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Summary of Contents for molex FineAdjust APPLICATOR
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Page 1: Fineadjust™ Applicator
FineAdjust Applicator FineAdjust™ APPLICATOR Operation Manual Order No 63800-4900 Description Operation Maintenance UNCONTROLLED COPY Doc. No: TM-638004900 Release Date: 09-04-03 Page 1 of 50 Revision: G Revision Date: 01-15-13... -
Page 2: Safety Warnings And Information
Keep this manual available when using this tool. Replacement manuals are available for download at no charge 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 damage. - Page 3 Installation in crimp presses with other than standard shut heights can cause severe tool breakage. It is advisable that before installation, a check of the shut height be performed. Molex will not be liable for any damages as a result of installation in a crimp press with nonstandard or improperly set shut height.
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Page 4: Table Of Contents
Safety Warnings and Information ..........................2 Table of Contents ................................ 4 Section 1 ................................... 6 General Description .............................. 6 Principal Mechanical Parts of the FineAdjust Applicator ..................7 Description..............................8 Features ..............................8 Technical Specification ..........................8 Delivery Check ............................8 Tools ................................ - Page 5 FineAdjust Applicator Statistical Process Control (Summary) ....................... 45 Crimp Process Control ..........................46 Process Capability ........................... 46 Production ............................... 47 Appendix C ................................49 Options ..................................49 Terminal Oiler ....................Error! Bookmark not defined.50 Order No. 63890-0719 ..................Error! Bookmark not defined.50 UNCONTROLLED COPY Doc.
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Page 6: Section 1
FineAdjust Applicator Section 1 General Description Description Features Technical Specifications Delivery Check Crimp Tooling Accessories Tools Specification Sheets UNCONTROLLED COPY Doc. No: TM-638004900 Release Date: 09-04-03 Page 6 of 50 Revision: G Revision Date: 01-15-13... -
Page 7: Principal Mechanical Parts Of The Fineadjust Applicator
FineAdjust Applicator Principal Mechanical Parts of the FineAdjust Applicator INSULATION ADJUSTING CAM PIVOT ARM FORWARD FEED LOCKING SCREW FORWARD FEED ADJUSTING KNOB FEED FINGER LEVER FEED FINGER REAR COVER LUG BOLT TRACK DRAG RELEASE DRAG FRAME CONDUCTOR ADJUSTING CAM BACK STROKE... -
Page 8: Description
The FineAdjust™ available for most Molex brand terminals. This applicator works in the Molex TM-2000 and TM-3000 Universal Press and in most industry standard presses. 1.3 Technical Specification The FineAdjust™ applicator offers minimal setup time without the need for shimming, is versatile, reliable, easy to... -
Page 9: Tools
Terminal Oiler (Appendix C) 63800-2800 Digital Crimp Micrometer The specification sheet should be filed. These are available on the Molex website (www.molex.com). 1.5 Tools The following tools are recommended for setup and adjustments to the applicator: 1. Metric standard hex wrench set 2. -
Page 10: Section 2
FineAdjust Applicator Section 2 Set-Up and Operation 2.1. Shut Height 2.2. Set-Up 2.3. Adjustments 2.4. Crimp Tooling Installation and Removal UNCONTROLLED COPY Doc. No: TM-638004900 Release Date: 09-04-03 Page 10 of 50 Revision: G Revision Date: 01-15-13... -
Page 11: Shut Height
Always turn off and disconnect the power supply to the press. Remove the press guards. Clean the quick change mounting plate of scrap or chips that may interfere with the FineAdjust applicator installation. For the TM-2000 and TM-3000 Presses follow the procedure below: a. - Page 12 The specified terminals are printed on the setup sheet for the PLATE Figure 2-2 applicator. Only use the Molex terminals on the setup sheet BASE PLATE which is supplied with the applicator. Always disconnect the power supply from the press. Remove the machine guards if necessary.
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Page 13: Adjustments
FineAdjust Applicator Punch and Anvil Alignments Note: Always clean mounting surfaces of crimp tooling and tooling holders before APPLICATOR alignment. Always disconnect the power supply from the press. Remove the machine guards if necessary. With a terminal in position over the anvils, slightly release anvil mounting screw. - Page 14 FineAdjust Applicator 3. Put a regular screwdriver through the hole in the lock screw and turn the adjusting screw to position the terminal in the correct location. See Figure 2-7. Turning the screw clockwise will move the track towards the operator; to move the track towards the applicator turn the screw counterclockwise.
- Page 15 FineAdjust Applicator Forward Feed Adjustments M5 SHCS FEED LOCK 1. The forward feed position must locate the terminal that is being crimped exactly over the anvils. 2. Disconnect the power from the press. Remove the machine guards if necessary. FORWARD 3.
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Page 16: Crimp Tooling Installation And Removal
Note: Due to the large variety of insulation wall thickness, materials, and diameter, Molex does not specify insulation crimp height. For each different wire type, the insulation crimp height can be measured, recorded, and inspected as a quality indicator. - Page 17 FineAdjust Applicator Installation and Removal of the Lower Tooling (Anvils) Caution: Always disconnect power supply before installing or removing tooling. NOTE: Always clean mounting surfaces of crimp tooling and tooling holders before installation. 1. Always turn off and disconnect the power supply from the press.
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Page 18: Section 3
FineAdjust Applicator Section 3 Maintenance Cleaning Lubrication Spare parts Perishable Parts Storage UNCONTROLLED COPY Doc. No: TM-638004900 Release Date: 09-04-03 Page 18 of 50 Revision: G Revision Date: 01-15-13... -
Page 19: Cleaning
An example of a maintenance chart is shown below. Copy and use this chart to track the maintenance of your FineAdjust Applicator or use this as a template to create you own schedule or use your company’s standard chart, if applicable. -
Page 20: Spare Parts
Customers are responsible for maintaining the FineAdjust Applicator. 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 kits in stock at all times. This will reduce the amount of production down time. For the proper perishable tool kit information, refer to the Crimp Tooling Specification Sheet supplied with the Applicator. -
Page 21: Storage
FineAdjust Applicator See the following chart for common signs of wear. Punches On Terminal Notes Scoring Uneven Curls Replace Tip Loss Open seam Replace Anvils Rounded Edges Large Extrusion Replace Chipping Burrs-On Tabs Replace Worn Cut Edges Burrs Replace Cut-Off Plungers and Punches... -
Page 22: Section 4
FineAdjust Applicator Section 4 Parts Lists, Assembly Drawings and Troubleshooting Style A FineAdjust Applicator Style B FineAdjust Applicator Style C FineAdjust Applicator Troubleshooting UNCONTROLLED COPY Doc. No: TM-638004900 Release Date: 09-04-03 Page 22 of 50 Revision: G Revision Date: 01-15-13... -
Page 23: Styles Of Fineadjust
STYLE C Figure 4-3 In the effort to continually improve the FineAdjust Applicator, we have multiple styles working in the field. To determine the style of applicator you are using, look at the pictures above. Figure 4-1, 4-2, and 4-3 point out the major differences between the styles of this applicator. -
Page 24: Style A-Fineadjust Applicator
FineAdjust Applicator 4.1 STYLE A-FineAdjust Applicator Parts List and Assembly Drawings (See Figure 4-4 and 4-5) STYLE A-FineAdjust Applicator Item Order No. Engineering No. Description 11-18-4238 60700-1 Feed Cam (Short) Optional 11-32-5346 600000Y422 M4 Ball Spring Plunger 11-41-0127 60678-27 Compression Spring (Associated # C0180-016-0500) - Page 25 FineAdjust Applicator STYLE A-FineAdjust Applicator Item Order No. Engineering No. Description M3 by 6mm Long FHCS M4 Hex Nut M4 by 8mm Long BHCS M4 by 8mm Long SHCS M4 by 10mm Long Set Screw M4 by 12mm Long BHCS...
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Page 26: Style A Fineadjust Applicator Assembly
FineAdjust Applicator 4.1 STYLE A FineAdjust Applicator Assembly See Figure 4-5 STYLE A Figure 4-4 UNCONTROLLED COPY Doc. No: TM-638004900 Release Date: 09-04-03 Page 26 of 50 Revision: G Revision Date: 01-15-13... -
Page 27: Style A Fineadjust Applicator Assembly (Cont.)
FineAdjust Applicator 4.1 STYLE A FineAdjust Applicator Assembly (Cont.) Reference See Figure 4-4 STYLE A Figure 4-5 UNCONTROLLED COPY Doc. No: TM-638004900 Release Date: 09-04-03 Page 27 of 50 Revision: G Revision Date: 01-15-13... -
Page 28: Style B-Fineadjust Applicator
FineAdjust Applicator 4.2 STYLE B-FineAdjust Applicator Parts List and Assembly Drawings (See Figure 4-6 and 4-7) STYLE B-FineAdjust Applicator Item Order No. Engineering No. Description 11-18-4238 60700-1 Feed Cam (Short) Optional 11-32-5346 600000Y422 M4 Ball Spring Plunger 11-41-0127 60678-27 Compression Spring (Associated # C0180-016-0500) - Page 29 FineAdjust Applicator STYLE B-FineAdjust Applicator Item Order No. Engineering No. Description 69028-0660 69028-0660 Compression Spring (Lee Spring # LC-032E-0MW) #2 (.098 in. Diameter) by .125 in. Long Drive Screw M3 by 5mm Long SHCS M3 by 6mm Long FHCS M3 by 12mm Long SHCS...
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Page 30: Style B Fineadjust Applicator Assembly
FineAdjust Applicator 4.2 STYLE B FineAdjust Applicator Assembly Figure 4-7 STYLE B Figure 4-6 UNCONTROLLED COPY Doc. No: TM-638004900 Release Date: 09-04-03 Page 30 of 50 Revision: G Revision Date: 01-15-13... -
Page 31: Style B Fineadjust Applicator Assembly (Cont.)
FineAdjust Applicator 4.2 STYLE B FineAdjust Applicator Assembly (Cont.) Reference See Figure 4-6 STYLE B Figure 4-7 UNCONTROLLED COPY Doc. No: TM-638004900 Release Date: 09-04-03 Page 31 of 50 Revision: G Revision Date: 01-15-13... -
Page 32: Style C-Fineadjust Applicator
FineAdjust Applicator 4.3 STYLE C-FineAdjust Applicator Parts List and Assembly Drawings (See Figure 4-8 and 4-9) STYLE C-FineAdjust Applicator- Item Order No. Engineering No. Description 11-18-4238 60700-1 Feed Cam (Short) Optional 11-32-5346 600000Y422 M4 Ball Spring Plunger 11-41-0127 60678-27 Compression Spring (Associated # C0180-016-0500) - Page 33 FineAdjust Applicator STYLE C-FineAdjust Applicator- Item Order No. Engineering No. Description 69028-0660 69028-0660 Compression Spring (Lee Spring # LC-032E-0MW) #2 (.098 in. Diameter) by .125 in. Long Drive Screw M3 by 5mm Long SHCS M3 by 6mm Long FHCS M3 by 12mm Long SHCS...
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Page 34: Style C Fineadjust Applicator Assembly
FineAdjust Applicator 4.3 STYLE C FineAdjust Applicator Assembly 70 (2) Figure 4-9 STYLE C Figure 4-8 UNCONTROLLED COPY Doc. No: TM-638004900 Release Date: 09-04-03 Page 34 of 50 Revision: G Revision Date: 01-15-13... -
Page 35: Style C Fineadjust Applicator Assembly (Cont.)
FineAdjust Applicator 4.3 STYLE C FineAdjust Applicator Assembly (Cont.) Reference STYLE C See Figure 4-8 Figure 4-9 UNCONTROLLED COPY Doc. No: TM-638004900 Release Date: 09-04-03 Page 35 of 50 Revision: G Revision Date: 01-15-13... -
Page 36: Troubleshooting
FineAdjust Applicator 4.4 Troubleshooting Symptom Cause Solution Terminals bent or damaged Replace terminals Feed finger worn or not properly adjusted Check proper finger setting Terminals not feeding Drag plate not holding terminal strip back Check compression springs Terminal jammed under cover plate... - Page 37 FineAdjust Applicator For more information use the Quality Crimping Handbook There is no charge for this book, which can be found on the Molex Website (www.molex.com) or contact your local Molex sales engineer UNCONTROLLED COPY Doc. No: TM-638004900 Release Date: 09-04-03...
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Page 38: Crimp Terminations
FineAdjust Applicator Appendix A Crimp Terminations Conductor Brush and Terminal Position Conductor Bell mouth and Terminal Cut-off Tab Conductor Crimp Height Measurement Insulation Crimp Pull Force Testing UNCONTROLLED COPY Doc. No: TM-638004900 Release Date: 09-04-03 Page 38 of 50 Revision: G... -
Page 39: Conductor Brush And Terminal Position
FineAdjust Applicator BEND UP Terminal Terminology ROLLING SEAM BELL CONDUCTOR BRUSH MOUTH CRIMP INSULATION CRIMP TWISTING STRIP LENGTH BEND DOWN CUT-OFF CRIMP HEIGHT A.1 Conductor Brush and Terminal Position Optimum crimp setup Figure A-1 The insulation edge should be centered in the middle of the transition area. -
Page 40: Conductor Bell Mouth And Terminal Cutoff Tab
FineAdjust Applicator Insulation edge under insulation crimp, Figure A-7 (with a good or wrong conductor brush length) Cause: Strip length too long. Solution: Verify strip length specification and adjust as necessary. Adjust the wire stop. Insulation edge under insulation crimp,... -
Page 41: Conductor Height Measurement
FineAdjust Applicator A.3 Conductor Height Measurement NOTE: Conductor height should be measured with a blade type micrometer or a caliper. CAUTION: Care must be taken not to measure the extrusions A.3.1 Crimp height off target Cause: 1) Changed wire type, stranding or vendor. - Page 42 FineAdjust Applicator A terminal is normally specified to cover a wide range of insulation wall thickness over a range of wire sizes. Within this specified range, an insulation crimp may not completely surround the wire or fully hold the full diameter of the wire.
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Page 43: Pull Force Testing
The pull is to be exerted by means of a tension testing machine or equivalent, so that there will be no sudden application of force or jerking during the test. The following is the procedure Molex uses for the qualification of pull force: 1. Cut wire length approximately 150mm (6.0”) long. - Page 44 FineAdjust Applicator 2) Terminal serration depth/form wrong. 3) Terminal plating thickness wrong. 4) Gold plating application. Solution: 1) Evaluate a new terminal. 2) Or Contact terminal manufacturer. 3) Evaluate selective Gold application. Stripping Evaluation Cause: Wrong strip length, poor conductor brush.
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Page 45: Statistical Process Control (Summary)
FineAdjust Applicator Appendix B Statistical Process Control (Summary) Crimp Process Control Process Capability Production UNCONTROLLED COPY Doc. No: TM-638004900 Release Date: 09-04-03 Page 45 of 50 Revision: G Revision Date: 01-15-13... -
Page 46: Crimp Process Control
Hand Molex qualifies each FineAdjust Applicator design for pull stripping of the wire will produce more variability than a force and crimp height. -
Page 47: Production
FineAdjust Applicator better than a hook type scale. It is important that the Production (Control Charting) measurement gauge has enough resolution. Two It should be normal procedure for the operator to visually operators may measure the same part differently, or the... - Page 48 The FineAdjust Applicator is extremely easy to adjust. It insulation crimp. Since the measurements are still is just as important to chart and document process within specification, would you stop production to adjust control with the FineAdjust applicator.
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Page 49: Options
FineAdjust Applicator Appendix C Options Oiler UNCONTROLLED COPY Doc. No: TM-638004900 Release Date: 09-04-03 Page 49 of 50 Revision: F Revision Date: 10-15-09... -
Page 50: Doc. No: Tm-638004900 Release Date: 09-04-03 Uncontrolled Copy
ASSEMBLY Fax: 708-599-1040 E-mail: sales@midtownoil.com www.midtownoil.com www.precisionlubricantsinc.com 7. For replacement wicks use part no. 63890-0727 (package of 25). Visit our Web site at http://www.molex.com UNCONTROLLED COPY Doc. No: TM-638004900 Release Date: 09-04-03 Page 50 of 50 Revision: G Revision Date: 01-15-13... - Page 51 Mouser Electronics Authorized Distributor Click to View Pricing, Inventory, Delivery & Lifecycle Information: Molex 63800-0115 63800-0313 63800-0119 63800-0127 63800-0330 63800-0345 63800-0116 63800-0120 63800- 0121 63800-0124 63800-0129 63800-0140 63800-0141 63800-0142 63800-0310 63800-0311 63800-0312 63800-0314 63800-0316 63800-0331 63800-0332 63800-0348 63800-4309 63800-4946 11-18-4238 63800-0302...
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