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molex TM-3000 Instruction Manual
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molex TM-3000 Instruction Manual

Universal press. use with molex fineadjust, mini-mac applicators and the molex tape terminal crimp module
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TM-3000 and TM-4000 Universal Press
Use with Molex FineAdjust, Mini-Mac Applicators and the Molex
Description
Operation
Maintenance
Order No: TM-638017299
Revision: D
TM-3000 UNIVERSAL PRESS
TM-4000 UNIVERSAL PRESS
Tape Terminal Crimp Module
Instruction Manual
Order No.63801-7299
Release Date: 06-06-05
Revision Date: 12-0-02-09
UNCONTROLLED COPY
Page 1 of 47

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Summary of Contents for molex TM-3000

  • Page 1 TM-3000 and TM-4000 Universal Press TM-3000 UNIVERSAL PRESS TM-4000 UNIVERSAL PRESS Use with Molex FineAdjust, Mini-Mac Applicators and the Molex Tape Terminal Crimp Module Instruction Manual Order No.63801-7299 Description Operation Maintenance UNCONTROLLED COPY Order No: TM-638017299 Release Date: 06-06-05 Page 1 of 47...
  • Page 2 CAUTION THIS PRESS IS SHIPPED FROM THE FACTORY AT A SHUT HEIGHT OF 135.80mm (5.346”). FAILURE TO HAND CYCLE THE PRESS WHEN INSTALLING APPLICATORS CAN CAUSE SEVERE DAMAGE TO THE TOOLING AND/OR PRESS. CAUTION MOLEX CRIMP SPECIFICATIONS ARE VALID ONLY WHEN USED WITH MOLEX TERMINALS, APPLICATORS AND TOOLING. WORK SAFELY AT ALL TIMES...
  • Page 3 TM-3000 and TM-4000 Universal Press Table of Contents SECTION General Description Installation Setup - Operation Maintenance and Troubleshooting Parts List, Assembly Drawings, Electrical Schematics EC Declaration of Conformity APPENDIX Options Taped Terminal Crimp Module UNCONTROLLED COPY Order No: TM-638017299 Release Date: 06-06-05...
  • Page 4 TM-3000 and TM-4000 Universal Press Section 1 General Description Description Features Technical Specifications Delivery Check Tools UNCONTROLLED COPY Order No: TM-638017299 Release Date: 06-06-05 Page 4 of 47 Revision: D Revision Date: 12-0-02-09...

  • Page 5: General Description

    Recommended step-up transformer: Allied cable. Both the TM-3000 and the TM-4000 are Electronics #836-0181 (phone: 1-800-433-5700). suited to mid-volume semi-automatic operations. Pneumatic Requirements (Air Feed Applicators...
  • Page 6 TM-3000 and TM-4000 Universal Press Tools Carton Contents Quantity 69018-6237 PowerCord The following tools are recommended for setup (for 63801-7200) and adjustments to the applicator in this press Metric hex wrench set 62500-1774 Power Cord 220V 10A Small standard screwdriver...
  • Page 7 TM-3000 and TM-4000 Universal Press Section 2 Installation Lifting/Mounting Reel Support Foot Pedal and Power Connection Pneumatic Supply Hook-up Terminal Feed Guide Function Test Safety and Work Area Check UNCONTROLLED COPY Order No: TM-638017299 Release Date: 06-06-05 Page 7 of 47...
  • Page 8 25mm (1.00”) grounded electrical outlet as the power source. See thick will offer quiet vibration-free operation. For Figure 2-2. thinner or sheet metal tops, the TM-3000 can be UNCONTROLLED COPY Order No: TM-638017299 Release Date: 06-06-05...
  • Page 9 TM-3000 and TM-4000 Universal Press A lubricator is supplied for those applicator air feeds that need lubrication. Molex air-feed applicators do FOOTSWITCH not require lubrication. The lubricator is shipped CORD without lubricant in it. To use, fill the lubricator (make...
  • Page 10 The press shut height gauge is spring loaded to give an accurate reading Safety and Work Area Check on the press shut height. See Figure 2-4. Molex recommends hand cycling the press each time an Check that the crimping position is ergonomic applicator is installed.

  • Page 11: Setup And Operation

    TM-3000 and TM-4000 Universal Press Section 3 Setup and Operation Applicator Installation Air Feed Applicator Installation Manually Cycling the Press Operation UNCONTROLLED COPY Order No: TM-638017299 Release Date: 06-06-05 Page 11 of 47 Revision: D Revision Date: 12-0-02-09...
  • Page 12 TM-3000 and TM-4000 Universal Press 3.1 Applicator Installation 3.2 Air Feed Applicator Installation Power down the press by turning off the “POWER” switch located on the control panel. Power down the press by turning off the “POWER” switch, located on the control panel.
  • Page 13 TM-3000 and TM-4000 Universal Press 7. To lock applicator, turn M5 SHCS counter “DOUBLE”, depending on the spacing of the taped clockwise until tight. terminals. See Figure 3-5. 8. Confirm that the applicator is secured properly. 9. Disconnect the air supply from the filter-regulator- 12.
  • Page 14 TM-3000 and TM-4000 Universal Press 2. Rotate the wrench clockwise. This turns the motor 5. Press the foot pedal down once. Use a sweeping and moves the ram down and up. motion to the right with the crimped wire and 3.
  • Page 15 TM-3000 and TM-4000 Universal Press Split Cycle Ram Adjustment 5. Retighten the M4 SHCS and the (2)M12 jam nuts positioning the prox for the 1 position of the split When setting up an applicator for split cycle operation it cycle. See Figure 3-7.
  • Page 16 TM-3000 and TM-4000 Universal Press 4. When adjustment is complete, retighten the four M6 SHCSs. 5. Close the guard. 6. Place a prestripped wire into the terminal and terminate under power. Examine the quality of the crimp. 7. Repeat steps 1 thru 6 if the desired crimp is not achieved.
  • Page 17 Molex Taped Terminal Crimp Module Section 4 Maintenance Oiler Troubleshooting UNCONTROLLED COPY Order No: ATS-638017299 Release Date: 06-06-05 Page 17 of 47 Revision: B Revision Date: 10-06-08...
  • Page 18 TM-3000 and TM-4000 Universal Press 4.1 Maintenance Power down the press by pressing the power button to off “O” located on the control panel. For efficient operation the press should be cleaned daily with a soft bristle brush to remove any carrier strip debris and terminal plating dust from the tooling area.

  • Page 19: Troubleshooting

    TM-3000 and TM-4000 Universal Press Oiler Wick Adjust the height of the oiler wick by pulling up or pushing down on the wick to the appropriate height. The wick can be moved using pliers or simply grab it with your fingers.
  • Page 20 TM-3000 and TM-4000 Universal Press Section 5 Parts List Assembly Drawings Electrical and Pnuematic Schematics UNCONTROLLED COPY Order No: TM-638017299 Release Date: 06-06-05 Page 20 of 47 Revision: D Revision Date: 12-0-02-09...

  • Page 21: Parts List

    TM-3000 and TM-4000 Universal Press 5.1. Parts List TM-3000 Main Assembly (Figure 5-1 and 5-2) Item No. Order No. Ref. No. Description Quantity 63801-7200 FE-2TC (110VAC) Universal Press (110VAC) See Notes Below 63801-7300 FE-2TC (220VAC) Universal Press (220VAC) See Notes Below...
  • Page 22 Universal Press (220VAC) See Notes Below Note: 1. For TM-3000 Press 220VAC use assembly no. 63801-7300. 2. For TM-4000 Press (220VAC only) use assembly no. 63801-7600. 3. All parts for both 63801-7200 and 63801-7300 Presses unless otherwise specified. ∗ ∗ ∗ ∗...
  • Page 23 TM-3000 and TM-4000 Universal Press 5.2. Assembly 78 (3) JAM NUT (2) (REF) Figure 5-1 UNCONTROLLED COPY Order No: TM-638017299 Release Date: 06-06-05 Page 23 of 47 Revision: D Revision Date: 12-0-02-09...
  • Page 24 TM-3000 and TM-4000 Universal Press Assembly (Continued) 110V 220V 110V 220V 110V Figure 5-2 220V UNCONTROLLED COPY Order No: TM-638017299 Release Date: 06-06-05 Page 24 of 47 Revision: D Revision Date: 12-0-02-09...
  • Page 25 TM-3000 and TM-4000 Universal Press Assembly (continued) Figure 5-3 Oiler Assembly Item No. 43 (63801-7240) Item No. Description Quantity Oiler Wick Oiler Lamp Tube Oiler Lamp Tube Nut Wide Mouth Glass Jar Oiler Glass Jar Lid Oiler Bracket UNCONTROLLED COPY...
  • Page 26 TM-3000 and TM-4000 Universal Press 5.3. Electrical Schematic UNCONTROLLED COPY Order No: TM-638017299 Release Date: 06-06-05 Page 26 of 47 Revision: D Revision Date: 12-0-02-09...
  • Page 27 TM-3000 and TM-4000 Universal Press 5.3. Pnuematic Schematic Figure 5-5 Americas Headquarters Far East North Headquarters Far East South Headquarters European Headquarters Corporate Headquarters Lisle, Illinois 60532 U.S.A. Yamato, Kanagawa, Japan Jurong, Singapore Munich, Germany 2222 Wellington Ct. 1-800-78MOLEX 81-462-65-2324...
  • Page 28 TM-3000 and TM-4000 Universal Press Section 6 EC Declaration of Conformity UNCONTROLLED COPY Order No: TM-638017299 Release Date: 06-06-05 Page 28 of 47 Revision: D Revision Date: 12-0-02-09...
  • Page 29 TM-3000 and TM-4000 Universal Press 6.1 EC Declaration of Conformity UNCONTROLLED COPY Order No: TM-638017299 Release Date: 06-06-05 Page 29 of 47 Revision: D Revision Date: 12-0-02-09...
  • Page 30 TM-3000 and TM-4000 Universal Press For more information use the Quality Crimping Handbook And Industrial Crimping Handbook There is no charge for these books, they can be found on the Molex Website (www.molex.com) or contact you local Molex sales engineer UNCONTROLLED COPY...
  • Page 31 TM-3000 and TM-4000 Universal Press APPENDIX A OPTIONS 1. Taped Terminal Crimp Module UNCONTROLLED COPY Order No: TM-638017299 Release Date: 06-06-05 Page 31 of 47 Revision: D Revision Date: 12-0-02-09...
  • Page 32 TM-3000 and TM-4000 Universal Press TAPED TERMINAL CRIMP MODULE Order Number 64016-2000 Instruction Manual Description Operation Maintenance UNCONTROLLED COPY Order No: TM-638017299 Release Date: 06-06-05 Page 32 of 47 Revision: D Revision Date: 12-0-02-09...
  • Page 33 POWER SOURCE. DISCONNECT POWER BY UNPLUGGING THE PRESS FROM ITS POWER SOURCE. CAUTION THE MOLEX CRIMP MODULE IS DESIGNED TO OPERATE ONLY IN THE MOLEX TM-3000 OR TM-4000 PRESSES. INSTALLATION IN OTHER CRIMP PRESSES CAN CAUSE SEVERE TOOL DAMAGE. IT IS ADVISABLE THAT BEFORE INSTALLATION, A CHECK OF THE PRESS SHUT HEIGHT BE PERFORMED.
  • Page 34 TM-3000 and TM-4000 Universal Press Table of Contents SECTION General Description Setup, Adjustments, and Operation Maintenance Parts List, Assembly Drawings, Troubleshooting, and Guard upgrade APPENDIX Pull Force Testing UNCONTROLLED COPY Order No: TM-638017299 Release Date: 06-06-05 Page 34 of 47...
  • Page 35 TM-3000 and TM-4000 Universal Press Section 1 General Description Description Features Technical Specifications Delivery Check Tools Specification Sheets UNCONTROLLED COPY Order No: TM-638017299 Release Date: 06-06-05 Page 35 of 47 Revision: D Revision Date: 12-0-02-09...
  • Page 36 TM-3000 and TM-4000 Universal Press Principal Mechanical Parts of the Taped Terminal Crimp Module CARRYING HANDLE PRESS YOKE WIRE STOP/ STRIPPER UNIT TAPE GUIDE ANVIL MOUNT COVER ATP-301 PUNCH HOLDER STORAGE STORAGE FOR WIRE STOP/ PUNCH HOLDER STRIPPER AND PRESS YOKE...
  • Page 37 TM-3000 and TM-4000 Universal Presses. The The crimp module is intended to be used with crimp module uses quick-change modular the guards supplied on the TM-3000 or TM- tooling, requires little or no adjustments, and is 4000 Universal Press. intended for mid-volume to high-volume, semi- A special retrofit guard kit is available when the automatic operations.
  • Page 38 TM-3000 and TM-4000 Universal Press Tools The specification sheet is available on the Molex website (www.molex.com). The following tools are recommended for setup and adjustments to the crimp module: Metric standard hex wrench set Inch standard hex wrench set Wire stripper / cutter...
  • Page 39 TM-3000 and TM-4000 Universal Press Section 2 Set-Up and Operation Shut Height Setup Crimp Height Adjustments Crimp Tooling Installation and Removal Specific Crimp Module Adjustments Operation UNCONTROLLED COPY Order No: TM-638017299 Release Date: 06-06-05 Page 39 of 47 Revision: D...
  • Page 40 6. If shut height adjustment is necessary: The shut height of the TM-3000 and the TM-4000 presses LOOSEN M6 SHCS are preset at the factory and labeled on the front of the press. Over time, however, the press may wear causing a change in the shut height.
  • Page 41 TM-3000 and TM-4000 Universal Press open” valve port. The other cylinder port (with the Crimp Module Installation and Removal flow control valve) must be connected to the “normally closed” valve port. 1. Turn off the press and disconnect the power. Open 10.
  • Page 42 See section 2.1 for shut height adjustment. Note: Due to the large variety of insulation wall thickness, materials, and durometers, Molex does not NOTE: Crimp height adjustments for closed-barrel specify insulation crimp height. industrial terminals are always based on solder slug heights, not terminal crimp heights.
  • Page 43 TM-3000 and TM-4000 Universal Press 1. Disconnect power from the press. Open the machine 3. To remove the anvils, use a 5/32” hex wrench to guard. remove the #10 SHCS holding the anvils to the anvil 2. If the ram is down, move it manually to the full up mount.
  • Page 44 TM-3000 and TM-4000 Universal Press 1. Disconnect power from the press. Open the 1. Disconnect power from the press. Open the machine guard. machine guard. 2. If the ram is down, move it manually to the full up 2. If the ram is down, move it manually to the full up position.
  • Page 45 TM-3000 and TM-4000 Universal Press Feed Speed Adjustments Some terminals have a tendency to stick in the Terminal feed speed is controlled by the flow control conductor punch after being crimped. The terminal valve on the feed cylinder. Loosen the locking ring, then...
  • Page 46 TM-3000 and TM-4000 Universal Press 1. Disconnect power from the press. Open the machine TRACK COVER HOLE LIFT KNOB UP guard. OPEN 2. If the ram is down, move it manually to the full up position. 3. To adjust the wire stop, loosen the M5 SHCS on the side of the stripper.
  • Page 47 TM-3000 and TM-4000 Universal Press While operating the crimp module, the tape entering the press should not become taut. The operator should occasionally turn the terminal reel to maintain a slack loop. The scrap tape exits below the press guard.

This manual is also suitable for:

Tm-4000