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TM-2000 Universal Press 

Order No.: TM-638008399  Release Date: 08-08-02 

UNCONTROLLED COPY

 

Page 1 of 36 

Revision: H 

Revision Date: 01-15-13

 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

TM-2000 UNIVERSAL PRESS 

Use with Molex FineAdjust or Mini-Mac Applicators 

Operation Manual 

Order No.63800-8399 

 

 

Description 

 

Operation 

 

Maintenance 

 

Содержание 638008300

Страница 1: ...8008399 Release Date 08 08 02 UNCONTROLLED COPY Page 1 of 36 Revision H Revision Date 01 15 13 TM 2000 UNIVERSAL PRESS Use with Molex FineAdjust or Mini Mac Applicators Operation Manual Order No 63800 8399 Description Operation Maintenance ...

Страница 2: ...used 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 ...

Страница 3: ...he 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...

Страница 4: ...nal Feed Guide 9 2 5 Function Test 9 2 6 Safety and Work Area Check 10 Section 3 11 Setup and Operation 11 3 1 Applicator Installation and Removal 12 3 2 Manually Cycling the Press 12 3 3 Operation 13 Section 4 14 4 1 Maintenance 15 4 2 Clutch Service Replacement 15 4 3 Shim Installation Removal 17 4 4 Oiler 18 Section 5 19 5 1 Parts List 20 5 2 Assembly 21 5 2 Assembly continued 22 5 2 Assembly c...

Страница 5: ...Order No TM 638008399 Release Date 08 08 02 UNCONTROLLED COPY Page 5 of 36 Revision H 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 Tools ...

Страница 6: ...dular solid state controls Power cord and foot pedal plug in easily CE certified for sale in Europe 240 50 Hz version 1 3 Technical Specifications Dimensions with reel mounted Height1260 00mm 49 60 Width 560 00mm 22 00 Depth 686 00mm 27 00 Unpacked weight 145kg 320 lbs Power Requirements Voltage 63800 8300 120V AC 60 HZ Voltage 63800 8400 240V AC 50 HZ Note Press shipped setup for 120V AC service ...

Страница 7: ...ase Date 08 08 02 UNCONTROLLED COPY Page 7 of 36 Revision H Revision Date 01 15 13 Section 2 Installation 2 1 Lifting Mounting 2 2 Reel Support 2 3 Foot Pedal and Power Connection 2 4 Terminal Feed Guide 2 5 Function Test 2 6 Safety and Work Area Check ...

Страница 8: ...ifting hooks are provided on each side of the press A heavy duty chain rope cable or belt can be used with loops links or rings on each end that can securely attach to the lifting hooks An electric hydraulic or mechanical crane should be used to lift the press Lift the press up approximately 12 00mm 50 and verify that the press is well balanced Upon verification the press can be lifted onto a stur...

Страница 9: ...irectly above the power socket To replace the fuses use a small screwdriver to open the fuse drawer remove damaged fuses and replace See Figure 2 3 2 4 Terminal Feed Guide Depending on side or rear feed applications the terminal guide plate and bracket must be repositioned The TM 2000 press is set for side feed applicators when shipped from the factory When rear feed applicators are used the four ...

Страница 10: ...ons for use and calibration See Section 4 3 of this manual for resetting the shut height of the TM 2000 to industrial standards 2 6 Safety and Work Area Check Check that the crimping position is ergonomic for the operator s size A bench height of 762 00 to 813 00mm 30 00 to 32 00 will provide operator comfort and allows both feet to rest on the floor The foot pedal should be placed in a comfortabl...

Страница 11: ... Order No TM 638008399 Release Date 08 08 02 UNCONTROLLED COPY Page 11 of 36 Revision H Revision Date 01 15 13 Section 3 Setup and Operation 3 1 Applicator Installation and Removal 3 2 Manually Cycling the Press 3 3 Operation ...

Страница 12: ... x 30 00 Lg SHCS clockwise until the locking clamp is in the full out position 5 Locate the applicator lug bolt in the press yoke See Figure 3 1 6 Align the applicator base plate with the locator clamps on the press quick change mounting plate 7 To lock applicator turn M5 x 30 00 Lg SHCS counter clockwise until tight 8 Confirm that the applicator is secured properly 3 2 Manually Cycling the Press ...

Страница 13: ... 4 3 4 Remove the 10mm hex wrench 3 3 Operation CAUTION Make sure the press guard is in position and all setup procedures are followed Follow the safety and work area instructions Steps 1 Wire should be stripped and prepared for processing 2 Place the prestripped wire through the slot in the press guard and push until it contacts the wire stop See Figure 3 3 3 Press the foot pedal down once Use a ...

Страница 14: ...sal Press Order No TM 638008399 Release Date 08 08 02 UNCONTROLLED COPY Page 14 of 36 Revision H Revision Date 01 15 13 Section 4 4 1 Maintenance 4 2 Clutch Service Replacement 4 3 Shim Installation Removal 4 4 Oiler ...

Страница 15: ...s Verify that the clutch control collar is in the locked position See Figure 4 3 Insert the 10mm hex wrench into the socket head cap screw This screw is located in the center of the flywheel See Figure 4 2 This screw is spring loaded to prevent the wrench being left in the unit 2 Attempt to rotate the hex wrench clockwise If the unit will not turn it is functioning properly 3 Next rotate the input...

Страница 16: ...nner race for the flywheel can be reused or be replaced Installing the Clutch Unit Note The 3 M6 x 16 00LG SHSS socket head shoulder screw used to mount the clutch plate permit free axial and radial movement around the crankshaft This allows the friction surfaces to be in perfect alignment for the wrap up function of the springs Free movement of the unit is necessary because the brake hub is rigid...

Страница 17: ...and corner If the gap is more or less than the recommended 0 25mm 010 loosen the M6 nut and adjust the screw to the appropriate gap Be certain to tighten the nut and double check the gap after securing the nut See Figure 4 6 Solenoid Clutch Assembly Lubrication The clutch has sintered metal components that have been impregnated at manufacturing with bearing infusion oil No 33 for permanent lubrica...

Страница 18: ...simply grab it with your fingers Maintenance Filling the Reservoir While firmly holding the lid screw the jar oil reservoir counter clockwise until it is removed Fill the jar with the desired lubricant oil and replace the lid Replacing the Wick While firmly holding the lid screw the jar oil reservoir counter clockwise until it is removed Feed a new wick up into the tube until it protrudes from the...

Страница 19: ...ersal Press Order No TM 638008399 Release Date 08 08 02 UNCONTROLLED COPY Page 19 of 36 Revision H Revision Date 01 15 13 Section 5 5 1 Parts List 5 2 Assembly Drawings 5 3 Electrical Schematics 5 4 Troubleshooting ...

Страница 20: ... 35 63600 0805 Post 4 36 63700 2493 Flexible Vinyl Plug 2 37 69018 5044 120V 1 3 HP motor 1 38 69018 6052 Limit Switch 1 39 69018 6219 8 0 Amp Fuse not shown 2 40 69018 6237 Power Cord 120V 1 41 69018 6241 Solenoid Clutch Assembly 1 42 69018 7031 Crankshaft Bearing 1 43 69018 7032 Inner Race 1 44 69018 7033 Eccentric Bearing 1 45 69018 7034 Inner Race 1 46 69018 7035 Eccentric Bearing 2 47 69018 7...

Страница 21: ... 14 12 M6 X 10LG BHCS 6 M6 X 60LG SSS W M6 NUT M5 X 20LG SSS 4 35 M8 FLAT WASHER 4 M8 X 35LG SHCS 4 M5 X 10LG BHCS 8 19 36 18 10 13 M6 HEX NUT 58 3 9 M6 X 25LG SET SCREW 17 M5 X 10LG BHCS 2 34 37 M8 X 16LG HHCS 4 W M8 WASHER 4 M5 X 12LG BHCS 2 56 8 24 5 16 1 1 4 TAPER GREASE FITTING M6 X 20LG SHCS 2 M6 X 16LG SHCS 4 M5 X 10LG BHCS 2 M6 X 25LG SHSS 2 M5 HEX NUT 2 M6 X 12LG BHCS M6 NUT W M6 WASHER 5...

Страница 22: ... 08 08 02 UNCONTROLLED COPY Page 22 of 36 Revision H Revision Date 01 15 13 M5 X 10LG FHCS M6 X 12LG FHCS 4 5MM DIA X 35LG SPIROL PIN 27 29 53 28 30 44 45 41 48 49 26 46 47 M6 X 40LG SHCS 3 M6 X 20LG SHSS 3 6 42 43 32 47 48 25 5 2 Assembly continued Figure 5 2 ...

Страница 23: ... Revision H Revision Date 01 15 13 5 2 Assembly continued Figure 5 3 63800 8397 CONVERSION CABLE REQUIRED WHEN USING FOOTSWITCH 63800 8394 WITH CONTROL ASSEMBLY 63800 8390 M4 X 6LG BHCS 4 M5 X 10LG BHCS 2 7 20 M5 WING NUT 4 31 33 40 15 38 21 22 51 M6 X 10LG BHCS 4 50 M6 X 12LG SSS M4 X 12LG SHCS 2 2 ...

Страница 24: ... 13 5 2 Assembly continued Figure 5 4 Quick Change Mounting Plate Assembly Item No 2 63800 6997 Item Order No Description Required 1 63800 6917 Press Mounting Plate 1 2 63800 6902 Alignment Block 2 3 63800 6918 Locking Clamp 1 4 63800 6919 Clamp Retainer 1 1 3 M5 X 30LG SHCS 4 2 M4 X 12LG SHCS 2 M4 X 12LG SHCS 2 M8 X 16LG BHCS 3 2 ...

Страница 25: ...TM 2000 Universal Press Order No TM 638008399 Release Date 08 08 02 UNCONTROLLED COPY Page 25 of 36 Revision H Revision Date 01 15 13 5 3 Electrical Schematic Figure 5 5 ...

Страница 26: ... 10 W 1 1 24 69018 6235 Resistor 5 11K Ohm 1 4 W 1 1 25 69018 6233 Capacitor 1200MFD 35V 1 26 69018 6228 Counter 7 Digit Non Resetable 1 27 69018 6242 Relay 3PDT 1 28 69002 5713 Blank PCB 1 29 63800 8391 Enclosure 1 30 69018 6221 Power Voltage Selector 115 230VAC 1 31 69018 6220 Module Power Entry 1 32 11 32 2733 Fuse Drawer 2 Pole 1 33 62500 1055 Micro DC Series 4 Pin Female 1 34 69018 6230 Relay...

Страница 27: ... slipping broken Adjust Replace Drive pulley loose Tighten Flywheel rotates press will not cycle Loose connection Refer to control schematic Foot switch connection Faulty footswitch Check Replace Check Connection Replace Faulty control assembly Check Connection Replace Faulty counter Check Connection Replace Clutch Solenoid failure See Section 4 2 Excessive clutch noise failure Out of adjustment A...

Страница 28: ... 08 08 02 UNCONTROLLED COPY Page 28 of 36 Revision H 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 you local Molex sales engineer ...

Страница 29: ...UNCONTROLLED COPY Page 29 of 36 Revision H 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 ...

Страница 30: ...d not extend into the contact area A 2 Insulation Under Conductor Crimp Good Conductor Brush Length Cause Strip length too short Solution Verify strip length specification and adjust as necessary A 3 Insulation Under Conductor Crimp Long Conductor Brush Length Cause Wire stop position incorrect Solution Adjust wire stop to center the insulation in the transition area A 4 Insulation Under Conductor...

Страница 31: ...th Cause Strip length too long Solution Verify strip length specification and adjust as necessary Adjust the wire stop A 8 Insulation Edge Under Insulation Crimp Form Short or No Conductor Brush Length Cause 1 Wire stop position incorrect 2 Verify operator s placement ability or crimp rate Solution 1 Adjust the wire stop to center the insulation in the transition area 2 Operator training reduce cr...

Страница 32: ...ht Measurement NOTE Conductor height should be measured with a blade type micrometer or a caliper CAUTION Care must be taken not to measure the extrusions A 3 1 Crimp height off target Cause 1 Changed wire type stranding or vendor 2 Changed insulation color or durometer 3 Changed crimp tooling 4 Changed crimping press Shut height 5 Changed press type Manufacturer 6 Changed terminal reel Lot code 7...

Страница 33: ...l Insulation Crimp An insulation diameter near the maximum and minimum specification of a terminal may cover less than what is normally considered acceptable These strain reliefs should only be used on applications that have low vibration or movement a An insulation crimp that covers less than 88 of a large insulation diameter Cause Not enough terminal grip length Solution 1 Evaluate if the same t...

Страница 34: ...r during installation the test should be conducted with the insulation in place if it is always supplied with the connector by the manufacturer Otherwise the test should be conducted without the insulation assembled to the connector Breaking or tearing of the insulation of an insulated connector is acceptable in the pullout test The pull is to be exerted by means of a tension testing machine or eq...

Страница 35: ...achine 2 Correct stripping machine setup A 5 2 2 Wire pulls out of conductor grip crimp height good Material Evaluation Cause 1 Terminal material thickness too small 2 Terminal serration depth form 3 Terminal plating thickness 4 Gold plating application Solution 1 Evaluate a new terminal 2 Or 3 Contact terminal manufacturer 4 Evaluate selective Gold application Stripping Evaluation Cause Wrong str...

Страница 36: ...ive 89 392 EEC This product is designed and manufactured in accordance with the following standards EMC Emissions EN55011 1998 EN 50081 2 1993 EN61000 3 2 1995 EN61000 3 3 1995 Immunity EN 50082 2 1995 EN 61000 4 2 3 4 5 6 8 11 Electrical Safety Safety of Machinery Electrical Equipment of Machines EN 60204 1 1993 Manufacturer Name Molex Application Tooling Group Address 2200 Wellington Court Lisle...

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