Molex TM42 User manual

Molex Terminator

Use In TM42, TM40, Base Unit Adapter

Description • Operation • Maintenance

DOCNo638500090

ReleaseDate99/07/01

RevisionA

RevisionDate99/07/01

WARNING

NEVER USE THIS TERMINATOR IN A PRESS WITHOUT GUARDS OR SAFETY DEVICES THAT

ARE INTENDED TO PREVENT INJURY. THE TERMINATOR IS SUPPLIED WITHOUT

GUARDS. PLEASE USE GUARDS SUPPLIED WITH THE PRESS. RUNNING THE PRESS

WITHOUT GUARDS UNDER ANY CIRCUMSTANCES CAN CAUSE SERIOUS INJURY.

NEVER INSTALL, OPERATE ADJUST, OR SERVICE THIS TERMINATOR WITHOUT PROPER IN-

STRUCTION AND WITHOUT FIRST READING AND UNDERSTANDING THE INSTRUC-

TIONS IN THIS MANUAL AND THE TM42 PRESS, TM40 PRESS, OR 3BF WITH BASE

UNIT ADAPTER MANUALS.

NEVER INSTALL,REMOVEORSERVICETERMINATOR TOOLING WHILETHE FLYWHEEL ISIN

MOTION OR POWER CONNECTED TO THE PRESS.

NEVER INSTALL, REMOVE OR SERVICE THE TERMINATOR TOOLING WITHOUT MANUALLY

CYCLING THE PRESS TO VERIFY THAT THE CLUTCH CONTROL IS IN THE LOCKED PO-

SITION PAST TOP DEAD CENTER, BLOCK THE RAM IN THE UP POSITION IF A DEFEC-

TIVE CLUTCH IS SUSPECTED.

CAUTION THE PRESS SHOULD ALWAYS BE HAND CYCLED WITH THE TERMINATOR INSTALLED

PRIOR TO RUNNING PRODUCTION. THIS PROCEDURE WILL PREVENT DAMAGE OR

REDUCE TOOL WEAR.

WORK SAFELY AT ALL TIMES

FOR SERVICE

CONTACT YOUR LOCAL SALES OFFICE

APPLICATION TOOLING GROUP

1150 DIEHL ROAD,

NAPERVILLE, ILLINOIS 60563

PH: (630) 969-4550

FAX: (630) 505-0049

Molex Terminator

Table of Contents

Section

1. GeneralDescription

2. Installation-Setup-Operation

3. Maintenance

Appendix

A. TerminatorTypes&T2AssemblyDrawing

B. CrimpDefinitions

C. StatisticalProcessControl(Summary)

SECTION 1

General Description

Page

1.1 Description................................................................... 9

1.2 Features .................................................................... 9

1.3 TechnicalSpecifications.......................................................... 9

1.4 DeliveryCheck............................................................... 10

1.5 Tools .......................................................................10

1.6 Safety &Work Area Check . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . .. . . .10

Molex Presses and Adapters

For “T” or “T2” Style Terminators

TM42 Press

■

ISOMetric.

■

Flexibleexternallight.

■

Resettablecounter.

■

1.5”Stroke.

TM40 Press

■

InternalLight.

■

Nonresettablecounter.

■

1.0”Stroke.

Base Unit Adapter

■

Allows3BFpresstorunTerminatorstyletooling.

General Description

1.1 Description

TheMolexTerminatorisaneasytousetoolfortheterminationofavarietyofMolexcrimpterminals.

Productionflexibilityisobtainedthroughtheuseofsimpleinterchangeabletooling. Thetoolingis

inexpensive,andunlikeamodularapplicator,allcrimpheightandterminalfeedadjustmentsarelocated

inthepress. TheterminatordiecanbeinstalledintheTM42,TM40pressesorBaseUnitadaptor,andis

ideallysuitedformid-volumebenchoperation.

TheMolexT2terminatoristhenewerversiontoolthatallowsfortrackadjustment. Itcontainstheidentical

perishabletoolingastheMolexFineAdjustapplicator. (Centercarrierexcluded)

1.2 Features

■

Flexibleandinexpensive.

■

Enhancedcrimpingproductivity.

■

Simpleinstallation.

■

Quickreleasepunches.

■

T2terminatorhasstandardizedtoolingwithMolexFineAdjustApplicator.

■

TrackAdjustmentcapabilitiesintheT2terminatorsforimprovedcontrolofthebellmouthsizeandcutoff

tablength.

1.3 Technical Specifications

Dimensions

Width- 127.0mm(5.0”)

Depth- 44.0mm(1.8”)

Height- 25.0mm(1”)

Weight- 1.4kg(3.0lbs)

1.4 Delivery Check

Qty

Terminator 1

Samplecrimpedterminals 5

Manual 1

Setup&SpecificationDocuments 1

1.5 Tools

Thefollowingtoolsarerecommendedforsetupandadjustmentsoftheterminatortool.

1. MetricAllenSet

2. EnglishAllenSet(forolderterminatortools)

3. LargeandSmallScrewdriver

4. CresentWrench

5. Pliers(needlenose)

6. CrimpMicrometer

7. EyeLoop(10x)

8. WireStripper/Cutter

1.6 Safety & Work Area Check

Checkthatthecrimpingpositionisergonomicforthe

operator’ssize. Abenchheightof762to813mm(30

to32inches)willprovideoperatorcomfort,andallow

bothfeettoreston the ground. The foot pedal should

bepositionedforeaseofreach.

Checkthatthepresspositionislocatedparalleledand

approximately150mm(6inches)fromtheedgeofthe

table. Achairorstool,withadjustableheightand

backrestshouldbeprovidedformaximumcomfortand

backsupporttotheoperator. Adjustpresslighttogive

appropriatevisibilitytotheworkarea.

Checkthattheoperatorsandobserversarewearing

approvedsafetygoggleswhenthepressisinoperation

and/orservice.

SECTION 2

Setup And Operation

Page

2.1 TerminatorDieInstallationandRemoval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 13

2.2 LoadingtheTerminalStrip ....................................................... 15

2.3 ManuallyCyclingthePress.................................................. . . . . . 17

2.4 PunchandAnvilAlignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.5 FeedFingerLocation ........................................................... 21

2.6 ForwardandBackFeedAdjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 23

2.7 ConductorCrimpAdjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.8 InsulationCrimpAdjustment...................................................... 27

2.9 FinalCheckandOperation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Ram

10-32x3/8 Lg. B.H.C.S. Punch Release Pin

ConductorPunch

InsulationPunch

T2TerminatorBase

M6x20 Lg. S.H.C.S.

RightLocatingPlate

LeftLocatingPlate

Bolster

FrontStriker

TERMINATOR INSTALLATION

Fig. 1

Terminator Die Installation & Removal

CAUTION

AlwayspowerdownthepresswheninstallingorremovingMolextoolingbypressingtheemergencystopbuttonlocatedon

thefrontpanel.

STEPS

(Ref.Fig.1)

1. RemovePressguard. (Ref.PressorBaseUnitmanual.)

2. ConfirmthattheTerminatoriscorrectforthespecifiedproduct. (Ref.Specificationsheetssuppliedwiththe

Terminator.)

3. Makesureallthetoolingfromaprevioussetupisremoved. (SeeStep11.)

4. Loadalltoptoolingfirst,startingwiththerearstriker. (SeeFig.16.)

5. Pullonpunchreleasepintoinstallpunchesintothepunchcavity.

6. Finishwithfrontstriker(ifspecified). Confirmthatallcomponentsfollowassemblydrawingsequence.

7. CleanbolsterplateofscraporchipsthatmayinterferewiththeTerminatorbaseinstallation.

8. Remove6mmS.H.C.S(TM42)andlifttherightlocatingplatefromthebolster.

9. PlacetheTerminatorbaseonthebolsterplateandslidetotheleft. Theslotinthebasewilllocateonthe

leftguideblock

10. Replacetherightlocatingplateandtighten6mmscrew.

11. ToremovetheTerminatorreversetheabovesteps.

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