molex 638082500 General Description, Setup And Operating Instructions Download Page 1

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FA2 Applicator

Doc. No: TM-638080200

Release Date: 02-08-18

UNCONTROLLED COPY

Page 1 of 33

Revision: B2

Revision Date: 05-04-18

FA2 CRIMP APPLICATOR

General Description, Setup and Operating Instructions

Document No. 63808-0200

Start-Up Guide

Page 10

Summary of Contents for 638082500

Page 1: ...o TM 638080200 Release Date 02 08 18 UNCONTROLLED COPY Page 1 of 33 Revision B2 Revision Date 05 04 18 FA2 CRIMP APPLICATOR General Description Setup and Operating Instructions Document No 63808 0200 Start Up Guide Page 10 ...

Page 2: ...FA2 Applicator Doc No TM 638080200 Release Date 02 08 18 UNCONTROLLED COPY Page 2 of 33 Revision B2 Revision Date 05 04 18 ...

Page 3: ...d could result in death or serious injury CAUTION CAUTION Indicates a potentially hazardous situation that if not avoided may result in minor or moderate injury May also be used to alert against unsafe practices associated with events that could lead to personal injury DANGER Never install or service this machine while connected to any electrical power source Disconnect power by unplugging the pre...

Page 4: ...without first reading and understanding the instructions in this manual and all applicable press or wire processing machine manuals CAUTION Always wear proper ear protection when operating or servicing this applicator CAUTION Molex applicators are designed to operate in presses with standard shut heights of 135 80mm 5 346 Installation of crimp presses with other than standard shut heights can caus...

Page 5: ...ting 12 Section 4 Setup and Operation 14 4 0 Press Shut Height 14 4 1 Applicator Installation and Removal 14 4 2 How to Make a Crimp 15 4 3 Crimp Height Adjustments 15 4 4 Track Guide Setup and Adjustment 16 4 5 Loading and Unloading Terminals in the Applicator Track 18 4 6 Terminal Feed Adjustments 19 4 7 Terminal Track Position Adjustment 22 4 8 Crimp Tooling Installation and Removal 23 4 9 Wire...

Page 6: ...t cams allow users to quickly adjust conductor or insulation crimp height without affecting each other The track position for bellmouth and cut off tab can be adjusted while the applicator is in the press This applicator does NOT fit in the Molex TM 40 or TM 42 presses Directly adapts to most automatic wire processing machines Compatible with 30mm and 40mm stroke presses no changes necessary in ap...

Page 7: ...KNOB PUNCH COVER 14 27 23 20 17 TRACK 23 19 18 22 19 FEED PAWL SCRAP CHUTE TERMINAL GUIDE TRACK LOCKING SCREW 22 17 18 TRACK ADJUSTING SCREW 22 DRAG BRAKE KNOB 18 DRAG BRAKE 29 16 RAM STORAGE SCREW INSULATION ADJUSTING CAM 15 14 15 CONDUCTOR ADJUSTING CAM 29 GREASE FITTING CYCLE COUNTER NON RESETTABLE 25 WIRE STOP ASSEMBLY BACK FRAME 16 MOUNTING DATUM 24 BASE PLATE Depending on conditions during a...

Page 8: ...M GREASE FITTING CYCLE COUNTER NON RESETTABLE BASE PLATE Indicates manual page number for more information LUG BOLT PUNCH COVER 14 SPEED CONTROL FORWARD STROKE 20 23 SPEED CONTROL BACK STROKE 21 20 ADJUSTING SCREW BACK STROKE 15 15 23 17 TRACK FEED PAWL 20 18 POSITION ADJUSTING KNOB 22 RAM SCRAP CHUTE TERMINAL GUIDE DRAG BRAKE KNOB 22 18 17 19 20 22 TRACK ADJUSTING SCREW TRACK LOCKING SCREW DRAG B...

Page 9: ...ment for your specific applicator to identify replacement parts and part numbers Tooling component used on some applicators CONDUCTOR PUNCH INSULATION PUNCH FEED CAM NOT USED ON AIR FEED APPLICATORS TERMINAL HOLD DOWN CONDUCTOR STUFFER BLADE AND SPRING INSULATION STUFFER AND SPRING FRONT PLUNGER STRIKER TERMINAL GUIDE COARSE FINE SPACERS HEIGHT SPACER CONDUCTOR ANVIL FRONT PLUNGER RETAINER PUNCH C...

Page 10: ...he first terminal above the anvils o Make sure the drag brake is ON before operating the press 16 20 6 Hand Cycle Slow Cycle the Press o Record the insulation adjusting cam and conductor adjusting cam factory settings o To prevent tool damage move the insulation adjusting cam to setting 1 and the conductor adjusting cam to setting A o Verify back feed pawl position engages the terminal strip carri...

Page 11: ...nals Application Tooling Support Phone 402 458 TOOL 8665 E Mail applicationtooling molex com Website www molex com applicationtooling 8 Inspection o Measure crimp characteristics as specified in the ATS and adjust accordingly ATS 9 Ready for Production Examples Improper Wire Preparation Optimal Crimp Measurement of Crimp Height Note Do not measure extrusions ...

Page 12: ... sheet ATS Debris buildup in plunger area Disassemble and clean Carrier strip jammed in cut off plunger Cut out damaged terminal strip and feed in clean strip Cutting edges worn or damaged cut off plunger retainer or insulation anvil Remove scoring marks and if problem not solved replace the worn cut off plunger cut off retainer or insulation anvil ATS 3 2 Crimp Troubleshooting Symptom Cause Solut...

Page 13: ...iameter specification ATS Gold plating including selective plating or some high tensile materials Install a terminal oiler and potentially replace tooling 23 24 Terminal nose bend up or bend down after crimping Terminal sticking in crimp punches See above troubleshooting Terminal track adjusted too far in or out Adjust track for correct bellmouth and cut off tab 22 Terminal nose hold down misadjus...

Page 14: ...licator Installation and Removal 1 Disconnect power to the press 2 Clean the bottom of the applicator base plate and the top of the press bolster of scrap or chips that may interfere with flat applicator installation 3 Remove the ram storage screw from the back of the applicator frame 4 Fit the applicator lug bolt into the press yoke and align the base plate notches to the press locking mechanism ...

Page 15: ...ake the crimp Then remove the crimped wire from the machine 5 Evaluate the crimp for any necessary adjustments Note Molex recommends performing a setup with the crimp height cams at their loosest setting A 1 to verify that the feed and cutoff are functioning properly This will help prevent tooling damage 4 3 Crimp Height Adjustments 1 Insulation crimp height is adjusted by rotating the insulation ...

Page 16: ...ulation crimp height For each different wire type insulation crimp height can be measured recorded and inspected as a quality indicator 4 4 Track Guide Setup and Adjustment IMPORTANT Electrical and pneumatic power must be disconnected from the press during setup Manual press cycling or slow cycling is an absolutely required procedure for safety and for preventing equipment damage Always hand cycle...

Page 17: ...the drag brake knob until the dot is down This holds the terminal strip in place 5 Look straight down into the feed pawl guide slot The slot must be centered to the centerlines of the pilot holes in the terminal carrier strip See Figure 4 4 2 6 If the guide needs adjustment loosen the two M3 button head screws and move the guide forward or backward until the slot is centered 7 Tighten the two M3 b...

Page 18: ...ure 4 5 1 When the dot is down the drag brake is on applying drag to the terminal carrier When the dot is up the drag brake is off not applying drag to the terminal carrier 4 Align the terminal carrier against the lip in the track and push the terminal strip in until the first terminal is approximately centered above the crimp anvils See Figures 4 5 2 and 4 5 3 5 Rotate the drag brake knob until t...

Page 19: ... back stroke of the feed is determined by the feed cam and is not adjustable The forward position of the feed pawl is adjustable to center the terminal exactly over the crimp anvils using the position adjusting knob See Figure 4 6 1 Caution Always disconnect press power before installing or removing tooling Caution DO NOT operate the applicator without guards in place 1 Disconnect power to the pre...

Page 20: ...ion Always disconnect press power before installing or removing tooling Caution DO NOT operate the applicator without guards in place 1 Disconnect power to the press Load terminals in the track and make sure the drag brake is on dot facing down 2 Operate the press air valve to feed the terminal over the anvils feed pawl forward 3 While holding the feed pawl lever down this keeps the lever from jum...

Page 21: ...he adjusting screw clockwise to increase the back stroke or counterclockwise to reduce the back stroke 6 Make sure the back stroke adjustment allows the feed pawl to drop into the terminal carrier strip pilot hole If adjusted too far back the feed pawl may not engage the terminal carrier strip pilot hole when feeding forward 7 When the adjustment is complete hold the adjusting screw with a 2 5mm h...

Page 22: ...m or 031 a Turn clockwise to move the track in away from the operator This adjustment increases the cut off tab length and decreases the bellmouth size b Turn counterclockwise to move the track out toward the operator This adjustment decreases the cut off tab length and increases the bellmouth size c Make adjustments in small increments to turn 5 Tighten the track locking screw until snug Do not o...

Page 23: ...ing loaded stuffers mounted between the insulation punch and front striker or between the conductor and insulation punches Make sure this tooling stays together Upper Tooling Installation Note Always clean the mounting surfaces of crimp punches other upper tooling and the ram pocket before installation Reverse the previous steps to install the punches The punches can be installed in only one direc...

Page 24: ...tooling spacers and mounting datum before installation 1 Install spacers in the proper order see the specific ATS document for part location The part number marking on each spacer must face the operator 2 Install anvils in the proper order see the specific ATS document for part location The part number marking on each anvil must face the operator See Figure 4 8 3 3 Install the cut off plunger cut ...

Page 25: ...plicator ram As it approaches the bottom of travel finish installing the ram storage screw When properly installed the screw prevents the ram from falling too far preventing tooling damage and prevents the ram from being unintentionally pulled out of the applicator frame See Figure 4 9 1 5 Use a 4mm hex wrench to loosen the M5 screw on the side of the applicator frame See Figure 4 9 1 6 Move the w...

Page 26: ...assembly as follows See Figure 4 9 4 Decrease brush length Move the wire stop assembly toward the operator Increase brush length Move the wire stop assembly away from the operator o Note When decreasing brush length be aware that the conductor punch can hit the wire stop assembly target if the wire stop assembly is adjusted too far forward toward the operator Hand cycle the press to ensure that th...

Page 27: ...an be removed to allow the wire processor to chop the scrap carrier strip At the completion of a job it is recommended that applicators are checked for lubrication and potential tooling wear to expedite future installation Feed Cam Orientation 1 The terminal feed stroke is driven by a cam mounted to the applicator ram The cam is compatible with press strokes between 28 6 41 3mm 1 1 8 1 5 8 Note Us...

Page 28: ...ial precisely adjusts the nose hold down tool to control terminal straightness bend up or bend down during crimping To adjust the dial loosen the M3 screw and turn the dial There is an indicator groove in the dial and a scale on the ram Although the scale is for reference turning the dial clockwise lowers the nose hold down and turning it counterclockwise raises the nose hold down Make adjustments...

Page 29: ...ease gun stop when the grease begins to show at the top of the applicator frame 3 Additional lubrication areas are shown in Figure 5 2 2 Oil Spindle oil 3 in One Oil or equivalent Grease Synco 41150 or equivalent 4 Frequency of lubrication depends on the use of the applicator An applicator run daily in an automatic wire processor should be lubricated at least twice per month Applicators used for o...

Page 30: ...74 Note General replacement parts shown Refer to ATS document for terminal specific tooling and service parts FEED PAWL SPRING 63600 5400 Section 6 Service Parts Basic Applicator Mechanical Feed Air Feed FLOATING JOINT 63600 5560 ADJUSTING SCREW 63600 5558 FLOW CONTROL 63600 4053 AIR CYLINDER 63600 5561 SLIDE BUSHING 63808 0276 BUSHING PIVOT 63600 5404 EXTENSION SPRING 63700 4636 SPRING ANCHOR 636...

Page 31: ...bly out of the applicator 7 Pull off the feed pawl assembly and feed pawl spring Discard the used spring 8 Install the new spring over the feed pawl shaft and make sure the leg of the spring is resting on top of the screw See Figure 6 1 3 Note Apply a few drops of oil on the shaft before installing 9 Install the feed pawl assembly When approaching the guide block make sure the leg of the spring go...

Page 32: ...n Date 05 04 18 6 2 Accessories For terminals that require lubrication for crimping terminal oiler 63801 7240 is available See document ATS 638017240 for more details 6 3 Contact Us Application Tooling Support Phone 402 458 TOOL 8665 E Mail applicationtooling molex com Website www molex com applicationtooling ...

Page 33: ...r more information use the Quality Crimping Handbook This handbook can be downloaded from the Molex website www molex com or contact your local Molex sales engineer 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 ...

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