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TM-3000 and TM-4000 Universal Press 

Doc. No: TM-638017299 

Release Date: 06-06-05 

UNCONTROLLED COPY

 

Page 1 of 36 

Revision: F 

Revision Date: 11-27-18 

 

 

 
 

 

 

 

 

 
 

 

 

 

 
 

 

 

 

 

 
 

 

 

 

 
 

 

 

 

 
 

 

 

 

 

 

 

TM-3000 Universal Press 
TM-4000 Universal Press 

 

Operation Manual 

 

Press Model Numbers 

63801-7200, 63801-7300, 63801-7600 

 

 

Original Instructions 

 

Summary of Contents for 63801-7200

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

Page 2: ...n serious eye injury from flying debris Heavy Object To avoid muscle strain or back injury use lifting aids and proper lifting techniques when moving this press Failure to observe these precautions may result in injury or property damage WARNING WARNING Never wear clothing or jewelry that is loose or that could potentially snag in the press and get caught Failure to observe this warning could resu...

Page 3: ...2 458 TOOL 8665 E Mail applicationtooling molex com Website www molex com applicationtooling WARNING WARNING Never use this press or wire processing machine without guards or safety devices that are intended to prevent hands from remaining in the die space Failure to observe this warning could result in severe injury or death Do not use compressed air to clean this equipment The forces created by ...

Page 4: ... Installation 9 2 1 Lifting Mounting 10 2 2 Foot Pedal and Power Connection 10 2 3 Reel Support 10 2 4 Pneumatic Supply Connection See Figures 3 2 and 3 3 11 2 5 Terminal Feed Guide 12 2 6 Shut Height 12 2 7 Safety and Work Area Check 13 2 8 Guards 13 Section 3 16 Setup and Operation 16 3 1 Applicator Installation 17 3 2 Air Feed Applicator Installation 17 3 3 Manually Cycling the Press 19 3 4 Ope...

Page 5: ... Press Doc No TM 638017299 Release Date 06 06 05 UNCONTROLLED COPY Page 5 of 36 Revision F Revision Date 11 27 18 Section 1 General Description 1 1 Description 1 2 Features 1 3 Technical Specifications 1 4 Delivery Check 1 5 Tools ...

Page 6: ...nt the press from operating if the hand cycle wrench is accidently left in the motor 1 2 Features Utilizes FineAdjust Mini Mac and FA2 applicators side and rear feed and most industry standard applicators Press is calibrated to 135 80mm 5 346 industry shut height Ideal for mid volume semi automatic applications Guarding for operator safety including sensors for guard closed and the hand cycle wren...

Page 7: ...minal and wire length TM 4000 press has a slightly slower cycle rate due to gear reduction to meet force capability Processing Capability TM 3000 press output 4 000 lbs 18kN Copper conductors up to 10 AWG 5 0mm in stranded wire TM 4000 Press output 7 000 lbs 31kN Copper conductors up to 4 AWG 21 0mm in stranded wire insulated or un insulated connector products Copper conductors up to 2 AWG 34 0mm ...

Page 8: ... 5 Tools The following tools are recommended for setup and adjustments to the applicator and the press Metric hex wrench set Small standard screwdriver Adjustable wrench Needle nose pliers Crimp micrometer Molex part no 63800 2850 Eye loupe 10x Molex part no 63800 2810 Wire stripper cutter English hex wrench set for some non metric applicators ...

Page 9: ... 06 05 UNCONTROLLED COPY Page 9 of 36 Revision F Revision Date 11 27 18 Section 2 Installation 2 1 Lifting Mounting 2 2 Reel Support 2 3 Foot Pedal and Power Connection 2 4 Pneumatic Supply Connection 2 5 Terminal Feed Guide 2 6 Function Test 2 7 Safety and Work Area Check ...

Page 10: ...ll 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 however bolting the press to the workbench is required for all bench placements 2 2 Foot Pedal and Power Connection Connect the 3 pin plug of the foot pedal cord in the rear of the press Turn the locking ring clockwise until tight Connect the power cor...

Page 11: ...d to properly condition the supply air The filter will remove particulates and moisture from the air that can damage or reduce the life of air cylinders and valves This filter and bowl should be serviced on a regular schedule See Section 4 1 The filter has an automatic drain at the bottom of the bowl that will automatically open and expel fluid when the bowl becomes full It is recommended that a 6...

Page 12: ... the side of the press with the two M6 socket head screws Figure 2 4 shows conversion between side feed and rear feed terminal guides 2 6 Shut Height As shipped from the factory the press is set to the industry standard shut height of 135 80mm 5 346 with a calibrated gauge Molex offers an industry standard shut height gauge order number 63800 7900 It is recommended that the crimp press shut height...

Page 13: ...ration or being serviced To prevent fatigue operators should be encouraged to take a short break every few hours The fuse is located on the control panel To replace the fuse 10AMP on 100 120V models and 7AMP or 10AMP on 200 240V models turn the holder counterclockwise Turn the holder clockwise install the fuse See Figure 2 6 2 8 Guards Upgrade Kit Safety Guard for Old Styles of the TM 3000 and TM ...

Page 14: ...m Hex Wrench 1 Install the angle guard behind the existing lamp bracket See Figure 2 9 NOTE The angle guard 64016 2581 must be installed to ensure operator safety 2 Install the spacer plate 64016 2579 and guard mounting frame on the press The spacer plate should be aligned so its rear most set of holes aligns to the threaded holes in the press frame 3 Place the guard mounting frame over the spacer...

Page 15: ... REFERENCE ONLY TERMINALGUDIE 63801 7234 NOT INCLUDED WITH 64016 2590 LOWER TERMINAL GUIDE 64016 2522 Figure 2 12 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 6 Install the lower terminal guide 64016 2522 into the terminal guide 63801 7234 wit...

Page 16: ...o TM 638017299 Release Date 06 06 05 UNCONTROLLED COPY Page 16 of 36 Revision F Revision Date 11 27 18 Section 3 Setup and Operation 3 1 Applicator Installation 3 2 Air Feed Applicator Installation 3 3 Manually Cycling the Press 3 4 Operation ...

Page 17: ...ycling 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 3 2 Air Feed Applicator Installation Always turn off and disconnect the power supply to the press Turn off the POWER switch located on the control panel N...

Page 18: ...icators feed terminals in the retracted position for those air tubes must be reversed In addition some applicators are air advance and spring return on those applicators one valve port will need to be plugged 11 Insert port A of the air valve with the tube that retracts the feed mechanism of the applicator See Figure 3 3 12 Insert port B of the air valve with the tube that advances the feed mechan...

Page 19: ... to engage the motor shaft See Figure 3 4 2 Rotate the wrench clockwise or counterclockwise This turns the motor and moves the ram down and up 3 Always return the ram back to the top so that the ram is in the start position 4 Remove the hand cycle wrench 3 4 Operation Full Cycle Operation CAUTION Make sure the press guard is in position and all setup procedures are followed Follow the safety and w...

Page 20: ...ycle Ram Adjustment When setting up an applicator for split cycle operation it may be necessary to adjust the split position of the ram first position so the terminal will be captured by the punch but not crimped To change the split position the sensor located on the left side of the ram cover must be adjusted See the following steps Steps 1 With the terminals in the applicator depress the foot pe...

Page 21: ...stable dial to the right to raise crimp height or to the left to lower crimp height Indicator lines on the dial represent increments of approximately 05mm 002 See Figure 3 8 4 When adjustment is complete tighten the four M6 socket head screws 5 Close the guard and restore power to the press 6 Place a pre stripped wire into the terminal and terminate under power Examine the quality of the crimp 7 R...

Page 22: ...TM 3000 and TM 4000 Universal Press Doc No TM 638017299 Release Date 06 06 05 UNCONTROLLED COPY Page 22 of 36 Revision F Revision Date 11 27 18 Section 4 4 1 Maintenance 4 2 Oiler 4 3 Troubleshooting ...

Page 23: ...tor mounting plate 4 2 Oiler Description A wick action oiler is included with the press The oiler applies a thin coat of stamping lubricant to the terminals which helps feeding and improves release from crimp punches Primarily used for terminals with gold plating the oiler is shipped with no stamping lubricant The oiler should only be used on applicators that require lubrication Customers must sup...

Page 24: ...ion and environment A lubricant is highly recommended for applications where gold plated terminals are being crimped or where terminals stick in the crimp punches 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 supplier This supplier is one source and cus...

Page 25: ... 4000 Universal Press Doc No TM 638017299 Release Date 06 06 05 UNCONTROLLED COPY Page 25 of 36 Revision F Revision Date 11 27 18 Section 5 5 1 Parts List 5 2 Assembly Drawings 5 3 Electrical and Pneumatic Schematics ...

Page 26: ...it Cycle Prox 1 13 63801 7213 Yoke Adapter 1 14 63801 7214 Mounting Block Cover 1 15 63801 7215 Mounting Block 1 16 63801 7216 Press Yoke 1 17 63801 7217 Press Shaft 1 18 63801 7218 Shaft E Ring 1 19 63801 7219 Front Bearing 1 20 63801 7222 Quick Change Plate 1 21 63801 7224 Name Plate Universal Press 1 22 63801 7232 Eye Bolt 1 23 63801 7233 Stand off 2 24 63801 7234 Terminal Guide 1 25 63801 7236...

Page 27: ...801 7276 Plug 1 4 Tube 2 54 63801 7277 Elbow Male 1 4 Tube for Filter Reg Lubricator 1 55 63801 7278 Elbow Male 1 4 Tube for 3 Way Valve 3 56 63801 7283 Side Guard 1 57 63801 7284 Hinge Mounting Bracket 1 58 63801 7285 Guard Hinge 2 59 63801 7286 Guard Sensor Bracket 1 60 63801 7288 Stand off Guard Side 3 61 63801 7290 Reel Support Assembly 1 62 63801 7631 Control Panel 1 63 64016 2590 Safety Guar...

Page 28: ...ress Doc No TM 638017299 Release Date 06 06 05 UNCONTROLLED COPY Page 28 of 36 Revision F Revision Date 11 27 18 50 47 52 Figure 5 1 3 55 48 57 2 M12 JAM NUT 2 REF 20 28 12 29 54 58 63 2 60 22 62 3 2 63 56 53 21 59 5 2 Main Assembly ...

Page 29: ...UNCONTROLLED COPY Page 29 of 36 Revision F Revision Date 11 27 18 20 7 46 10 4 5 18 17 19 34 6 14 13 15 16 32 11 3 24 40 23 57 31 61 30 36 63 33 45 44 35 37 8 41 42 38 64 63 27 26 Figure 5 2 2 2 2 2 110V 220V 39 43 100 120V 200 240V REF 1 9 63 25 51 49 5 2 Main Assembly Continued ...

Page 30: ... 2 5 5 3 3 4 Reel Support Parts List Reel Support Assembly 63801 7290 Item No Order No Engineering No Description Quantity 1 63801 7260 63801 7260 Reel Support 1 2 63801 7261 63801 7261 Reel Boss 2 3 63801 7262 63801 7262 Reel Disc 2 4 63801 7263 63801 7263 Reel Spring 1 Hardware 5 N A N A M6 by 16 Long Wing Screw 2 Available from an industrial supply company Reel Support Assembly ...

Page 31: ... 4 63801 7279 63801 7279 Terminal Guide Standoff 4 5 63801 7287 63801 7287 Bracket Guard 1 6 64016 2521 64016 2521 Guard Front 1 7 64016 2522 64016 2522 Terminal Guide Lower 1 8 64016 2523 64016 2523 Mounting Bracket 8 9 64016 2537 64016 2537 Guard Point of Operation 1 10 64016 2541 64016 2541 Guard Right 1 11 64016 2579 64016 2579 Spacer Plate 1 12 64016 2581 64016 2581 Guard 1 13 64016 2586 6401...

Page 32: ...versal Press Doc No TM 638017299 Release Date 06 06 05 UNCONTROLLED COPY Page 32 of 36 Revision F Revision Date 11 27 18 Figure 5 4 1 7 2 5 15 14 8 2 14 8 8 14 13 4 4 2 15 6 12 10 11 8 16 4 3 2 4 9 17 8 Safety Guard Assembly ...

Page 33: ...ssembly Figure 5 1 Item No 29 Item No Order No Description Quantity 1 N A Oiler Wick 1 2 N A Oiler Lamp Tube 1 3 N A Oiler Lamp Tube Nut 2 4 N A Wide Mouth Glass Jar 1 5 N A Oiler Glass Jar Lid 1 6 63801 7230 Oiler Bracket Side Rear Feed Applicators 1 6 63890 0713 Oiler Bracket Molex Mini Mac and FineAdjust Applicators not shown 1 6 63808 0258 Oiler Bracket Molex FA2 Applicator not shown 1 ...

Page 34: ...TM 3000 and TM 4000 Universal Press Doc No TM 638017299 Release Date 06 06 05 UNCONTROLLED COPY Page 34 of 36 Revision F Revision Date 11 27 18 5 3 Electrical Schematic ...

Page 35: ...TM 3000 and TM 4000 Universal Press Doc No TM 638017299 Release Date 06 06 05 UNCONTROLLED COPY Page 35 of 36 Revision F Revision Date 11 27 18 5 3 Pnuematic Schematic Figure 5 5 ...

Page 36: ...no charge for these books They can be found on the Molex website www molex com or by contacting your local Molex sales engineer Application Tooling Support 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 list...

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