molex TM-3000 Operation Manual
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molex TM-3000 Operation Manual

Universal press
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TM-3000 and TM-4000 Universal Press
Doc. No: TM-638017299
Revision: F
TM-3000 Universal Press
TM-4000 Universal Press
Operation Manual
Press Model Numbers
63801-7200, 63801-7300, 63801-7600
Original Instructions
Release Date: 06-06-05
Revision Date: 11-27-18
UNCONTROLLED COPY
Page 1 of 36

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  • Page 1 TM-3000 and TM-4000 Universal Press TM-3000 Universal Press TM-4000 Universal Press Operation Manual Press Model Numbers 63801-7200, 63801-7300, 63801-7600 Original Instructions UNCONTROLLED COPY Doc. No: TM-638017299 Release Date: 06-06-05 Page 1 of 36 Revision: F Revision Date: 11-27-18...

  • 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 that could result in an injury or property damage.
  • Page 3 Installation in crimp presses with other-than-standard shut heights can cause severe tool or applicator damage. 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 a nonstandard or improperly set shut height.

  • Page 4: Table Of Contents

    TM-3000 and TM-4000 Universal Press Table of Contents Contents TM-3000 Universal Press .................................. 1 TM-4000 Universal Press .................................. 1 Safety Warnings and Information ................................ 2 Table of Contents ....................................4 Section 1 General Description ..................................5 Description ..................................6 Features ..................................6 Technical Specifications ..............................

  • Page 5: General Description

    TM-3000 and TM-4000 Universal Press Section 1 General Description Description Features Technical Specifications Delivery Check Tools UNCONTROLLED COPY Doc. No: TM-638017299 Release Date: 06-06-05 Page 5 of 36 Revision: F Revision Date: 11-27-18...

  • Page 6: Description

    They are designed to provide an effective method of applying a wide range of side-feed and rear-feed terminals to a pre-stripped discrete wire or cable. Both the TM-3000 and the TM-4000 are suited to mid-volume semi-automatic operations.

  • Page 7: Delivery Check

    Humidity: Less than 90% relative humidity, non-condensing Atmospheric Pressure: 86-106KPa (12.5-15.4 psi) The TM-3000 and TM-40000 press systems require only electrical power, however these press systems include an air valve for air feed applicators where air is required (Mylar Tape Applicators for example).

  • Page 8: Tools

    TM-3000 and TM-4000 Universal Press Tools The following tools are recommended for setup and adjustments to the applicator and the press:   Metric hex wrench set Eye loupe (10x) (Molex part no. 63800-2810)   Small standard screwdriver Wire stripper/cutter ...

  • Page 9: Installation

    TM-3000 and TM-4000 Universal Press Section 2 Installation Lifting/Mounting Reel Support Foot Pedal and Power Connection Pneumatic Supply Connection Terminal Feed Guide Function Test Safety and Work Area Check UNCONTROLLED COPY Doc. No: TM-638017299 Release Date: 06-06-05 Page 9 of 36...
  • Page 10 A wooden workbench that is a minimum of 25mm (1.0”) thick will offer quiet, vibration-free operation. The TM-3000 and TM-4000 can be attached to the table with two 12mm (.50”) bolts. Bolts are not supplied by Molex;...

  • Page 11: Pneumatic Supply Connection (See Figures 3-2 And 3-3)

    A lubricator is supplied for air feed applicators that need lubrication. Molex air feed applicators do not require lubrication. The lubricator is shipped without lubricant in it. Fill the lubricator (make sure the main air supply is disconnected or the slide...

  • Page 12: Terminal Feed Guide

    As shipped from the factory, the press is set to the industry- standard shut height of 135.80mm (5.346”) with a calibrated PRESS QUICK CHANGE gauge. Molex offers an industry-standard shut height gauge MOUNTING PLATE (order number 63800-7900). It is recommended that the crimp press shut height be checked regularly.

  • Page 13: Safety And Work Area Check

    Upgrade Kit Safety Guard for Old Styles of the TM-3000 and TM-4000 Guards Figure 2-7 For existing TM-3000 and TM-4000 presses with older guards (see Figure 2-7), the 64016-2595 safety guard upgrade kit is available. See document ATS-640162595. Applicable press order numbers: 63801-7200, 63801-7300 and 63801-7600.
  • Page 14 TM-3000 and TM-4000 Universal Press Tools To install the 64016-2595 safety guard assembly, the following tools will be needed: #3 Phillips Screw Driver 10mm Combination Wrench 3mm Hex Wrench 4mm Hex Wrench 1. Install the angle guard behind the existing lamp bracket. See Figure 2-9.
  • Page 15 M4 X 8 LG. BHCS (2) LOWER TERMINAL Figure 2-12 GUIDE 64016-2522 Note: Clearance holes may need to be drilled into the existing terminal guide on some older TM-3000 presses. UNCONTROLLED COPY Doc. No: TM-638017299 Release Date: 06-06-05 Page 15 of 36...

  • Page 16: 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 Doc. No: TM-638017299 Release Date: 06-06-05 Page 16 of 36 Revision: F Revision Date: 11-27-18...

  • Page 17: Applicator Installation

    TM-3000 and TM-4000 Universal Press Applicator Installation Always turn off and disconnect the power supply to the press. Turn off the “POWER” switch located on the control panel. Note: Once the press guard is open, the guard sensor will disconnect power to the motor.
  • Page 18 TM-3000 and TM-4000 Universal Press 8. Confirm that the applicator is secured properly. 9. Remove ram spacer before hand cycling the press. Note: A ram spacer should be used when storing or transporting an applicator. Remove ram spacer prior to hand cycling the press, and replace it before removing the applicator from the press to avoid potential damage to the tooling.

  • Page 19: Manually Cycling The Press

    TM-3000 and TM-4000 Universal Press 3.3. Manually Cycling the Press Always turn off and disconnect the power supply to the press. MOTOR Always hand cycle the applicator in the press to ensure the tooling is properly aligned. Note: Once the hand cycle wrench is inserted into the back of the HAND CYCLE motor, the wrench sensor will disconnect power to the motor.
  • Page 20 TM-3000 and TM-4000 Universal Press GUARD WIRE STOP Split Cycle Operation Description Split cycle is only used for closed barrel terminals and helps locate the terminal before crimping. The ram will close partially to assist in locating the terminal. With the terminal located, the wire can be placed into the terminal barrel and crimped.
  • Page 21 Always return the shut height to the factory setting before installing another applicator or recalibrating shut height. See Section 2.6.1. ADJUSTABLE Note: Molex does not recommend making shut height adjustments to any DIAL LOOSEN M6 SOCKET bench top crimp press. All adjustments should be made at the applicator,...

  • Page 22: Maintenance

    TM-3000 and TM-4000 Universal Press Section 4 Maintenance Oiler Troubleshooting UNCONTROLLED COPY Doc. No: TM-638017299 Release Date: 06-06-05 Page 22 of 36 Revision: F Revision Date: 11-27-18...
  • Page 23 TM-3000 and TM-4000 Universal Press OIL CUP Maintenance Before performing any maintenance, always turn off and disconnect the power supply to the press. 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 24 Using lubricant also helps extend the life of crimp punches and anvils. The lubricant manufacturer above has no affiliation to Molex, nor is Molex promoting or requiring any customer to use this ...
  • Page 25 TM-3000 and TM-4000 Universal Press Section 5 Parts List Assembly Drawings Electrical and Pneumatic Schematics UNCONTROLLED COPY Doc. No: TM-638017299 Release Date: 06-06-05 Page 25 of 36 Revision: F Revision Date: 11-27-18...

  • Page 26: Main Parts List

    TM-3000 and TM-4000 Universal Press 5.1. Main Parts List TM-3000 Main Assembly (Figure 5-1 and 5-2) Item No. Order No. Description Quantity 63801-7200 Universal Press (100-120VAC) See Notes Below 63801-7300 Universal Press (200-240VAC) See Notes Below 63801-7600 Universal Press (200-240VAC) See Notes Below ...
  • Page 27  69018-6237 Power Cord (110VAC) 20 AMP Note: 1. For TM-3000 Press 200-240VAC, use assembly number 63801-7300. 2. For TM-4000 Press (200-240VAC only), use assembly number 63801-7600. 3. All parts for both 63801-7200 and 63801-7300 presses unless otherwise specified. ...

  • Page 28: Main Assembly

    TM-3000 and TM-4000 Universal Press 5.2. Main Assembly JAM NUT (2) (REF) Figure 5-1 UNCONTROLLED COPY Doc. No: TM-638017299 Release Date: 06-06-05 Page 28 of 36 Revision: F Revision Date: 11-27-18...

  • Page 29: Main Assembly (Continued)

    TM-3000 and TM-4000 Universal Press Main Assembly (Continued) 110V 220V 200-240V Figure 5-2 100-120V UNCONTROLLED COPY Doc. No: TM-638017299 Release Date: 06-06-05 Page 29 of 36 Revision: F Revision Date: 11-27-18...
  • Page 30 TM-3000 and TM-4000 Universal Press Reel Support Parts List Reel Support Assembly 63801-7290 Item No. Order No. Engineering No. Description Quantity 63801-7260 63801-7260 Reel Support 63801-7261 63801-7261 Reel Boss 63801-7262 63801-7262 Reel Disc 63801-7263 63801-7263 Reel-Spring Hardware M6 by 16 Long Wing Screw * Available from an industrial supply company.
  • Page 31 TM-3000 and TM-4000 Universal Press Safety Guard Parts List Safety Guard Assembly 64016-2590 Item No. Order No. Engineering No. Description Quantity 63700-2342 63700-2342 Label-Caution (Eye Glasses) 63700-2344 63700-2344 Label-Caution (Guard in Place) 63801-7212 63801-7212 Handle, Guard 63801-7279 63801-7279 Terminal Guide Standoff...
  • Page 32 TM-3000 and TM-4000 Universal Press Safety Guard Assembly Figure 5-4 UNCONTROLLED COPY Doc. No: TM-638017299 Release Date: 06-06-05 Page 32 of 36 Revision: F Revision Date: 11-27-18...
  • Page 33 63801-7230 Oiler Bracket: Side & Rear Feed Applicators Oiler Bracket: Molex Mini-Mac and FineAdjust 63890-0713 Applicators (not shown) 63808-0258 Oiler Bracket: Molex FA2 Applicator (not shown) UNCONTROLLED COPY Doc. No: TM-638017299 Release Date: 06-06-05 Page 33 of 36 Revision: F...

  • Page 34: Electrical Schematic

    TM-3000 and TM-4000 Universal Press 5.3. Electrical Schematic UNCONTROLLED COPY Doc. No: TM-638017299 Release Date: 06-06-05 Page 34 of 36 Revision: F Revision Date: 11-27-18...

  • Page 35: Pnuematic Schematic

    TM-3000 and TM-4000 Universal Press 5.3. Pnuematic Schematic Figure 5-5 UNCONTROLLED COPY Doc. No: TM-638017299 Release Date: 06-06-05 Page 35 of 36 Revision: F Revision Date: 11-27-18...
  • Page 36 Phone: (402) 458-TOOL (8665) E-Mail: applicationtooling@molex.com Website: www.molex.com/applicationtooling Molex is a registered trademark of Molex, LLC in the United States of America and may be registered in other countries; all other trademarks listed herein belong to their respective owners. UNCONTROLLED COPY Doc.

This manual is also suitable for:

Tm-400063801-720063801-730063801-7600

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