molex 64000-0041 User manual

Manual Press for SC Power
Order No: TM-640000041 Release Date: 05-02-13 UNCONTROLLED COPY Pa e 1 of 16
Revision: C Revision Date: 05-02-13
Basic Press-with Tool Kit
Operation Manual
Order No 64000-0041
 Description
 Operation
 Maintenance

Manual Press for SC Power
Order No: TM-640000041 Release Date: 05-02-13 UNCONTROLLED COPY Pa e 2 of 16
Revision: C Revision Date: 05-02-13
Safety Warnings and Information
Read and understand all of the instructions and safety information in this
manual before operatin or servicin this tool.
Keep this manual available when usin this tool.
Replacement manuals are available at www.molex.com.
SAFETY ALERT SYMBOL
This symbol is used to call your attention to hazards or unsafe practices which could result in an injury
or property dama e. The si nal word, defined below, indicates the severity of the hazard. The messa e
after the si nal word provides information for preventin or avoidin 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 a ainst unsafe practices associated with events that could lead
to personal injury.
WARNING
Always
wear proper eye protection when Operatin o
r servicin this tool.
Failure to wear eye protection could result in serious eye injury from flyin debris.
WARNING
Never
operate, service, install, or adjust this
equipement without proper instruction and without
first
readin and understandin the instructions in this manual.
WARNING
Do not use
compressed air to clean
the equipment. The forces created by
compressed air can force
debris into the tool.
Failure to observe these precautions may result in injury or property dama e.
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 and toolin .
Failure to observe this precaution may result in injury and / or property dama e.

Manual Press for SC Power
Order No: TM-640000041 Release Date: 05-02-13 UNCONTROLLED COPY Pa e 3 of 16
Revision: C Revision Date: 05-02-13
Tooling Technical Assistance
Molex offers toolin technical assistance for customers who may need some uidance for toolin adjustments. This
support can be obtained by callin either of the two numbers listed below and askin for the Molex Toolin Group.
Call Toll Free 1-800-786-6539 (US) 1-630-969-4550 (Global).
This assistance is limited to the operation and set-up of a customer’s Molex tool. Questions with re ard to Molex
connector products or how to identify the proper toolin and/ or toolin documentation should be directed to your
local Molex personnel or Customer Service Representative.
When callin for service on the Basic Press it is recommended to have the followin : a copy of the Operation
Manual and a person familiar with the press should be present. The followin information is also recommended to
supply:
1. Customer name
2. Customer address
3. Person to contact such as (name, title, e-mail, and telephone number)
4. Tool Order number
5. Ur ency of request
6. Nature of problem
Molex Application Tooling Group
2200 Wellin ton Court
Lisle, IL 60532, USA
Tel: [phone]
Fax:[phone]
Visit our Web site at http://www.molex.com

Manual Press for SC Power
Order No: TM-640000041 Release Date: 05-02-13 UNCONTROLLED COPY Pa e 4 of 16
Revision: C Revision Date: 05-02-13
Table of Contents
Contents
Basic Press-with Tool Kit ...................................................................................................................................................... 1
Order No. 64000-0041 .......................................................................................................................................................... 1
Safety Warnin s and Information ...................................................................................................................................... 2
Toolin Technical Assistance ............................................................................................................................................ 3
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 .................................................................................................................................................. 6
1.5 Tools .................................................................................................................................................................. 6
Section 2 .............................................................................................................................................................................. 7
Operation ........................................................................................................................................................................... 9
2.1 Installation ......................................................................................................................................................... 9
2.2 Set Up ............................................................................................................................................................... 9
2.3 Operation ......................................................................................................................................................... 10
Section 3 ............................................................................................................................................................................ 11
Maintenance .................................................................................................................................................................... 11
3.1 Cleanin .......................................................................................................................................................... 12
3.2 Lubrication ....................................................................................................................................................... 12
3.3 Perishable Parts .............................................................................................................................................. 13
3.4 Spare Parts...................................................................................................................................................... 13
3.5 Troubleshootin ............................................................................................................................................... 14
Section 4 ............................................................................................................................................................................ 15
Parts List and Assembly .................................................................................................................................................. 15
4.1 Parts List ......................................................................................................................................................... 16
4.2 Assembly ......................................................................................................................................................... 16

Manual Press for SC Power
Order No: TM-640000041 Release Date: 05-02-13 UNCONTROLLED COPY Pa e 5 of 16
Revision: C Revision Date: 05-02-13
Section 1
General Description
1.1 Description
1.2 Features
1.3 Technical Specifications
1.4 Delivery Check
1.5 Tools
1.6 Products

Manual Press for SC Power
Order No: TM-640000041 Release Date: 05-02-13 UNCONTROLLED COPY Pa e 6 of 16
Revision: C Revision Date: 05-02-13
General Description
1 1 Description
The 64000-0041 is the Complete Manual Press
and with the Tool Kit Assembly. The 64000-0045
Tool Kit is used in the Molex Basic Assembly Press
Order No. 011316356. It is desi ned to terminate 2
Circuit Round Cable with Ground onto a Self-
Contained Power Connector.
The operator loads a connector into the nest then
loads the cable into the cable uide and pulls the
press lever forward and down terminatin the cable
into the connector. This tool is ideally suited for
low volume production.
It is desi ned to terminate discrete wires onto a
connector assembly, 19403 series. It will
accommodate 2 circuit connectors.
1 2 Features
 Full cycle ratchet assures complete crimp.
 Handle is easily chan ed to suit ri ht or left
handed operators.
 Modular toolin is quickly installed into the Basic
Press.
 Manually operated, no shop air or electricity
required.
1 3 Technical Specifications
Dimensions Press with tooling
Hei ht 533.0mm (21.00”)
Width 152mm (6.00“)
Depth 267mm (10.50“)
Unpacked wei ht 25k (55 lbs)
Production Rate
300 terminations per hour maximum, dependin on
operator skill and wire len th.
Ram
Force 3000 lbs. (1360k ) Maximum
Stroke 44.45mm (1.750”)
1 4 Delivery Check
The followin items are included in this packa e :
Decription: Quantity
Basic Press 011316356 1
Terminator Tool Kit 64000-0045 1
Operation Manual TM-640000041 1
Specification Sheet ATS-640000045 1
1 5 Tools
The followin tools are recommended for setup and
adjustments to the this tool.
 Inch hex wrench set
 Small standard screwdriver
 Adjustable wrench
 5X Eye Loupe
 Needle Nose Pliers

Manual Press for SC Power
Order No: TM-640000041 Release Date: 05-02-13 UNCONTROLLED COPY Pa e 7 of 16
Revision: C Revision Date: 05-02-13
Section 2
2.1 Installation
2.2 Set-Up
2.3 Operation
2.4 Products

Manual Press for SC Power
Order No: TM-640000041 Release Date: 05-02-13 UNCONTROLLED COPY Pa e 8 of 16
Revision: C Revision Date: 05-02-13
Figure 2
-
1
RAM HANDLE
ASSEMBLY
RAM CAM
RATCHET
RELEASE LEVER
TOOLING
HOLDER
BASE PLATE
NEST
LOWER TOOLING
UPPER
TOOLING
FRAME H
ANDLE
ASSEMBLY
Principal Mechanical Parts of the 64000-0041 Press

Manual Press for SC Power
Order No: TM-640000041 Release Date: 05-02-13 UNCONTROLLED COPY Pa e 9 of 16
Revision: C Revision Date: 05-02-13
Figure 2
-
3
REMOVE SPRING
LOADED SCREW (2)
LOWER
TOOLING
BASE PLATE
#8-32 BHCS (2)
Figure 2-2
LATCH
RAM
UPPER
TOOLING
RAM
ADJUSTING
SCREW
UPPER
TOOLING
HOLDER
Operation
2 1 Installation
To secure the press, use a bench capable of
supportin at least 150 pounds (70k ), with
adequate li htin for easy operation. There are two
(2) holes for 5/16” la screws provided in the press
base for fastenin the press to the workbench. Be
sure there is adequate room around the press to
operate easily.
The 64000-0041 Complete Manual Press comes
with tool kit already installed. See Fi ure 2-1. If the
64000-0045 Tool Kit is not installed in the Press,
follow the steps below:
Upper Tooling
NOTE: Lowerin the press ram sli htly may assist
in installin the upper toolin .
1. Slide the upper toolin holder with upper toolin ,
upward over the ram adjustin screw, until it
comes to a stop. See Fi ure 2-2.
2. Push the latch backward (away from the
operator). The upper toolin will now slide up
onto the ram an additional approximately 4.0mm
(0.16”).
3. Release the latch, the upper toolin will stay in
place.
Lower Tooling
1. Remove the two (2) sprin loaded screws with
the washers and sprin s on the base plate of
the Basic Press.
2. With the press ram in the up position, position
the lower toolin in the press.
3. Slide the lower toolin onto the base plate.
Fasten down with the (2) #8-32 BHCS
(Furnished with the tool kit). See Fi ure 2-3.
4. Slowly lower the press ram by pullin the press
lever forward and down.
5. Return the press ram to the full up position.
2 2 Set Up
The only setup required for this toolin is to adjust
the press ram stroke.
Ram Stroke Adjustment
1. Loosen the #8-32 set screw in the Ram which
locks the Ram Adjustin Screw into place. See
Fi ure 2-4.
2. There is an indicator en raved on the ram just
above the Ram Adjustin Screw. Turn the Ram
Adjustin Screw clockwise (CW) toward the “+”
si n to increase the ram stroke. To decrease
the stroke, turn the Ram Adjustin Screw
counterclockwise (CCW) toward the “-” si n.
Stroke adjustment controls the shut hei ht of the
connector assembly. Ram stroke is set so that
the connector measures a specific shut hei ht
when terminated. See Product Specifications

Manual Press for SC Power
Order No: TM-640000041 Release Date: 05-02-13 UNCONTROLLED COPY Pa e 10 of 16
Revision: C Revision Date: 05-02-13
Figure 2-4
LOWER
ADJUSTING
KNOB
#8
-
32 SHSS
RAISE
MAXIMUM DEPTH
5 26mm
ADJUSTMENT
RANGE
Figure 2-5
PRESS HANDLE
RATCHET
RELEASE
LEVER
SC POWER
CONNECTOR
LOCAT0R
PINS
PUSHER
Figure 5
MOUNTING HOLES
ANVIL
for proper shut hei ht dimensions and related
information.
3. When the correct stroke is set, ti hten the #8-32
set screw.
2 3 Operation
Press Operation
1. Install the cable and the connector assembly, in
position in the nest. Make sure the connector is
on the locatin pins. See Fi ure 2.5.
2. Cycle the press by pullin the press crimp lever
forward and down.
3. Return the press lever to the full up position.
4. Remove the terminated assembly.
WARNING: After the press ram handle has started
to descend, it cannot be returned to the up position
until the full stroke of the press has been completed.
In case of a jam or some other problem, should the
press ram ever need to be returned to the up
position before completin the full stroke, pull up on
the ratchet release lever and raise the press ram
handle. The ratchet release lever is located on the
upper left side of the press frame. See Fi ure 2-5.

Manual Press for SC Power
Order No: TM-640000041 Release Date: 05-02-13 UNCONTROLLED COPY Pa e 11 of 16
Revision: C Revision Date: 05-02-13
Section 3
Maintenance
3.1 Cleanin
3.2 Lubrication
3.3 Perishable Parts
3.4 Spare Parts
3.5 Troubleshootin

Manual Press for SC Power
Order No: TM-640000041 Release Date: 05-02-13 UNCONTROLLED COPY Pa e 12 of 16
Revision: C Revision Date: 05-02-13
GREASE
OIL
Figure 3
-
1
OIL
OIL ROLLERS and
BEARINGS (2)
OIL ROLLERS and
BEARINGS (2)
GREASE
3 1 Cleaning
This press should be cleaned daily. Use a soft bristle brush to remove debris from critical areas such as the housin
nest. See the Chart on next pa e for recommended Preventive Maintenance Schedule.
NOTE: Usin compressed air to clean toolin is not recommended. Chips can wed e in the toolin and/or fly at an
operator.
3 2 Lubrication
1. Grease the ram includin the cam follower roove.
2. Oil all movin parts of the press.
3. Lubricate with multipurpose synthetic lubricant with Teflon or an equivalent. Molex ships its presses pre- reased
with Permatex multi-purpose synthetic rease with Teflon No. 82329. A SAE 30WT non-deter ent oil or li ht
spindle oil or 3-in-1 oil should be used on pivot points.
WARNING: Never use penetrants such as WD40 for any lubrication on the press.
4. Lubricate all points shown in Fi ures 3-1 with the specified oil and rease (or equivalent).

Manual Press for SC Power
Order No: TM-640000041 Release Date: 05-02-13 UNCONTROLLED COPY Pa e 13 of 16
Revision: C Revision Date: 05-02-13
An example of a maintenance chart is shown below. Copy and use this chart to track the maintenance of your Press
or use this as a template to create your own schedule or use your company’s standard chart, if applicable.
Preventive Maintenance Chart
Daily: Clean. See Section 3.1.
As Required: Lubricate. See Section 3.2.
CHECK SHEET MONTH _________YEAR _________
Week Daily Clean
Days of the Week
Solution
MON
TUE
WED
THU
FRI
SAT
SUN
1
2
3
4
Cleanin
Reapply reasin
Reapply oil
Yes Soft Brush Industrial
De reaser
Inspect all toolin
for wear Yes Replace if si ns of wear.
Schedule should be adjusted up or down dependin on usa e. Molex recommends that a lo of preventive
maintenance be kept with the press.
3 3 Perishable Parts
Customers are responsible for maintainin the Basic Press and with the Tool kit Assembly. Perishable parts are
those parts that come in contact with the product and will wear out over time. Molex recommends that all
customers keep at least one set of the perishable tool kit in stock at all times. This will reduce the amount of
production down time.
For the proper perishable tool kit information, refer to the Specification Sheet supplied with the Press
3 4 Spare Parts
Customers are responsible for maintainin the Basic Press and with the Tool kit Assembly. Spare parts are
available. Movin and functionin parts can be dama ed or wear out over time and will require replacement.
Molex recommends that the customer keep some or all of them in stock to reduce production down time. These
parts are identified in the Parts List. See Section 4.

Manual Press for SC Power
Order No: TM-640000041 Release Date: 05-02-13 UNCONTROLLED COPY Pa e 14 of 16
Revision: C Revision Date: 05-02-13
3 5 Troubleshooting
Symptom

Cause
Solution
Ram oes down but
will not o back up

Stickin ratchet pawl or debris
in mechanism Clean and lubricate pivot points.
 Ram set too low
Release ram with release lever
and adjust ram stroke.
See Section 2.2, Ram Stroke Adjustment.
Full stroke ratchet
mechanism not
en a in

Stickin ratchet pawl or debris
in mechanism Clean and lubricate pivot points

Broken ratchet pawl sprin
or dama ed pawl Repair or Replace.

Worn anti
-
backup sprocket.
Replace
.
Connector
dama ed

Dama ed upper and/or lower
toolin
Replace.

Connector
not positioned correctly
over
pins
Connector nest not positioned correctly.
See Section 2.2, Connector Nest.
 Press ram stroke too lon
Adjust the press stroke.
See Section 2.2., Ram Stroke Adjustment
Connector
assembly not
fully terminated
 Press ram stroke too short Adjust the press stroke.
See Section 2.2., Ram Stroke Adjustment
Consult Press Manual order number ATS
-
011316356 for any press problems.

Manual Press for SC Power
Order No: TM-640000041 Release Date: 05-02-13 UNCONTROLLED COPY Pa e 15 of 16
Revision: C Revision Date: 05-02-13
Section 4
Parts List and Assembly
4.1 Parts List
4.2 Assembly Drawin s

Manual Press for SC Power
Order No: TM-640000041 Release Date: 05-02-13 UNCONTROLLED COPY Pa e 16 of 16
Revision: C Revision Date: 05-02-13
1
2
Figure 4-1
4 1 Parts List
Basic
Press with
Tool
Kit
64000
-
0041
Item
Order No
Engineering No
Description
Quantity
1
64000
-
0045
64000
-
0045
Tool Kit
1
2
11
-
31
-
6356
AM60026
Basic
Press
1
4 2 Assembly
Visit our Web site at http://www.molex.com