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molex FineAdjust APPLICATOR, Operation Manual

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molex FineAdjust APPLICATOR Operation Manual Download Page 21

FineAdjust Applicator 

Doc. No: TM-638004900 

Release Date: 09-04-03 

UNCONTROLLED COPY

 

Page 21 of 50 

Revision: G 

Revision Date: 01-15-13 

 
See the following chart for common signs of wear. 
 

Punches 

On Terminal 

Notes 

Scoring 

Uneven Curls 

Replace 

Tip Loss 

Open seam 

Replace 

 

 

 

Anvils 

 

 

Rounded Edges 

Large Extrusion 

Replace 

Chipping 

Burrs-On Tabs 

Replace 

Worn Cut Edges 

Burrs 

Replace 

 

 

 

Cut-Off Plungers and Punches 

 

 

Chipped or Rounded 

Burr on Tab 

Replace 

Cut Edge 

Burr on Tab 

Replace 

Cut-off Dies 

Burrs on Cut Area 

Replace 

 

3.5  Storage 

 
To prevent the bottoming of the ram, which can cause damage to the crimp punches and anvils leave a strip of 
terminals in the applicator or place a piece of wood or rubber between the punches and the anvils.  
 
 

Summary of Contents for FineAdjust APPLICATOR

Page 1: ... Applicator Doc No TM 638004900 Release Date 09 04 03 UNCONTROLLED COPY Page 1 of 50 Revision G Revision Date 01 15 13 FineAdjust APPLICATOR Operation Manual Order No 63800 4900 Description Operation Maintenance ...

Page 2: ...ed to alert against unsafe practices associated with events that could lead to personal injury WARNING WARNING Always wear proper eye protection when Operating or servicing this equipment Failure to wear eye protection could result in serious eye injury from flying debris Heavy Object To avoid muscle strain or back injury use lifting aids and proper lifting techniques when removing or replacing Fa...

Page 3: ... equipment Molex crimp specifications are valid only when used with Molex terminals applicators and tooling Failure to observe this precaution may result in injury and property damage Tooling Technical Assistance Molex offers tooling technical assistance for customers who may need some guidance for tooling adjustments This support can be obtained by calling either of the two numbers listed below a...

Page 4: ...ion 3 18 Maintenance 18 3 1 Cleaning 19 3 2 Lubrication 19 3 3 Spare Parts 20 3 4 Perishable Parts 20 3 5 Storage 21 Section 4 22 Styles of FineAdjust 23 4 1 STYLE A FineAdjust Applicator 24 4 1 STYLE A FineAdjust Applicator Assembly 26 4 1 STYLE A FineAdjust Applicator Assembly Cont 27 4 2 STYLE B FineAdjust Applicator 28 4 2 STYLE B FineAdjust Applicator Assembly 30 4 2 STYLE B FineAdjust Applic...

Page 5: ...PY Page 5 of 50 Revision G Revision Date 01 15 13 Statistical Process Control Summary 45 B 1 Crimp Process Control 46 B 2 Process Capability 46 B 3 Production 47 Appendix C 49 Options 49 Terminal Oiler Error Bookmark not defined 50 Order No 63890 0719 Error Bookmark not defined 50 ...

Page 6: ... Date 09 04 03 UNCONTROLLED COPY Page 6 of 50 Revision G Revision Date 01 15 13 Section 1 General Description 1 1 Description 1 2 Features 1 3 Technical Specifications 1 4 Delivery Check 1 5 Crimp Tooling Accessories 1 6 Tools 1 7 Specification Sheets ...

Page 7: ...icator Figure 1 1 PIVOT ARM FORWARD FEED LOCKING SCREW FORWARD FEED ADJUSTING KNOB INSULATION ADJUSTING CAM RAM REAR COVER DRAG FRAME DRAG RELEASE TRACK FEED FINGER CONDUCTOR ADJUSTING CAM BACK STROKE LOCKING SCREW BASE PLATE LUG BOLT WIRE STOP ANVIL MOUNTING BLOCK ANVILS FRONT COVER TRACK ADJUSTING SCREW CUT OFF PLUNGER AND RETAINER FEED FINGER LEVER BACK STROKE ADJUSTING KNOB ...

Page 8: ...and 29 settings in increments of 063mm 0025 for insulation height Independent adjustment rings allow users to quickly adjust the conductor or insulation crimp height without affecting each other Quick tooling removal with the push of a button for fast and easy punch change Track adjustment for bell mouth and cut off tab is adjusted while the applicator is in the press for fast and easy setup Compa...

Page 9: ... set 2 Adjustable wrench 3 Wire stripper cutter 4 Scissors 1 6 Specification Sheets Molex ships specification sheets with every applicator The specification sheet contains the following Ε Ε Ε Ε Terminal numbers Ε Ε Ε Ε Wire AWG ranges Ε Ε Ε Ε Insulation diameter ranges Ε Ε Ε Ε Strip lengths Ε Ε Ε Ε Pull force Ε Ε Ε Ε Crimp heights Ε Ε Ε Ε Bell mouth Ε Ε Ε Ε Bend twist and roll limits Ε Ε Ε Ε Tooli...

Page 10: ...Doc No TM 638004900 Release Date 09 04 03 UNCONTROLLED COPY Page 10 of 50 Revision G Revision Date 01 15 13 Section 2 Set Up and Operation 2 1 Shut Height 2 2 Set Up 2 3 Adjustments 2 4 Crimp Tooling Installation and Removal ...

Page 11: ...3 Place the shut height gauge into the press on the press quick change mounting plate See Figure 2 1 4 Manually cycle the press to the down stroke position Follow press manufacturer s instructions on manually cycling the press 5 Read the shut height measurement from the front of the gauge Follow gauge manufacturers instruction usually the gauge reads 0 when set correctly 6 If adjustments are neces...

Page 12: ...nt damage to the tooling See Section 3 5 Storage Fitting Terminal Strip 1 The specified terminals are printed on the setup sheet for the applicator Only use the Molex terminals on the setup sheet which is supplied with the applicator 2 Always disconnect the power supply from the press Remove the machine guards if necessary 3 Rotate the drag release until the drag frame is in the upright position T...

Page 13: ...wer supply from the press Remove the machine guards if necessary 2 Remove the applicator from the press Refer to Applicator Installation and Removal 3 Rotate the drag release until the drag frame is in the upright position The rear cover plate should be adjusted so that the terminal strip will slide smoothly through the track with no resistance 4 Some applicators require the removal of the applica...

Page 14: ...r enough remove the M3 SHCS completely and install it in another tapped hole in the feed finger lever In addition the feed finger mount can be reversed the feed finger must be reversed as well to gain additional adjustment 5 Tighten the M3 SHCS to lock the feed finger in position Feed Stroke Cam Adjustments 1 The terminal feed stroke is driven by a cam mounted to the applicator ram Two feed cams a...

Page 15: ...oosen the M5 FHCS holding the pivot clamp Turning the backstroke adjustment knob which is located above the hinge bushing clockwise will raise the hinge bushing and will increase the backstroke Turning the knob counter clockwise CCW will lower the hinge bushing and will decrease the feed backstroke When adjustment is complete tighten the pivot clamp securely See Figure 2 10 4 Since back feed strok...

Page 16: ...will need to be removed when running on an automated machine 1 Check the setup documents to obtain the correct strip length 2 Place the correct wire into the terminal and crimp the wire under power 3 Observe quality of crimp and the wire position See Appendix A 1 Conductor Brush and Terminal Position 4 If adjustments are necessary turn off and disconnect the power supply from the press Remove the ...

Page 17: ... tooling NOTE Always clean mounting surfaces of crimp tooling and tooling holders before installation 1 Always turn off and disconnect the power supply from the press Remove the machine guards if necessary 2 Make sure the ram is all the way in the up position 3 Remove the M4 SHCS that are holding the lower tooling in place and pull out the tooling See Figure 2 14 4 Put in the new anvils leaving th...

Page 18: ...licator Doc No TM 638004900 Release Date 09 04 03 UNCONTROLLED COPY Page 18 of 50 Revision G Revision Date 01 15 13 Section 3 Maintenance 3 1 Cleaning 3 2 Lubrication 3 3 Spare parts 3 4 Perishable Parts 3 5 Storage ...

Page 19: ... with a clean cloth 3 2 Lubrication WARNING Disconnect electrical power before all maintenance 1 Grease the ram including the cam 2 Oil the feed finger assembly and all moving parts 3 Lubricate with multipurpose synthetic lubricant with Teflon or an equivalent Molex ships its applicators pre greased with Permatex multi purpose synthetic grease with Teflon No 82329 A SAE 30WT non detergent oil or l...

Page 20: ...ers are responsible for maintaining the FineAdjust Applicator Perishable parts are those parts that come in contact with the product and will wear out over time Molex recommends that all customers keep at least one set of the perishable tool kits in stock at all times This will reduce the amount of production down time For the proper perishable tool kit information refer to the Crimp Tooling Speci...

Page 21: ...e Anvils Rounded Edges Large Extrusion Replace Chipping Burrs On Tabs Replace Worn Cut Edges Burrs Replace Cut Off Plungers and Punches Chipped or Rounded Burr on Tab Replace Cut Edge Burr on Tab Replace Cut off Dies Burrs on Cut Area Replace 3 5 Storage To prevent the bottoming of the ram which can cause damage to the crimp punches and anvils leave a strip of terminals in the applicator or place ...

Page 22: ...09 04 03 UNCONTROLLED COPY Page 22 of 50 Revision G Revision Date 01 15 13 Section 4 Parts Lists Assembly Drawings and Troubleshooting 4 1 Style A FineAdjust Applicator 4 2 Style B FineAdjust Applicator 4 3 Style C FineAdjust Applicator 4 4 Troubleshooting ...

Page 23: ...KNOB FLAT HEAD CAP SCREW FLAT SURFACE KNOB Styles of FineAdjust In the effort to continually improve the FineAdjust Applicator we have multiple styles working in the field To determine the style of applicator you are using look at the pictures above Figure 4 1 4 2 and 4 3 point out the major differences between the styles of this applicator Identify your applicator style and use the appropriate pa...

Page 24: ...00 0142 Roller Cam Follower 1 20 63800 0143 63800 0143 Pin Cam Follower 1 21 63800 0144 63800 0144 Key Stock 3mm by 3mm by 29mm Long 2 22 63800 0301 63800 0301 Back Frame 1 23 63800 0302 63800 0302 Face Plate 1 24 63800 0303 63800 0303 Base Plate 1 25 63800 0304 63800 0304 Ram Terminator Tooling 1 26 63800 0305 63800 0305 Feed Cam 1 27 63800 4906 63800 4906 Insulation Striker 1 28 63800 0308 63800...

Page 25: ...m Long BHCS 1 57 N A N A M5 by 10mm Long SHCS 1 58 N A N A M5 by 35mm Long SHCS 4 59 N A N A M6 by 10mm Long BHCS 2 60 N A N A M6 by 8mm Long Set Screw 1 61 N A N A M12 Self Locking Hex Nut 1 62 N A N A 3mm by 12mm Long Roll Pin 2 63 N A N A 5mm by 20mm Long Dowel Pin 1 64 N A N A 5mm by 25mm Long Dowel Pin 1 65 N A N A 6mm by 10mm Long Dowel Pin 1 66 N A N A 6mm by 12mm Long Dowel Pin 2 67 N A N ...

Page 26: ... 26 of 50 Revision G Revision Date 01 15 13 Figure 4 4 7 6 18 12 14 5 8 10 13 15 20 22 11 17 2 31 2 19 9 24 21 2 See Figure 4 5 23 2 2 4 58 54 62 64 45 57 63 66 68 49 2 34 30 29 65 59 56 67 69 2 51 44 61 2 2 35 28 32 44 2 39 55 50 33 54 STYLE A 4 1 STYLE A FineAdjust Applicator Assembly ...

Page 27: ...elease Date 09 04 03 UNCONTROLLED COPY Page 27 of 50 Revision G Revision Date 01 15 13 4 25 16 23 26 1 27 2 Reference See Figure 4 4 4 3 2 STYLE A Figure 4 5 36 38 43 37 48 47 41 40 52 42 53 60 52 4 1 STYLE A FineAdjust Applicator Assembly Cont ...

Page 28: ...311 63800 0311 Locking Screw 1 19 63800 0312 63800 0312 Drag Frame 1 20 63800 0313 63800 0313 Drag Cam 1 21 63800 0314 63800 0314 Retaining Bar 1 22 63800 0316 63800 0316 Guide Pin Drag Frame 2 23 63800 0330 63800 0330 Lug Bolt 1 24 63800 0331 63800 0331 Conductor Adjusting Cam 1 25 63800 0332 63800 0332 Insulation Adjusting Cam 1 26 63800 0345 63800 0345 Retaining Plate 1 27 63800 0347 63800 0347...

Page 29: ...Screw 1 58 N A N A M4 by 12mm Long BHCS 3 59 N A N A M4 by 16mm Long SHCS 1 60 N A N A M5 by 6mm Long BHCS 1 61 N A N A M5 by 8mm Long FHCS 1 62 N A N A M5 by 10mm Long SHCS 1 63 N A N A M5 by 35mm Long SHCS 4 64 N A N A M6 by 8mm Long Set Screw 1 65 N A N A 3mm by 12mm Long Roll Pin 2 66 N A N A 5mm by 20mm Long Dowel Pin 1 67 N A N A 5mm by 25mm Long Dowel Pin 1 68 N A N A 6mm by 10mm Long Dowel...

Page 30: ...ion G Revision Date 01 15 13 4 2 STYLE B FineAdjust Applicator Assembly 2 19 46 61 69 8 7 52 42 37 STYLE B Figure 4 6 16 29 12 47 30 68 10 58 2 49 13 21 39 See Figure 4 7 2 2 4 70 49 50 65 41 59 65 66 2 62 51 2 2 53 17 58 22 2 43 60 6 11 45 2 40 44 38 48 56 20 54 72 5 2 2 36 2 9 63 47 67 18 14 35 71 2 ...

Page 31: ...elease Date 09 04 03 UNCONTROLLED COPY Page 31 of 50 Revision G Revision Date 01 15 13 4 2 STYLE B FineAdjust Applicator Assembly Cont 4 15 33 30 34 1 31 2 Reference See Figure 4 6 4 3 2 STYLE B Figure 4 7 23 25 28 24 74 73 32 26 55 27 57 64 55 ...

Page 32: ...ooling 1 18 63800 0310 63800 0310 Adjusting Screw 1 19 63800 0311 63800 0311 Locking Screw 1 20 63800 0312 63800 0312 Drag Frame 1 21 63800 0314 63800 0314 Retaining Bar 1 22 63800 0316 63800 0316 Guide Pin Drag Frame 2 23 63800 0345 63800 0345 Retaining Plate 1 24 63800 0347 63800 0347 Retaining Rod 1 25 63800 4309 63800 4309 Rear Support Block 1 26 63800 4903 63800 4903 Face Plate 1 27 63800 490...

Page 33: ...4 by 10mm Long Set Screw 1 58 N A N A M4 by 12mm Long BHCS 1 59 N A N A M4 by 16mm Long SHCS 1 60 N A N A M5 by 6mm Long BHCS 1 61 N A N A M5 by 8mm Long FHCS 1 62 N A N A M5 by 10mm Long SHCS 1 63 N A N A M5 by 35mm Long SHCS 4 64 N A N A M6 by 8mm Long Set Screw 1 65 N A N A M6 by 10mm Long BHCS 2 66 N A N A M8 by 20mm Long FHCS 1 67 N A N A 3mm by 12mm Long Roll Pin 2 68 N A N A 5mm by 20mm Lon...

Page 34: ...ion G Revision Date 01 15 13 STYLE C Figure 4 8 19 49 10 60 18 40 49 20 68 2 33 72 52 9 See Figure 4 9 26 2 2 4 14 15 12 65 70 2 32 71 21 34 51 25 2 67 7 2 2 8 4 46 61 2 48 74 44 6 54 56 2 41 50 31 22 43 13 47 35 53 2 2 42 2 47 59 45 11 62 69 73 58 63 16 30 2 4 3 STYLE C FineAdjust Applicator Assembly ...

Page 35: ...Release Date 09 04 03 UNCONTROLLED COPY Page 35 of 50 Revision G Revision Date 01 15 13 4 3 STYLE C FineAdjust Applicator Assembly Cont 3 17 36 26 29 1 27 2 Reference See Figure 4 8 5 3 2 STYLE C Figure 4 9 66 39 37 38 2 28 23 55 24 57 64 55 2 ...

Page 36: ...damaged or broken Replace spring Cut edges worn plunger sides or plunger retainer scored Remove scoring marks If problem not solved replace with new cut off parts Conductor crimp is too loose Wrong tooling Replace with proper tooling Tooling worn or damaged Replace tooling Wrong cam setting Back off one setting Press shut height too high Calibrate press shut height Conductor crimp is too tight Wro...

Page 37: ...9 04 03 UNCONTROLLED COPY Page 37 of 50 Revision G Revision Date 01 15 13 For more information use the Quality Crimping Handbook There is no charge for this book which can be found on the Molex Website www molex com or contact your local Molex sales engineer ...

Page 38: ...CONTROLLED COPY Page 38 of 50 Revision G Revision Date 01 15 13 Appendix A Crimp Terminations A 1 Conductor Brush and Terminal Position A 2 Conductor Bell mouth and Terminal Cut off Tab A 3 Conductor Crimp Height Measurement A 4 Insulation Crimp A 5 Pull Force Testing ...

Page 39: ... stop position incorrect Solution Adjust wire stop to center the insulation in the transition area A 4 Insulation under conductor crimp with a short or no conductor brush length Cause 1 Strip length too short and 2 Wire stop position incorrect Solution 1 Verify strip length specification and adjust as necessary 2 Adjust wire stop to center the insulation in the transition area A 5 Insulation edge ...

Page 40: ...to produce conductor bell mouth to nominal specification and or approximately 1x to 2x terminal material thickness The cutoff tab is approximately 1x terminal material thickness A 2 2 Excessive bell mouth cut off tab flush with Insulation crimp Cause 1 Wrong conductor crimp tooling used 2 Camber in the terminal strip Solution 1 Verify that correct tooling is installed 2 Adjust terminal track into ...

Page 41: ...ming product for variability 3 Tooling replacement or tightening 4 Gauge capability analysis 5 Tooling crimp height adjustment 6 Stripping process adjustment Most common cause of crimp height variability A 4 Insulation Crimp A 4 1 Preferred Insulation Crimp It is preferred that the insulation crimp completely surrounds the outside diameter of the insulation The terminal should hold on to the wire ...

Page 42: ...rminal is available in a different wire range 2 Try crimping the wire one setting tighter This will embed the terminal more into the insulation The insulation wall thickness is normally enough therefore cutting strands is not a worry Terminal insulation grips kicking back away from the terminal or slight insulation bulging may be noticed Evaluate the terminal loaded into housing for acceptability ...

Page 43: ... the appropriate terminal to the wire to the nominal crimp height 4 Visually inspect the termination for bell mouth wire brush and cut strands 5 Set pull tester to 25 4mm 1 0 per minute For most applications a higher rate will not have a significant impact on the data Verify higher pull rates with data taken at 25 4mm 1 0 per minute 6 Knot the non terminated end of the wire 7 Regardless of pull te...

Page 44: ...Terminal serration depth form wrong 3 Terminal plating thickness wrong 4 Gold plating application Solution 1 Evaluate a new terminal 2 Or Contact terminal manufacturer 3 Evaluate selective Gold application Stripping Evaluation Cause Wrong strip length poor conductor brush Solution Adjust strip length Figure A 5 0 Pull Force Testing ...

Page 45: ...or Doc No TM 638004900 Release Date 09 04 03 UNCONTROLLED COPY Page 45 of 50 Revision G Revision Date 01 15 13 Appendix B Statistical Process Control Summary B 1 Crimp Process Control B 2 Process Capability B 3 Production ...

Page 46: ...e a new crimping tool is put in production it is recommended that the customer using their specific wire in their process should do a capability study A capability study is based on the assumption of a normal distribution bell type curve It provides an estimate on the probability of a measurement being outside of specification Cpk Sigma Yield PPM 0 67 2 95 45 45 500 1 3 99 73 2 699 1 33 4 99 99 63...

Page 47: ...p to the appropriate setting Re check crimp height and make the proper adjustments if necessary Crimp five more samples and document the average crimp height the maximum reading and the minimum reading The range is considered the maximum reading minus the minimum reading With a crimp micrometer and an experienced operator the range for crimp terminations is normally only a few ten thousandths of a...

Page 48: ...fter a jam would not indicate an adjustment but a close evaluation of the tooling A shift in the process between operators would not indicate an adjustment but an evaluation of measurement capability The idea of the control chart is to identify what caused the shift to justify if an adjustment to the process is warranted The FineAdjust Applicator is extremely easy to adjust It is just as important...

Page 49: ...FineAdjust Applicator Doc No TM 638004900 Release Date 09 04 03 UNCONTROLLED COPY Page 49 of 50 Revision F Revision Date 10 15 09 Appendix C Options 1 Oiler ...

Page 50: ...l hand tight Do not over tighten 5 Mount terminal oiler assembly with bracket on the frame of the FineAdjust or Mini Mac Applicator 6 Recommended lubricant oil Product Name Transdraw B 19 Vendor Mid Town Petroleum 9707 South 76th Avenue Bridgeview IL 60455 Toll Free 877 255 3533 Direct 708 599 8700 Fax 708 599 1040 E mail sales midtownoil com www midtownoil com www precisionlubricantsinc com 7 For...

Page 51: ...00 0119 63800 0127 63800 0330 63800 0345 63800 0116 63800 0120 63800 0121 63800 0124 63800 0129 63800 0140 63800 0141 63800 0142 63800 0310 63800 0311 63800 0312 63800 0314 63800 0316 63800 0331 63800 0332 63800 0348 63800 4309 63800 4946 11 18 4238 63800 0302 63800 0117 63800 0118 63800 0143 63800 0122 11 32 5346 11 41 0127 63800 0126 ...

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