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molex TM42 Manual

Molex terminator
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Molex Terminator
Use In TM42, TM40, Base Unit Adapter
Description • Operation • Maintenance
DOC No 638500090
Release Date 99/07/01
Revision A
Revision Date 99/07/01

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  • Page 1 Molex Terminator Use In TM42, TM40, Base Unit Adapter Description • Operation • Maintenance DOC No 638500090 Release Date 99/07/01 Revision A Revision Date 99/07/01...
  • Page 2 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, REMOVE OR SERVICE TERMINATOR TOOLING WHILE THE FLYWHEEL IS IN MOTION OR POWER CONNECTED TO THE PRESS.
  • Page 3 Molex Terminator Table of Contents Section General Description Installation - Setup - Operation Maintenance Appendix Terminator Types & T2 Assembly Drawing Crimp Definitions Statistical Process Control (Summary)

  • Page 4: Table Of Contents

    SECTION 1 General Description Page Description..............9 Features .
  • Page 5 Molex Presses and Adapters For “T” or “T2” Style Terminators TM42 Press ISO Metric. Flexible external light. Resettable counter. 1.5” Stroke. TM40 Press Internal Light. Non resettable counter. 1.0” Stroke. Base Unit Adapter Allows 3BF press to run Terminator style tooling.

  • Page 6: Description

    The terminator die can be installed in the TM42, TM40 presses or Base Unit adaptor, and is ideally suited for mid-volume bench operation.

  • Page 7: Delivery Check

    Delivery Check Terminator Sample crimped terminals Manual Setup & Specification Documents Tools The following tools are recommended for setup and adjustments of the terminator tool. Metric Allen Set English Allen Set (for older terminator tools) Large and Small Screwdriver Cresent Wrench Pliers (needle nose) Crimp Micrometer Eye Loop (10x)
  • Page 8 SECTION 2 Setup And Operation Page Terminator Die Installation and Removal..........13 Loading the Terminal Strip .
  • Page 9 10-32 x 3/8 Lg. B.H.C.S. Punch Release Pin Front Striker Conductor Punch Insulation Punch T2 Terminator Base M6 x 20 Lg. S.H.C.S. Right Locating Plate Left Locating Plate Bolster TERMINATOR INSTALLATION Fig. 1...

  • Page 10: Terminator Die Installation And Removal

    Terminator Die Installation & Removal CAUTION Always power down the press when installing or removing Molex tooling by pressing the emergency stop button located on the front panel. STEPS (Ref. Fig. 1) Remove Press guard. (Ref. Press or Base Unit manual.) Confirm that the Terminator is correct for the specified product.
  • Page 11 Lift the Feed Finger Up Terminal Strip Feeding Drag Frame Drag Cam Rotate Drag Cam Either Direction to Raise or to Lower Drag Frame First Terminal Above Anvils "T2" Style Drag Finger / Anti-Back Up Finger Lift up to Feed Terminal Strip Terminal Strip Feeding Release to Apply Drag on Terminal Strip First Terminal...

  • Page 12: Loading The Terminal Strip

    Loading The Terminal Strip Note Terminator Drag mechanism may vary on product selection or Terminator type. Steps (Ref. Fig. 2) Confirm terminal part number matches the terminator specification sheet. Install the terminal reel on the press reel holder. Raise the drag plate (T2) and slide the terminal strip under both the cover plate and the drag plate. For other “T”...
  • Page 13 Manual Cycle Clutch Release Manually Cycling HAND CYCLING Fig. 3...

  • Page 14: Manually Cycling The Press

    Manually Cycling the Press Note Hand cycling is necessary to confirm correct tool alignment, terminal feed adjustment, and also to give the setup person the ability to step through the press cycle manually. Steps (Ref. Fig. 3) Always power down the press by pressing the emergency stop button on the front control panel. Release the clutch by inserting a screwdriver through the access hole to trip the locked actuator.
  • Page 15 Press Ram at Bottom of Full Down Stroke Terminal in Position over the Anvils Anvil Mounting Screws Hex Wrench Conductor Punch M4 x 20 Lg. S.H.C.S. Insulation Punch M4 X 50 Lg. S.H.C.S. Conductor Anvil Insulation Avil PUNCH & ANVIL ALIGNMENT Fig.

  • Page 16: Punch And Anvil Alignment

    Punch and Anvil Alignment Note Correct punch and anvil alignment will insure quality crimps and excellent tool life. Steps (Ref. Fig. 4) Slightly loosen the anvil mounting screws. Place the hand cycling wrench through the hole in the center of the rear cover. Gently lower the press ram until it is in the fully down position, with a terminal sitting on the the anvils the punch will align the bottom tooling.

  • Page 17: Feed Finger Location

    Feed Finger Location Dual Carrier Feed Finger Location End Carrier Feed Finger Location Nose Carrier Feed Finger Location Center Carrier Feed Finger Location Center Carrier FEED FINGER LOCATION Fig. 5...
  • Page 18 Feed Finger Location Adjustment Note Feed finger location will vary depending on product selections see the feed finger location chart. (Ref. Fig. 5) Steps (Ref. Fig. 5.1) Select feed finger position. Loosen the feed finger shaft locking screw and position the feed finger in the selected position. With a small screwdriver or 6"...
  • Page 19 Forward Feed Adjustment Lock Screw Forward Feed Adjustment Lock Wheel Adjusting Backward Adjusting Forward Forward Feed Adjustment Indicator Min. Backward Feed Max. Forward Feed Backward Forward Feed Finger M6 Jam Nut and Fine Adjust Screw FORWARD AND BACKFEED ADJUSTMENT Fig. 6...

  • Page 20: Forward And Back Feed Adjustment

    Forward and Back Feed Adjustment Note Because of different terminal progressions, feed adjustment may be necessary. Steps (Ref. Fig. 6) Make sure the press ram is in the fully up position and the clutch collar is engaged by the actuator. Slide the terminal carrier strip all the way forward until it is centered over the anvils.
  • Page 21 Conductor Adjustment Indicator Lower Crimp Height Setting (Loosest) Setting (Tightest) Higher Crimp Height Conductor Adjustment Lock Screw Conductor Adjustment Screw CONDUCTOR HEIGHT ADJUSTMENT Fig. 7...
  • Page 22 Conductor Height Adjustment Note It is desirable to adjust the conductor adjustment wheel all the way to (1) on the conductor adjustment indicator, to avoid punch crash prior to beginning this process. Steps (Ref. Fig. 7) Replace the press guard. Prepare wire for crimping.
  • Page 23 Insulation Adjustment Indicator Setting (Loosest) Setting (Tightest) Lower Crimp Height Higher Crimp Height Insulation Adjustment Cam INSULATION CRIMP ADJUSTMENT Fig. 8...

  • Page 24: Insulation Crimp Adjustment

    Insulation Crimp Adjustment Note The insulation crimp provides strain relief for the conductor crimp. The quality of the insulation crimp will depend on the insulation diameter and durometer. Refer to the specification sheet for insulation diameter parameters. Steps (Ref. Fig. 8) Place a stripped wire against the wire stop, crimp it under power.
  • Page 25 OPERATION Fig. 9...
  • Page 26 Operation Note Check that all setup procedures were followed and all locking screws have been tightened. Follow the safety and work area instructions. Steps (Ref. Fig. 9) Press guard should be in position. Wire should be pre stripped and prepared for crimping. Place pre stripped wire through the slot in the press guard.

  • Page 27: Maintenance

    Take a small brush and clean in and around the terminator anvils. Inspect perishable tooling for wear or fracture. Molex recommends that you maintain a spare tooling kit at your facility. The Terminator should be free of all carrier strip tabs and plating that may have accumulated during...
  • Page 28 Terminator Types Note Molex supplies different types of Terminators depending on the vintage. The following illustrations are a generic guide to the Tool that you may have. Track Adjustment ......Fig. 10 End carrier T2 .
  • Page 29 T2 Terminator Track Adjustment Back Track Adjustment Front T2 Terminator Base Terminal Track M5 x 10 Lg. S.H.C.S. T2 TERMINATOR Fig. 10 Track Adjustment T2 Series The T2 Terminator allows for adjustment of both the bellmouth and cut-off tab by loosening the 6 mm S.H.C.S and moving the terminator track in or out to achive desired conditions on crimp.
  • Page 30 Conductor Punch Rear Cover Insulation Punch Front Front Cover Plunger Striker Track Conductor Base Anvil Insulation Front Cut-Off Anvil Plunger Wire Stop Cut-Off Plunger Spring Anvil Mount Plunger Retainer Tooling Key Scrap Deflector T2 END CARRIER (GENERIC) Fig. 11...
  • Page 31 Hold Down Spring Hold Down Rear Cover Conductor Shaft Punch Insulation Punch Wire Front Stop Cover Front Plunger Striker Rear Striker Base Rear Cut-Off Plunger Track Cut-Off Plunger Spring Cut-Off Front Cut-Off Blade Plunger Rear Spacer Cut-Off Plunger Rear Plunger Retainer Spring Front Tooling Key...
  • Page 32 Stop Finger Torsion Spring Carrier Hold Down Cover Plate Hold Down Spring Hold Down Plunger Stop finger Cut-Off Punch Conductor Punch Spiral Pin Pivot Pin Insulation Punch Cover Mounting Screw Cover Guiding Pin Front Cover Wire Stop Track Rear Cut-Off Die Tooling Mounting Screw Spacer Front Cut-Off Die...
  • Page 33 Rear Cover Front Cover Track Adjusting Screw Pin Lock Conductor Punch Adjustor Bar Insulation Wire Stop Punch Bracket Plunger Striker Wire Stop Base Adjusting Screw Anvil Mounting Block Plunger Combination Anvil Retainer Cut-Off Plunger Tooling Mounting Screw Cut-Off Plunger Spring Spring Plate MICRO TERMINAL (GENERIC) Fig.
  • Page 34 T2 Terminator Bill of Materials Item No. Order No. Description Qty. 638008501 T2 Terminator Base 638000108 Terminal Track 690280660 Drag Springs 638000316 Guide Pin-Drag Frame 638000312 Drag Frame 638000115 Spacer Tube 638000313 Drag Cam M4 x 12 Lg. B.H.C.S. M5 x 10 Lg. S.H.C.S. T2 TERMINATOR ASSEMBLY Fig.
  • Page 35 Hold Down Plunger Set Screw Hold Down Spring Rear Striker Hold Down Plunger Rear Striker Mounting Screw REAR STRIKER INSTALLATION Fig. 16...
  • Page 36 Crimp Terminations...
  • Page 37 Definitions Anatomy Of A Crimp Termination Bellmouth ( Flare) The flare that is formed on the edge of the conductor crimp acts as a funnel for the wire strands. The funnel reduces the possibility that a sharp edge on the conductor crimp will cut or nick the wire strands. Bend Up /Bend Down /Twisting / Rolling The terminal bending up, bending down, twisting or rolling indicates that the nose of the terminal is reacting to the crimping process...
  • Page 38 Statistical Process Control (Summary) Process Confirmation. Molex recommends that prior to production, a 25 piece process capability study on both crimp height and pull force. Setup/Visual Inspection Minimum 5 piece sample should be checked for crimp height per specification sheet.
  • Page 39 Naperville, IL, 60563 Tel : 630-969-4550 European Headquarters Munich, Germany Tel : 49-89-413092-0 Far East North Headquarters Kanagawa, Japan Tel : 81-462-2324 Far East South Headquarters Jurong Town, Singapore Tel : 65-268-6868 Printed in U.S.A 1999 Molex Incorporated Order Number - 638500090...

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