molex TM2000 User manual

TM-2000 Universal Press
Order No.: TM-638008399 Release Date: 08-08-02 UNCONTROLLED COPY Page 1 o 36
Revision: H Revision Date: 01-15-13
TM-2000 UNIVERSAL PRESS
Use with Molex FineAdjust or Mini-Mac Applicators
Operation Manual
Order No 63800-8399
 Description
 Operation
 Maintenance

TM-2000 Universal Press
Order No.: TM-638008399 Release Date: 08-08-02 UNCONTROLLED COPY Page 2 o 36
Revision: H Revision Date: 01-15-13
Safety Warnings and Information
Read
and
understand
all o the in
structions and sa ety in ormation in this manual be ore
operating or servicing this tool.
Keep this manual available when using this tool.
Replacement manuals are available or download at no charge at www.molex.com.
SAFETY ALERT SYMBOL
This symbol is used to call your attention to hazards or unsa e practices which could result in an injury
or property damage. The signal word, de ined below, indicates the severity o the hazard. The message
a ter the signal word provides in ormation or preventing or avoiding the hazard.
DANGER
DANGER:
Indicates an imminently hazardous situation which, i not avoided, could result in death or serious injury.
WARNING
WARNING:
Indicates a potentially hazardous situation which, i not avoided, could result in death or serious injury.
CAUTION
CAUTION:
Indicates a potentially hazardous situation which, i not avoided, may result in minor or moderate injury.
CAUTION may also be used to alert against unsa e 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 rom lying debris.
Heavy Object
To avoid muscle strain or back injury, use li ting
aids and proper li ting techniques when removing
or replacing.
Failure to observe these precautions may result in
injury or property damage.
WARNING
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.
Never
install or service this machine while
connected to any electrical power source.
Disconnect power by unplugging the press
rom 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
irst reading and understanding the instructions
in this manual and all applicable press and/or
wire processing machine.
manuals.
Always hand cycle the applicator in the equipment
to ensure the tooling is properly aligned.
Failure to observe these precautions may result in
Injury or property damage.

TM-2000 Universal Press
Order No.: TM-638008399 Release Date: 08-08-02 UNCONTROLLED COPY Page 3 o 36
Revision: H Revision Date: 01-15-13
WARNING
WARNING
Never use this press or wire processing machine
without guards or sa ety devices that are intended
to prevent hands rom 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 orces created by compressed
air can orce 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
The Molex applicators are designed to operate in presses with standard shut heights o 135.80mm (5.346”).
Installation in crimp presses with other than standard shut heights can cause severe tool breakage. It is advisable that be ore
installation, a check o the shut height be per ormed. Molex will not be liable or any damages as a result o 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
per orm any service or maintenance other than as described in this manual.
Never modi y, alter or misuse the equipment
Molex crimp speci ications 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 o ers tooling technical assistance or customers who may need some guidance or tooling adjustments. This support can be
obtained by calling either o the two numbers listed below and asking or 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 o a customer’s Molex Press. Questions with regard to Molex connector products
or how to identi y the proper tooling and/ or tooling documentation should be directed to your local Molex personnel or Customer Service
Representative.
When calling or service on the press a copy o the Tooling Manual and Speci ic Applicator Tooling Specification Sheet should be
present and a person that is amiliar with the applicator should be present. Be sure the ollowing in ormation is supplied:
1. Customer name
2. Customer address
3. Person to contact such as (name, title, e-mail, and telephone number
4. Applicator order number (Lease number also i applicable)
5. Serial number (Lease number also i applicable)
6. Molex Connector product order number
7. Urgency o request
8. Nature o problem
Molex Application Tooling Group
2200 Wellington Court
Lisle, IL 60532, USA
Tel: [phone]
Fax:[phone]
Visit our Web site at http://www.molex.com

TM-2000 Universal Press
Order No.: TM-638008399 Release Date: 08-08-02 UNCONTROLLED COPY Page 4 o 36
Revision: H Revision Date: 01-15-13
Table of Contents
Contents
TM-2000 UNIVERSAL PRESS ............................................................................................................................................. 1
Order No 63800-8399 ........................................................................................................................................................... 1
Safety Warnings and Information ...................................................................................................................................... 2
Table of Contents ................................................................................................................................................................ 4
Section 1 ........................................................................................................................................................................... 5
General Description ...................................................................................................................................................... 6
1.1 Description......................................................................................................................................................... 6
1.2 Features ............................................................................................................................................................ 6
1.3 Technical Speci ications .................................................................................................................................... 6
1.4 Delivery Check .................................................................................................................................................. 6
1.5 Tools .................................................................................................................................................................. 6
Section 2 ........................................................................................................................................................................... 7
Installation..................................................................................................................................................................... 7
2.1 Li ting/Mounting ................................................................................................................................................. 8
2.2 Reel Support...................................................................................................................................................... 8
2.3 Foot Pedal and Power Connection .................................................................................................................... 9
2.4 Terminal Feed Guide ......................................................................................................................................... 9
2.5 Function Test ..................................................................................................................................................... 9
2.6 Sa ety and Work Area Check .......................................................................................................................... 10
Section 3 ......................................................................................................................................................................... 11
Setup and Operation ................................................................................................................................................... 11
3.1 Applicator Installation and Removal ................................................................................................................ 12
3.2 Manually Cycling the Press ............................................................................................................................. 12
3.3 Operation ......................................................................................................................................................... 13
Section 4 ......................................................................................................................................................................... 14
4.1 Maintenance .................................................................................................................................................... 15
4.2 Clutch Service/Replacement ........................................................................................................................... 15
4.3 Shim Installation/Removal ............................................................................................................................... 17
4.4 Oiler ................................................................................................................................................................. 18
Section 5 ......................................................................................................................................................................... 19
5.1 Parts List ......................................................................................................................................................... 20
5.2 Assembly ......................................................................................................................................................... 21
5.2 Assembly (continued) ...................................................................................................................................... 22
5.2 Assembly (continued) ...................................................................................................................................... 23
5.2 Assembly (continued) ...................................................................................................................................... 24
5.3 Electrical Schematic ........................................................................................................................................ 25
5.3 Electrical Parts List .......................................................................................................................................... 26
5.4 Troubleshooting ............................................................................................................................................... 27
Appendix A ...................................................................................................................................................................... 29
A.1 Conductor Brush and Terminal Position ......................................................................................................... 30
A.2 Conductor Bell Mouth and Terminal Cuto Tab ............................................................................................... 31
A.3 Crimp Height Measurement .................................................................................................................................. 32
A.4 Insulation Crimp ............................................................................................................................................... 33
A.5 Pull Force Testing ............................................................................................................................................ 34

TM-2000 Universal Press
Order No.: TM-638008399 Release Date: 08-08-02 UNCONTROLLED COPY Page 5 o 36
Revision: H Revision Date: 01-15-13
Section 1
General Description
1.1 Description
1.2 Features
1.3 Technical Speci ications
1.4 Delivery Check
1.5 Tools

TM-2000 Universal Press
Order No.: TM-638008399 Release Date: 08-08-02 UNCONTROLLED COPY Page 6 o 36
Revision: H Revision Date: 01-15-13
General Description
1 1 Description
The 63800-8300 (120V AC version) and the 63800-
8400 (240V AC version) TM-2000 Universal Press is
an economical, electrically-operated, single-cycle
lywheel press. It is designed to provide an e ective
method o applying a wide range o side- eed and
rear- eed terminals to a pre-stripped discrete wire or
cable. The TM-2000 is suited to mid-volume semi-
automatic operations.
Production lexibility is obtained through the use o
interchangeable FineAdjust or Mini-Mac applicators.
The TM-2000 will complete one crimping cycle with
each depression o the oot pedal. Sa e operation is
provided by an interlock switch that renders the
press inoperative i the sa ety guard is removed.
1 2 Features
 Utilizes both FineAdjust and Mini-Mac applicators,
and most industry standard applicators
 Industry shut height o 135.80mm (5.346”)
 Ideal or mid-volume, semi-automatic applications
 Meets ISO standard
 Totally enclosed or operator sa ety, including a
power interlock switch or the ront guard, with “guard
open” indicator light
 Resettable counter or accurate batch counting
 Modular solid state controls. Power cord and oot
pedal plug in easily
 CE certi ied or sale in Europe (240/50 Hz version)
1 3 Technical Specifications
Dimensions with reel mounted
Height 1260.00mm (49.60“)
Width 560.00mm (22.00“)
Depth 686.00mm (27.00“)
Unpacked weight 145kg (320 lbs)
Power Requirements
Voltage: 63800-8300-120V AC 60 HZ
Voltage: 63800-8400-240V AC 50 HZ
Note: Press shipped setup or 120V AC service
Production Rate
500 terminations per hour maximum, depending on
operator skill and wire length.
Flywheel Rotation: 210 RPM
Processing Capability
Up to 10 AWG (5.0mm²) o copper conductor in solid or
stranded wire.
Sound Level
Operator will be exposed to less than 85 DB.
1 4 Delivery Check
A ter removing the packaging band, the top and sides o
the box should li t o easily. The ollowing items are
included in this package :
Quantity
Main Press Body 1
Reel Support Assembly 1
Carton Contents Quantity
69018-6237 PowerCord
( or 63800-8300) 1
OR
62500-0113 Power Cord
( or 63800-8400) 1
63800-8394 Foot Pedal 1
69018-8235
10 mm Hex Wrench 1
63800-8399
TM-2000 Instruction Manual 1
* For international applications, the power cord/plug may
need to be replaced or adapted with the appropriate
connection.
1 5 Tools
The ollowing tools are recommended or setup and
adjustments to the applicator in this press
 Metric hex wrench set
 Small standard screwdriver
 Adjustable wrench
 Needle nose pliers
 Crimp micrometer
 Eye loupe (10x)
 Wire stripper/cutter

TM-2000 Universal Press
Order No.: TM-638008399 Release Date: 08-08-02 UNCONTROLLED COPY Page 7 o 36
Revision: H Revision Date: 01-15-13
Section 2
Installation
2.1 Li ting/Mounting
2.2 Reel Support
2.3 Foot Pedal and Power Connection
2.4 Terminal Feed Guide
2.5 Function Test
2.6 Sa ety and Work Area Check

TM-2000 Universal Press
Order No.: TM-638008399 Release Date: 08-08-02 UNCONTROLLED COPY Page 8 o 36
Revision: H Revision Date: 01-15-13
ROTATE REEL SUPPORT
ASSEMBLY FOR PROPER
FEEDING ORIENTATION
SLIDE DOWN
INTO HOLE
PULL UP
FROM HOLE
TERMINAL
GUIDE
Figure 2-2
FOOT PEDAL
ASSEMBLY
PRESS CO
NTROL
ASSEMBLY
Figure 2-1
MAIN PRESS BODY
LIFTING HOOKS
REEL SUPPORT
ASSEMBLY
TERMINAL GUIDE
ASSEMBLY (INSTALLED)
POWER CORD
WORK BENCH
2 1 Lifting/Mounting
WARNING: The TM-2000 Press weighs over 145 kg (320 lbs); it should not attempt to be li ted by one individual.
Mechanical li ting devices should be used. A person li ting the press can sustain severe back or other injuries.
Li ting hooks are provided on each side o 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 li ting hooks. An electric, hydraulic, or mechanical crane
should be used to li t the press. Li t the press up
approximately 12.00mm (.50”) and veri y that the press is
well balanced. Upon veri ication, the press can be li ted
onto a sturdy workbench. Access to the back o the
machine is required or manual cycling. A wooden bench
that is a minimum o 25.00mm (1.00”) thick will o er quiet
vibration- ree operation. For thinner or sheet metal tops,
the TM-2000 can be attached to the table with two 12mm
bolts. Bolts are not supplied by Molex.
2 2 Reel Support
Install the reel support in the hole located on the le t side o
the top cover. For rear eed, rotate the reel support as
required. See Figure 2-2.

TM-2000 Universal Press
Order No.: TM-638008399 Release Date: 08-08-02 UNCONTROLLED COPY Page 9 o 36
Revision: H Revision Date: 01-15-13
FOOTSWITCH
CORD
FUSE
DRAWER
Figure 2
-
3
POWER CORD PLUG
REPLACE (4)
M5 WINGS NUTS
REMOVE (4)
M5 WING NUTS
REMOVE (4)
M4 BHCS
TERMINAL
GUIDE
TERMINAL
GUIDE
TURN TERMINAL
GUIDE BRACKET
AROUND
INSTALL (4)
M4 BHCS
Figure 2-4
2 3 Foot Pedal and Power Connection
Connect the 4-pin plug or the oot pedal in the rear o the press
control assembly. Turn the locking ring clockwise until tight.
Connect the power cord plug to the socket in the back o the
control assembly. Use a grounded electrical outlet as the power
source. Two uses are located in the use drawer directly above the
power socket. To replace the uses, use a small screwdriver to
open the use drawer, remove damaged uses and replace. See
Figure 2-3.
2 4 Terminal Feed Guide
Depending on side or rear- eed applications, the terminal guide plate and
bracket must be repositioned.
The TM-2000 press is set or side- eed applicators when shipped rom
the actory. When rear- eed applicators are used, the our 5mm wing
nuts are removed. The guide bracket is rotated 180 degrees and the assembly is then mounted on the right side o the press.
See Figure 2-4.
2 5 Function Test
When the TM-2000 is shipped rom the actory, it is set to the industry shut height o 135.80 mm (5.346”) with a calibrated load
gauge. The press shut height gauge is spring loaded to give an accurate reading on the press shut height. See Figure 2-5.
Molex recommends hand cycling the press each time an applicator is installed.

TM-2000 Universal Press
Order No.: TM-638008399 Release Date: 08-08-02 UNCONTROLLED COPY Page 10 o 36
Revision: H Revision Date: 01-15-13
EMERGENCY
STOP BUTTON
GUARD OPEN
INDICATOR
LIGHT
RUN
INDICATOR
LIGHT
Figure 2-6
ON
BUTTON
CAUTION: Always manually cycle the press be ore restoring power to the machine.
Verification of Press Shut Height
The shut height o 135.80mm (5.346”) should not change throughout the li e o the press. However, the shut height should be
checked on a periodic basis with a calibrated shut height gauge or i it is thought the shut height might have been altered.
Shut height gauges may be purchased rom:
Artos Eng. 602-581-0070
Komax Corp. 847-537-6640
The gauges should come with instructions or use and calibration.
See Section 4.3 o this manual or resetting the shut height o the
TM-2000 to industrial standards.
2 6 Safety and Work Area Check
Check that the crimping position is ergonomic or the operator’s
size. A bench height o 762.00 to 813.00mm (30.00 to 32.00”) will
provide operator com ort, and allows both eet to rest on the loor.
The oot pedal should be placed in a com ortable position. Check
that the press position is located approximately 150.00mm (6.00“)
rom the edge o the bench. A chair or stool with adjustable height
and backrest should be provided or maximum com ort and back
support or the operator. Observe where the emergency stop
button is on the control panel. See Figure 2-6.
CAUTION: Molex recommends that the operator and observers wear eye protection when the press is in
operation or being serviced.
SHUT HEIGHT
GAUGE
PRESS QUICK CHANGE
MOUNTING PLATE
Figure 2
-
5
PRESS

TM-2000 Universal Press
Order No.: TM-638008399 Release Date: 08-08-02 UNCONTROLLED COPY Page 11 o 36
Revision: H Revision Date: 01-15-13
Section 3
Setup and Operation
3.1 Applicator Installation and Removal
3.2 Manually Cycling the Press
3.3 Operation

TM-2000 Universal Press
Order No.: TM-638008399 Release Date: 08-08-02 UNCONTROLLED COPY Page 12 o 36
Revision: H Revision Date: 01-15-13
LOCATOR
CLAMPS
PRESS QUICK
CHANGE
MOUNTING PLATE
LOCKING
CLAMP
USE 4mm
HEX WRENCH
Figure 3-1
ENGAGE PRESS
YOKE
APPLICATOR
LUG
BOLT
BASE PLATE
3 1 Applicator Installation and Removal
Always turn o and disconnect the power supply to the press. Turn o the “POWER” switch located on the control
panel.
Steps
1. Remove press guard.
2. Veri y that the applicator is or the product. (Re erence speci ication sheets supplied with the applicator).
3. Clean the press quick change mounting plate o scrap or chips that may inter ere with the applicator installation.
4. Using a 4mm hex wrench, turn the M5 x 30.00 Lg. SHCS clockwise until the locking clamp is in the ull out
position.
5. Locate the applicator lug bolt in the press yoke. See Figure 3-1.
6. Align the applicator base plate with the locator clamps on the press quick change mounting plate.
7. To lock applicator, turn M5 x 30.00 Lg. SHCS counter clockwise until tight.
8. Con irm that the applicator is secured properly.
3 2 Manually Cycling the Press
Power down the press by pressing the emergency stop button located on the control panel.
Always hand cycle the applicator in the press to ensure the tooling is properly aligned and terminal feed
adjustment It also gives the setup person the ability to step through the press cycle manually
Steps
1. Insert the 10mm hex wrench through the access hole in the center o the rear cover and locate it in the M12 SHCS.
See Figure 3-2.
2. Rotate the hex wrench counter clockwise. This turns the lywheel and moves the ram down and up.

TM-2000 Universal Press
Order No.: TM-638008399 Release Date: 08-08-02 UNCONTROLLED COPY Page 13 o 36
Revision: H Revision Date: 01-15-13
Figure 3-2
10mm HEX
WRENCH
3. Always return the press back to top dead center insuring that the clutch collar is engaged by the actuator. This is
done by reversing the direction o the 10mm wrench a ter hearing the clutch actuator make a click sound.
SeeFigure 4-3.
4. Remove the 10mm hex wrench.
3 3 Operation
CAUTION: Make sure the press guard is in position and all setup procedures are ollowed. Follow the sa ety and work
area instructions.
Steps
1. Wire should be stripped and prepared or processing.
2. Place the prestripped wire through the slot in the press
guard and push until it contacts the wire stop. See Figure
3-3.
3. Press the oot pedal down once. Use a sweeping motion
to the right with the crimped wire.
4. Check the crimped wire and con irm that it meets the
applicator speci ications and visual inspection.
WIRE STOP
PRE
-
STRIPPED
WIRE
Figure 3
-
3

TM-2000 Universal Press
Order No.: TM-638008399 Release Date: 08-08-02 UNCONTROLLED COPY Page 14 o 36
Revision: H Revision Date: 01-15-13
Section 4
4.1 Maintenance
4.2 Clutch Service/Replacement
4.3 Shim Installation/Removal
4.4 Oiler

TM-2000 Universal Press
Order No.: TM-638008399 Release Date: 08-08-02 UNCONTROLLED COPY Page 15 o 36
Revision: H Revision Date: 01-15-13
INPUT HUB
CLUTCH
COLLAR
DISENGAGED
POSITION
ENGAGED
POSITON
ACTUATOR
Figure 4-3
M6 X 16LG SHCS (4)
GREASE
FITTING
GREASE
GROOVES
Figure 4-1
RAM
M6 X 60LG SSS
AND HEX NUT
CONTROL
COLLAR
BACK SPRING
HOUSING
INPUT
HUB
FLYWHEEL
I
NSERT 10mm
HEX WRENCH
HERE
PRESS CASTING
Figure 4-2
4 1 Maintenance
Always turn o and disconnect the power supply to the press.
Turn o the “POWER” switch located on the control panel.
The TM-2000 press requires very little maintenance. The press
ram will need to be greased periodically using the grease itting
located on the ace plate or remove the ace plate and apply
grease as indicated. See Figure 4-1.
For e icient operation the TM-2000 press should be cleaned
daily with a so t bristle brush to remove any carrier strip debris
and terminal plating dust rom the tooling area.
4 2 Clutch Service/Replacement
Operation Check 1
Always turn o and disconnect the power supply to the
press. Turn o the “POWER” switch located on the
control panel.
1. Remove the rear cover o the TM-2000 press. Veri y
that the clutch control collar is in the locked position.
See Figure 4-3. Insert the 10mm hex wrench into the
socket head cap screw. This screw is located in the
center o the lywheel. See Figure 4-2. This screw is
spring loaded to prevent the wrench being le t in the
unit.
2. Attempt to rotate the hex wrench clockwise. I the unit
will not turn, it is unctioning properly.
3. Next, rotate the input hub/ lywheel clockwise by hand.
The input hub/ lywheel should be ree to rotate. During
this portion o the operational check, the black spring
housing should not rotate. See Figure 4-2.
4. I the unit ails operational check 1, the clutch unit has
ailed internally or the actuator is not unctioning
properly and the clutch unit must be replaced.
Operation Check 2
CAUTION: By disengaging the actuator, (See Figure 4-3) the ram
will be ree to move. The weight o the ram can result in downward
motion. Use caution to ensure that the area under the ram is clear
o ingers and hand tools. The machine guard should be in place.
1. Veri y that the clutch control collar is unlocked. See Figure 4-3.
The cranksha t, input hub/ lywheel, and black spring housing
should rotate reely with the 10mm wrench moving the ram down
and up.
2. A ter 360 degrees o clockwise rotation, the actuator will engage
the clutch control collar and rotation will stop. This is normal
operation.

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Revision: H Revision Date: 01-15-13
3. I rotation with the 10mm wrench is not possible, and the actuator is disengaged, the clutch unit is demonstrating early signs
o ailure and must be replaced.
Removing the Clutch Unit
WARNING: This procedure should be ollowed to ensure compliance with sa ety instructions. Molex cannot accept
liability in the event o a subsequent accident caused by clutch ailure when improperly serviced by the customer.
Always turn o and disconnect the power supply to the press. Turn o the “POWER” switch located on the control panel.
See Figure 4-4 or the ollowing steps.
1. Remove the V-Belt.
2. Disconnect the leads rom the clutch solenoid.
3. Remove the lywheel bearing retainer screw and washer rom the end o the cranksha t.
4. Remove (3) M6 x 40.00 Lg. SHCS rom the lywheel.
5. Remove the lywheel. The inner race o the lywheel may stay on the cranksha t when the lywheel is removed.
6. Remove the 5.0mm x 35.00 Lg. spiral pin rom the clutch and cranksha t using a drive punch.
7. Remove the (3) M6 x 16.00 Lg. SHSS (socket head shoulder screw) rom the clutch plate.
8. Pull the clutch/solenoid assembly rom the cranksha t. This may require pry bars to push rom the rear side o the clutch
plate. I the inner race o the lywheel remained on the cranksha t, it will be pushed o be ore the solenoid/clutch assembly.
9. Determine i the inner race or the lywheel can be reused or be replaced.
Installing the Clutch Unit
Note: The (3) M6 x 16.00LG SHSS (socket head shoulder screw) used to mount the clutch plate permit ree axial and radial
movement around the cranksha t. This allows the riction sur aces to be in per ect alignment or the wrap-up unction o the
springs. Free movement o the unit is necessary because the brake hub is rigidly attached to the clutch plate and any
restrictions could result in mal unction and possible damage to the springs.
See Figure 4-4 or the ollowing steps.
1. Slide the solenoid/clutch assembly onto the cranksha t.
2. Replace (3) M6 x 16 Lg. SHSS.
3. Secure the clutch to the cranksha t by inserting
a new 5.0mm x 35 Lg. spiral pins.
4. Adjust the clutch timing. See section 4.2.5:
Solenoid/Clutch Assembly Adjustment.
5. Slide the inner race onto the cranksha t ollowed
by the lywheel.
6. Replace the (3) M6 x 40 Lg. SHCS in the
lywheel.
7. Replace the lywheel bearing retainer screw and
washer in the end o the cranksha t.
8. Reconnect the leads or the clutch solenoid.
9. Replace the V-Belt.
Solenoid/Clutch Assembly Adjustment
CAUTION: By disengaging the actuator, (See Figure 4-3) the ram will be ree to move. The weight o the ram can result in
downward motion. Use caution to ensure that the area under the ram is clear o ingers and hand tools. The machine guard
should be in place.
1. Locate the retaining ring in ront o the clutch control collar, (See Figure 4-2). Using a regular tip screwdriver, unseat the ring
rom its groove and slide it toward the lywheel.
CLUTCH
5mm X 35LG
SPIROL PIN
M6 X 20LG SHSS (3)
FLYWHEEL
V-BELT
WASHER
RETAINER SCREW
M6 X 40LG
SHCS (3)
Figure 4-4

TM-2000 Universal Press
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Revision: H Revision Date: 01-15-13
RAM
RAM YOKE
SHIM SET
M
6 X 20LG
SHCS (2)
Figure 4-7
2. Insert the 10mm hex wrench into lywheel bearing retainer screw. Hold the wrench irmly and release the clutch control collar
by pushing the actuator. See Figure 4-5. The cranksha t, input hub/ lywheel, and black spring housing are now ree to
rotate.
3. Rotate the 10mm hex wrench clockwise observing the ram down and up motion. When the ram has traveled a complete
down and up motion, hold the position o the ram just past top dead center (this is when the ram has traveled to the ull up
position and starts its descent downward).
4. Now observe the relationship o the control collar to the actuator. See Figure 4-5. I the control collar is butted up against the
actuator, no adjustment is required.
5. I the control collar stops short o the actuator, pull the control collar back towards the lywheel and reposition the collar to the
new setting. The control collar uses spline teeth to control the engagement.
6. Replace the retaining ring to lock the control collar in position.
7. Veri y proper clearance or radial movement o the solenoid/clutch assembly.
Check the gap between the solenoid/clutch mounting plate and the M6 stop
screw located on the upper le t hand corner. I the gap is more or less than the
recommended 0.25mm (.010”) loosen the M6 nut and adjust the screw to the
appropriate gap. Be certain to tighten the nut and double check the gap a ter
securing the nut. See Figure 4-6.
Solenoid/Clutch Assembly Lubrication
The clutch has sintered metal components that have been impregnated at
manu acturing with bearing in usion oil No. 33 or permanent lubrication. When the
machine is subjected to continuous heavy-duty operation or the machine operates
in high temperature or in less than clean environments, the bearing oil may wash
out or the assembly may become polluted with oreign matter. Flushing in a lighter
bearing in usion oil as used in manu acturing can restore e iciency. I this process
proves ine ective, the solenoid/clutch assembly should be replaced.
4 3 Shim Installation/Removal
Always turn o and disconnect the power supply to the press. Turn o the
“POWER” switch located on the control panel.
The TM-2000 is shipped rom the actory set at the industry shut height o 135.80mm ( 5.346”) . The shut height can be
changed by adding or removing shims. SeeFigure 4-7.
CAUTION: Molex will not be responsible or damage to applicators when the industry shut height o 135.80mm (5.346”) has
been changed on the press. Molex recommends that all shim adjustments be done to the applicator.
INPUT HUB
CLUTCH
COLLAR
DISENGAGED
POSITION
ENGAGED
POSITON
ACTUATOR
Figure 4
-
5
PUSH
ACTUATOR
RADIAL
MOVEMENT
ENGAGED
POSITON
ACTUATOR
Figure 4
-
6
M6 NUT
25MM
( 010”) GAP
M6 X 16LG
SHSS (3)
(CUP PT)
M6 X 60LG SSS
(CUP PT)

TM-2000 Universal Press
Order No.: TM-638008399 Release Date: 08-08-02 UNCONTROLLED COPY Page 18 o 36
Revision: H Revision Date: 01-15-13
4 4 Oiler
Description
The wick action oiler is included as an option to lubricate. This ensures the products when entering and eeding through tooling to
ensure smooth, trouble- ree operation. The oiler applies a thin coat o oil to the terminals or proper eed and better release rom
termination punches. The oiler is primarily used or terminals with gold plating. To avoid contamination when shipped and during
setup, the oiler is shipped rom the actory with no lubricant oil.
Adjustments
Oiler Position
Adjust the position o the oiler unit using the mounting screw that attaches the oiler to the guard assembly. Simply loosen the
screw, slide the unit to the desired position, and tighten the screw. The unit can be removed and placed on the right side o the
guard assembly or rear- eed applications.
Oiler Wick
Adjust the height o the oiler wick by pulling up or pushing down on the wick to the appropriate height. The wick can be moved
using pliers or simply grab it with your ingers.
Maintenance
Filling the Reservoir
While irmly holding the lid, screw the jar (oil reservoir) counter
clockwise until it is removed. Fill the jar with the desired lubricant oil
and replace the lid.
Replacing the Wick
While irmly holding the lid, screw the jar oil reservoir) counter
clockwise until it is removed. Feed a new wick up into the tube until it
protrudes rom the top end o the tube and replace the lid.
Package of 25 Wicks: Molex Order No: 63890-0727
Lubricant Oil
Recommended oil: Transdraw B-19
Vendor: Mid-Town Petroleum
9707 South 76th Avenue
Bridgeview, IL 60455
Toll-Free: 877-255-3533
Direct: 708-599-8700
Fax: [phone]
E-mail: [e-mail]
www.midtownoil.com
www.precisionlubricantsinc.com
Maintenance Schedule
The ollowing is o ered as a general guideline or maintenance. Tool li e can be increased with good maintenance practices or
decrease with lack o maintenance.
Items
Frequency
Cycles
Frequency
Time
Materials
Rams
25,000
Daily
Bearing Lube
Clutch
Settings
500,000
Quarterly
None Required
Cleaning
25,000
Daily
Use so t bristle brush on
ap
plicator mounting plate
V-Belt 500,000 Quarterly
Check tension and or cracks.
Replace i required.
LID
TUBE
WICK
(PKG OF (25
#638900727)
MOUNTING
BRACKET
JAR
(OIL RESERVOIR)
Figure 4
-
8 OILER ASSEMBLY

TM-2000 Universal Press
Order No.: TM-638008399 Release Date: 08-08-02 UNCONTROLLED COPY Page 19 o 36
Revision: H Revision Date: 01-15-13
Section 5
5.1 Parts List
5.2 Assembly Drawings
5.3 Electrical Schematics
5.4 Troubleshooting

TM-2000 Universal Press
Order No.: TM-638008399 Release Date: 08-08-02 UNCONTROLLED COPY Page 20 o 36
Revision: H Revision Date: 01-15-13
5 1 Parts List
Item
Order No
Descriptio
n
Qty
1
63800
-
6905
Press Yoke
1
2
63800
-
6997
Quick Change Mounting Plate
1
3
63800
-
8301
Press Frame
1
4
63800
-
8302
Press Face Plate
1
5
63800
-
8303
Press Ram
1
6
63800
-
8306
Cranksha t
1
7
63800
-
8309
Mounting Bracket
1
8
63800
-
8350
Guard Assembly
1
9
63800
-
8311
Trip Rod
1
10
63800
-
8357
Actuator Mounting Block
1
11
63800
-
8315
Rear Cover
1
12
63800
-
8316
Front Cover
1
13
63800
-
8317
Adjustment Screw
1
14
63800
-
8318
Press Motor Mount
1
15
63800
-
8319
Limit Switch Bracket
1
16
63800
-
8320
Shim Set
1
17
63800
-
8326
Serial Number Plate
1
18
63800
-
8327
Upper Cover Plate
1
19
63800
-
8328
Lower Cover Plate
1
20
63800
-
8398
Control Assembly
1
21
63800
-
8330
Support Tube Weldment
1
22
69002
-
5013
Disc Assembly
2
23
69002
-
5073
Main Wiring Harness (not shown)
1
24
63890
-
0720
Oiler Assembly
1
25
69002
-
5518
Eccentric Bearing Retainer
1
26
69002
-
5520
Cranksha t Bearing Retainer
1
27
69002
-
5521
Flywheel
1
28
69002
-
5523
Bearing Retainer
1
29
69002
-
5541
Plunger
1
30
69002
-
5555
Flywheel Bearing Screw
1
31
690
02
-
5556
Terminal Guide
1
32
69002
-
5607
Front Bearing Retainer
1
33
63800
-
8394
Footswitch Assembly
1
34
11
-
40
-
0185
Li ting Hooks
2
35
63600
-
0805
Post
4
36
63700
-
2493
Flexible Vinyl Plug
2
37
69018
-
5044
120V
-
1/3 HP motor **
1
38
69018
-
6052
Limit Sw
itch
1
39
69018
-
6219
8.0 Amp Fuse (not shown) **
2
40
69018
-
6237
Power Cord (120V) **
1
41
69018
-
6241
Solenoid/Clutch Assembly
1
42
69018
-
7031
Cranksha t Bearing
1
43
69018
-
7032
Inner Race
1
44
69018
-
7033
Eccentric Bearing
1
45
69018
-
7034
Inner Ra
ce
1
46
69018
-
7035
Eccentric Bearing
2
47
69018
-
7036
Inner Race
2
48
69018
-
7037
V
–
Belt
1
49
69018
-
7038
Pulley
1
50
69018
-
8135
Knurled Knob
1
51
69018
-
8136
Quick Release Pin
1
REF
69018
-
8235
Hex Wrench (10 mm)
1
53
69018
-
9542
Compression Spring
1
REF
63800
-
8399
TM
-
2000 Manual
1
55
69002
-
5552
RPM Label
1
56
63800
-
8355
Guard Insert (Deep)
1
57
63800
-
8356
Guard Insert (Shallow) (Optional)
REF
58
63700
-
2344
Caution Label
1
**Components for 240V AC Version
Item
Order no
Description
Qty
59
62500
-
0113
Power Cord (240V)
1
60
69018
-
5021
240V AC 50 Hz Motor
1
61
69018
-
6239
5 Amp Fuse (not shown) RSP
2
Hardware
Item
Description
Qty
1
M4 X 6LG BHCS
4
2
M4 X12LG SHCS
2
3
M5 X 10LG BHCS
14
4
M5 X 10LG FHCS
1
5
M5 X 20LG SSS
4
6
M5 X 12LG BHCS
2
7
M5 Hex Nut
2
8
M5 Wing Nut
4
9
5mm Dia X 35LG Spiral Pin
1
10
M6 X 10LG BHCS
10
11
M6 X 12LG BHCS
1
12
M6 X 12LG FHCS
4
13
M6 X 12LG SSS
1
14
M6 X 16LG SHCS
4
15
M6 X 20LG SHSS
3
16
M6 X 20LG SHCS
6
17
M6 X 25LG SHSS
2
18
M6 X 25LG Set Scre
w
1
19
M6 X 40LG SHCS
3
20
M6 X 60LG SSS
1
21
M6 Flat Washer
1
22
M6 Hex Nut
3
23
M8 X 16LG HHCS
4
24
M8 X 35LG SHCS
4
25
M8 Hardened Flat Washer
8
26
¼”
-
28 Taper Grease Fitting
1