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: +1 (630) 969-4550
Fax:+1 (630) 505-0049
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
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