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

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TM-3000 and TM4000 Universal Press
Description
Operation
Maintenance
Doc. No: TM-638017299
Revision: E
TM-3000 Universal Press
TM-4000 Universal Press
Operation Manual for the following order numbers
63801-7200 (TM-3000, 120V)
63801-7300 (TM-3000, 240V)
63801-7600 (TM-4000, 240V)
Release Date: 06-06-05
Revision Date: 09-05-13
UNCONTROLLED COPY
Page 1 of 36

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  • Page 1 TM-3000 and TM4000 Universal Press TM-3000 Universal Press TM-4000 Universal Press Operation Manual for the following order numbers 63801-7200 (TM-3000, 120V) 63801-7300 (TM-3000, 240V) 63801-7600 (TM-4000, 240V) Description Operation Maintenance UNCONTROLLED COPY Doc. No: TM-638017299 Release Date: 06-06-05 Page 1 of 36...

  • 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 / 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 nonstandard or improperly set shut height.

  • Page 4: Table Of Contents

    TM-3000 and TM4000 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 TM4000 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: E Revision Date: 09-05-13...

  • Page 6: Description

    General Description Description The 63801-7200 (120V AC version), the 63801-7300 (240V AC version) TM-3000 Universal Press and the 63801-7600 (240V AC version) TM-4000 Universal Press are economical, electrically-operated, single-cycle and split cycle direct drive presses. 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.

  • Page 7: Delivery Check

    TM-3000 and TM4000 Universal Press 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). Pneumatic Requirements (Air Feed Applicators only) 75 psi min.

  • Page 8: Installation

    TM-3000 and TM4000 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 Doc. No: TM-638017299 Release Date: 06-06-05 Page 8 of 36...
  • Page 9 25mm (1.00”) thick will offer quiet vibration-free operation. For thinner or sheet metal tops, the TM-3000 can be attached to the table with two 12mm bolts. Bolts are not supplied by Molex, however bolting presses to the work bench is recommended for all bench placements.

  • Page 10: Pneumatic Supply Hook-Up (See Figure 3-2 And 3-3)

    Due to the many types of air connection and quick connect air fittings available; Molex only supplies the press with a 1/4 NPT female threaded fitting.

  • Page 11: Terminal Feed Guide

    When the press is shipped from the factory, it is set to the industry shut height of 135.80 mm (5.346”) with a calibrated PRESS QUICK CHANGE gauge. Molex offers an industry standard shut height gauge MOUNTING PLATE (order number 63800-7900). The 63800-7900 will work with most industry standard crimp presses.

  • Page 12: Safety And Work Area Check

    See Figure 2-6. Figure 2-6 Guards Upgrade Kit Safety Guard for Old Styles of the TM-3000 and TM-4000 Guards Figure 2-7 For existing presses, the 64016-2595 safety guard upgrade kit can be purchased separately. See documents: ATS- 640162595.
  • Page 13 TM-3000 and TM4000 Universal Press Tools To install the 64016-2595 Guard Assembly the following tools will be needed. #3 Phillips Screw Driver 10mm Box Open End Wrench 3mm Allen Wrench 4mm Allen Wrench 1. Install the angle guard behind the existing lamp bracket. See Figure 2-9.
  • Page 14 TM-3000 and TM4000 Universal Press 4. Install the guard mounting frame. Use the left (Front) mounting holes that the guard mounting frame originally used. 5. Install the rear guard and the new front door assembly to the hinges. See Figure 2-11.

  • Page 15: Setup And Operation

    TM-3000 and TM4000 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 15 of 36 Revision: E Revision Date: 09-05-13...

  • Page 16: Applicator Installation

    8. Confirm that the applicator is secured properly. Figure 3-1 9. Remove the Molex ram spacer (order number SPACER 63443-7200) prior to hand cycling the press. Note: A ram spacer should be used when storing or transporting your applicator. Remove ram spacer proir to hand cycling the press and replace it before removing the applicator from the press to avoid potenial damage to the tooling.
  • Page 17 TM-3000 and TM4000 Universal Press 7. To lock applicator, turn M5 socket head screw counter clockwise until tight. 8. Confirm that the applicator is secured properly. 9. Remove ram spacer order number 63443-7200 before hand cycling the press. Note: A ram spacer should be used when storing or transporting your 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 18: Manually Cycling The Press

    TM-3000 and TM4000 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 wrench is inserted into the back of the motor, the HAND CYCLE guard interlock switch will disconnect power to the motor.
  • Page 19 TM-3000 and TM4000 Universal Press GUARD WIRE STOP Split Cycle Operation Description: The split cycle is used only for closed barrel terminals, and helps to locate the terminal before crimping the wire. The ram will close partially to assist in locating the terminal for the termination. With the terminal located the wire can be placed into the terminal and terminated.
  • Page 20 See Section 2.6.1. ADJUSTABLE DIAL LOOSEN M6 SOCKET Note: Molex does not recommend making shut height adjustments to any HEAD SCREW bench top crimp press. All adjustments should be made at the applicator Figure 3-8 including shimming of the applicator if required to achieve the proper crimp height for the crimped terminal.

  • Page 21: Maintenance

    TM-3000 and TM4000 Universal Press Section 4 Maintenance Oiler Troubleshooting UNCONTROLLED COPY Doc. No: TM-638017299 Release Date: 06-06-05 Page 21 of 36 Revision: E Revision Date: 09-05-13...
  • Page 22 TM-3000 and TM4000 Universal Press OIL CUP Maintenance Always turn off and disconnect the power supply to the press. Turn off the “POWER” switch 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 23 The lubricant vendor above has no affiliation to Molex nor is Molex promoting requiring any customer to use this supplier. This supplier is just one source and customers need to determine if this source is acceptable for their needs.
  • Page 24 TM-3000 and TM4000 Universal Press Section 5 Parts List Assembly Drawings Electrical and Pneumatic Schematics UNCONTROLLED COPY Doc. No: TM-638017299 Release Date: 06-06-05 Page 24 of 36 Revision: E Revision Date: 09-05-13...

  • Page 25: Main Parts List

    TM-3000 and TM4000 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 (110VAC) See Notes Below 63801-7300 Universal Press (220VAC) See Notes Below 63801-7600 Universal Press See Notes Below ∗...
  • Page 26 69018-6237 Power Cord (110VAC) 20 AMP 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 27: Main Assembly

    TM-3000 and TM4000 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 27 of 36 Revision: E Revision Date: 09-05-13...

  • Page 28: Main Assembly (Continued)

    TM-3000 and TM4000 Universal Press Main Assembly (Continued) 110V 220V 220V Figure 5-2 110V UNCONTROLLED COPY Doc. No: TM-638017299 Release Date: 06-06-05 Page 28 of 36 Revision: E Revision Date: 09-05-13...
  • Page 29 TM-3000 and TM4000 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 such as MSC (1-800-645-7270).
  • Page 30 TM-3000 and TM4000 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 63801-7287...
  • Page 31 TM-3000 and TM4000 Universal Press Safety Guard Assembly Figure 5-4 UNCONTROLLED COPY Doc. No: TM-638017299 Release Date: 06-06-05 Page 31 of 36 Revision: E Revision Date: 09-05-13...
  • Page 32 TM-3000 and TM4000 Universal Press Oiler Assembly 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 Doc.

  • Page 33: Electrical Schematic

    TM-3000 and TM4000 Universal Press 5.3. Electrical Schematic UNCONTROLLED COPY Doc. No: TM-638017299 Release Date: 06-06-05 Page 33 of 36 Revision: E Revision Date: 09-05-13...

  • Page 34: Pnuematic Schematic

    TM-3000 and TM4000 Universal Press 5.3. Pnuematic Schematic Figure 5-5 UNCONTROLLED COPY Doc. No: TM-638017299 Release Date: 06-06-05 Page 34 of 36 Revision: E Revision Date: 09-05-13...

  • Page 35: Ec Declaration Of Conformity

    TM-3000 and TM4000 Universal Press Section 6 EC Declaration of Conformity UNCONTROLLED COPY Doc. No: TM-638017299 Release Date: 06-06-05 Page 35 of 36 Revision: E Revision Date: 09-05-13...
  • Page 36 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 your local Molex sales engineer Visit our Web site at http://www.molex.com UNCONTROLLED COPY Doc.

This manual is also suitable for:

Tm-400063801-720063801-730063801-7600

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