasa
graduateddialontop,turnthedialtothe1or2setting.
Caution:Donotoverlubricate. Onlyaverysmallamountof
lubricantisrequiredto assuresmoothoperation. Excesslubricant
isexhaustedtotheatmosphere.
Iflubricationisnotrequiredsetthedialto0toturn off the
lubricator.
2.5 Terminal Feed Guide
Depending on side or rear-feedapplications,theterminal
guideplateandbracketmustberepositioned.
TheTM-3000pressissetforside-feedapplicatorswhen
shippedfromthefactory. Whenrear-feedapplicatorsare
used,thetwoM6BHCSfromtheterminalguide-mounting
bracketaretoberemoved. SeeFigure2-3. Theguide
bracketisrotated180 degreesandtheassembly isthen
mountedonthetwostandoffsintherearofthepresswiththe
twoM6SHCS. SeeFigure2-3.

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SHUT HEIGHT GAUGE
PRESS QUICK CHANGE
MOUNTING PLATE
Figure 2-4
PRESS
MOTOR ON
PUSH BUTTON
COUNTER
TOGGLE SWITCH
FOR FULL OR
SPLIT CYCLE
Figure 2-5
MAIN
POWER
FUSE HOLDER
2.6 Function Test
WhentheTM-3000isshippedfromthefactory,itissettothe
industryshutheightof135.80mm(5.346”)withacalibrated
loadgauge. The pressshutheight gaugeisspring loadedto
giveanaccuratereadingonthepress shutheight. SeeFigure
2-4. Molexrecommendshandcyclingthepresseachtimean
applicatorisinstalled. SeeSection3-3.
CAUTION:Alwaysmanually cyclethepressbefore
restoringpowertothemachine.
2.6.1Verification of Press Shut Height
Thispress comes factorysetat an IndustryStandard shut height
of135.80mm(5.346”). Alabelisattachedtothefrontof
eachpressindicatingthefactorysettings. Thispresshasan
adjustableshut height,seeSection 3.4.3for crimpheight
adjustment. Alwaysreturnthepresstothefactorysettingon
thelabel beforeinstalling applicatorsto avoidtooling damage.
Checkthe factorysetting periodicallywitha calibratedshut
heightgage.
Shutheightgaugesmaybepurchasedfrom:
ArtosEng. 602-581-0070
KomaxCorp. 847-537-6640
Thegauges shouldcome withinstructionsfor useand
calibration.
2.7 Safety and Work Area Check
Checkthatthecrimpingpositionisergonomic forthe
operator’ssize. A bench height of762.00to813.00mm
(30.00to32.00”)willprovideoperatorcomfort,and
allowsbothfeettorestonthefloor. Thefootpedal
shouldbeplacedin acomfortableposition. Checkthat
thepresspositionislocatedapproximately150.00mm
(6.00“)fromtheedgeofthebench. A chairorstoolwith
adjustableheightandbackrestshouldbeprovidedfor
maximumcomfortandbacksupportforthe operator.
SeeFigure2-5forthecontrolpanel.
CAUTION: Molexrecommendsthattheoperatorand
observersweareyeprotectionwhenthepressisinoperation
orbeingserviced.
Thefuse islocatedon thecontrolpanel. To replacethe
fuse(10AMPon110Vmodelsand5AMPon220V
models),turntheholderinthedirectionasshown. Turn
clockwiseto secure holder in place whenreplaced. See
Figure2-5.