0011317105

Molex Standard Manual Assembly Press Molex Standard Manual Assembly Press Instruction Manual Order No. 11-31-6356 Engineering No. AM-60026-50 Description Operation Maintenance Order No: TM-011316356 Revision: D Release Date: 02-05-99 Revision Date: 10-08-09 UNCONTROLLED COPY Page 1 of 16 Molex Standard Manual Assembly Press WARNING NEVER OPERATE, SERVICE, OR ADJUST THIS PRESS OR INSTALL CRIMP DIES WITHOUT PROPER INSTRUCTION AND WITHOUT FIRST READING AND UNDERSTANDING THE INSTRUCTIONS IN THIS MANUAL. WORK SAFELY AT ALL TIMES For Service, Contact Your Local Molex Sales Office Molex Application Tooling Group 2200 Wellington Court Lisle, Illinois 60532 Tel: 630-969-4550 Fax: 630-505-0049 Order No: TM-011316356 Revision: D Release Date: 02-05-99 Revision Date: 10-08-09 UNCONTROLLED COPY Page 2 of 16 Molex Standard Manual Assembly Press Table of Contents SECTION 1 General Description 2 Installation, Setup, and Operation 3 Maintenance and Troubleshooting 4 Parts List and Assembly Drawings Order No: TM-011316356 Revision: D Release Date: 02-05-99 Revision Date: 10-08-09 UNCONTROLLED COPY Page 3 of 16 Molex Standard Manual Assembly Press Section 1 General Description 1.1. Description 1.2. Features 1.3. Technical Specifications 1.4. Delivery Check 1.5. Tools Order No: TM-011316356 Revision: D Release Date: 02-05-99 Revision Date: 10-08-09 UNCONTROLLED COPY Page 4 of 16 Molex Standard Manual Assembly Press General Description 1.1 1.3 Dimensions Height Description Features 152mm (6.00“) 267mm (10.50“) 23.2kg (50.5 lbs) Production Rate 300 cycles per hour maximum, depending on operator skill and tool kit installed. Operating Parameters Maximum Force Shut Height Stroke Length Adjustment 1.4 Press and tooling is easily portable. Accepts a wide variety of terminating and crimping tools kits. Full cycle ratchet assures complete termination Easily setup for left or right hand operation. Tooling changeover is simple and quick. Termination height is easily adjusted in the upper tooling holder. Manually operated, no shop air or electricity required. Low handle force to reduce operator fatigue. Press with tooling 533mm (21.00”) Width Depth Unpacked weight The Molex Standard Manual Assembly Press (1131-6356) is versatile, reliable, and inexpensive to operate. It is designed to provide an effective method of apply force to a wide variety of terminating and crimping dies. The Press is easily converted from right to left hand operation. When the combinations of crimping dies have been installed the operator pulls the handle down and then returns it to the original position. A ratchet mechanism insures that the press goes through a full cycle for a complete termination. The press is suited for low to mid-volume production requirements. 1.2 Technical Specifications 13.3kN (3,000lbs) 42.0mm (1.65”) 43.0mm (1.69”) 5.26mm (.207”) Delivery Check The following items are included in this package : Decription: Quantity Molex Standard Assembly Press 11-31-6356 (AM-60026-50) 1 Instruction Manual TM-011316356 1 1.5 Tools The following tools are recommended for setup and adjustments to the this tool. Adjustable wrench Needle nose pliers English hex wrench set for some non-metric tools. Order No: TM-011316356 Revision: D Release Date: 02-05-99 Revision Date: 10-08-09 UNCONTROLLED COPY Page 5 of 16 Molex Standard Manual Assembly Press Section 2 Installation 2.1. Instaltion 2.2. Set-Up 2.3. Operation Order No: TM-011316356 Revision: D Release Date: 02-05-99 Revision Date: 10-08-09 UNCONTROLLED COPY Page 6 of 16 Molex Standard Manual Assembly Press 2. Remove the Ram Handle Assembly and rotate it 1800. 3. Replace the Ram Handle Assembly to the Ram Cam. 4. Replace the #1/4-20 X 1.0” Long SHCS and tighten securely. RAM HANDLE FRAME HANDLE RAM CAM RATCHET RELEASE LEVER RAM HANDLE ASSEMBLY RAM CAM RATCHET FRAME REMOVE THE #1/4-20 X1.0LG SHCS RAM RIGHT HAND OPERATION Figure 2-2 BASE PLATE Figure 2-1 ROTATE HANDLE ASSEMBLY 180O 2.1 Installation The Molex Standard Assembly Press 11-31-6356 (AM-60026-50) will need to be secured to a work surface. To secure the press, use a bench capable of supporting at least 150 pounds, with adequate lighting for easy operation. There are two (2) holes for 5/16” screws provided in the press base for fastening the press to the workbench. 2.2 Set Up RAM HANDLE ASSEMBLY REPLACE THE #1/4-20 X1.0LG SHCS LEFT HAND OPERATION Ram Stroke Adjustment Left of Right Handed Operation The Molex Standard Manual Press can be set up for either left or right handed operators by simply reversing the handle on the press lever by following these steps: 1. Remove the #1/4-20 X 1.0” Long SHCS at the base of the Ram Handle. Order No: TM-011316356 Revision: D RAM CAM Release Date: 02-05-99 Revision Date: 10-08-09 The Ram Stroke Adjustment is made only when there is a tool kit installed. 1. Place the proper tooling into the press. 2. Loosen the #8-32 set screw in the Ram which locks the Ram Adjusting Screw into place. See Figure 2-3. UNCONTROLLED COPY Page 7 of 16 Molex Standard Manual Assembly Press 2.3 Operation RAM RAM ADJUSTING SCREW Ram To cycle the press, pull the press ram handle down and then return it to its original position. #8-32 SET SCREW UP POSITION MINIMUM DEPTH .207” (5.26mm) MAXIMUM DEPTH IN THE DOWN POSITION RAM HANDLE RATCHET RELEASE LEVER Figure 2-3 3. There is an indicator engraved on the ram just above the Ram Adjusting Screw. Turn the Ram Adjusting Screw clockwise (CW) toward the “+” sign to increase the ram stroke. To decrease the stroke, turn the Ram Adjusting Screw counterclockwise (CCW) toward the “-” sign. Stroke adjustment controls the shut height of the connector assembly. See Figure 2-4. LOWER FOR DOWN POSITION RAISE FOR UP POSITION RAM Figure 2-4 Figure 2-5 Warning: Once the press ram handle has started to descend, it cannot be returned to the up position until the full stroke of the press has been completed. In case of a jam or some other problem, should the press ram ever need to be returned to the up position before completing the full stroke, pull up on the ratchet release lever, and raise the press ram handle. The ratchet release lever is located on the upper left side of the press frame. See Figure 2-5. RAM ADJUSTING SCREW 4. Once the correct stroke is set, tighten the locking #8-32 set screw. All tool kits are different and may need additional adjustments. Refer to the individual Instruction Manuals for the proper tool kit. Order No: TM-011316356 Revision: D Release Date: 02-05-99 Revision Date: 10-08-09 UNCONTROLLED COPY Page 8 of 16 Molex Standard Manual Assembly Press Section 3 Maintenance 3.1. Cleaning 3.2. Lubrication 3.3. Perishable Parts 3.4. Spare Parts 3.5. Troubleshooting Order No TM-011316356 Revision: D Release Date: 02-05-99 Revision Date: 10-08-09 UNCONTROLLED COPY Page 9 of 16 Molex Standard Manual Assembly Press 3.1 Cleaning For efficient operation, the tooling should be cleaned daily. Use a soft bristle brush to remove debris from critical areas. For best results, remove the tooling dies from the press. Brush and then use a clean cloth to wipe off the upper and lower tooling mounting areas. Before reinstalling tooling, wipe all sides of the forms with a clean cloth. See Chart 3.1 for recommended Preventive Maintenance Schedule. NOTE: Using compressed air to clean tooling is not recommended. Chips can wedge in the tooling and/or fly at an operator. 3.2. 1. 2. 3. Lubrication Grease the ram including the up and down stroke feed arm. Oil all moving parts of the press. Lubricate with multipurpose synthetic lubricant with Teflon or an equivalent. Molex ships its presses pre-greased with Permatex multi-purpose synthetic grease with Teflon No. 82329. A SAE 10 non-detergent oil or light spindle oil or 3-in-1 oil should be used on pivot points. WARNING: Never use penetrants such as WD40 for any lubrication on the press. 4. Lubricate all points shown in Figures 3-1 with the specified oil and grease (or equivalent). GREASE OIL OIL OIL ROLLERS and BEARINGS (2) OIL ROLLERS and BEARINGS (2) GREASE Figure 3-1 Order No: TM-011316356 Revision: D Release Date: 02-05-99 Revision Date: 10-08-09 UNCONTROLLED COPY Page 10 of 16 Molex Standard Manual Assembly Press An example of a maintenance chart is shown below. Copy and use this chart to track the maintenance of your Press or use this as a template to create your own schedule or use your company’s standard chart, if applicable. Preventive Maintenance Chart Daily: Clean. See Section 3.1. As Required: Lubricate. See Section 3.2. CHECK SHEET MONTH _________YEAR _________ Week Daily Clean Days of the Week MON TUE WED THU FRI SAT SUN Solution 1 2 3 4 Cleaning Lubricate Inspect all tooling for wear Yes Soft Brush Industrial Yes Replace if signs of wear. Schedule should be adjusted up or down depending on usage. Molex recommends that a log of preventive maintenance be kept with the press. 3.3. Perishable Parts Perishable parts are those parts that come in contact with the product and will wear out over time. Customers are responsible for maintaining these parts. There are no perishable parts for Molex Standard Manual Assembly Press. The various tooling kits will have perishable parts. Molex recommends that all customers keep at least one set of the perishable tool kit in stock at all times. This will reduce the amount of production down time. For the proper perishable tool kit information, refer to the Individual Instruction Manual supplied with the Tooling Kits. 3.4. Spare Parts Customers are responsible for maintaining the Molex Standard Manual Assembly Press. Spare parts are moving and functioning parts that can be damaged or wear out over time and will require replacement. Molex recommends that the customer keep some or all of them in stock to reduce production down time. These parts are identified in the parts list in Section 4. Order No: TM-011316356 Revision: D Release Date: 02-05-99 Revision Date: 10-08-09 UNCONTROLLED COPY Page 11 of 16 Molex Standard Manual Assembly Press 3.5. Troubleshooting Symptom Wire does not terminate properly in terminal Cause Improper gauge wire Sticking ratchet pawl or debris in mechanism Broken or damaged ratchet pawl or spring Solution See product for wire gauge Adjust the ram stroke. See Ram Stroke Adjustment See Set-Up. Section 2.2 Clean and lubricate pivot points. See Section 3 Maintenance. Release the ram with the ratchet release lever and re-adjust the ram stroke. See Ram Stroke Adjustment See Set-Up. Section 2.2 Clean and lubricate pivot points. See Section 3 Maintenance Repair and replace. Worn Anti-Backup Sprocket Replace. Termination punch set to high or to deep Sticking ratchet pawl or debris in mechanism Ram goes down but will not go up. Full stroke ratchet mechanism not engaging Order No: TM-011316356 Revision: D Ram set too low Release Date: 02-05-99 Revision Date: 10-08-09 UNCONTROLLED COPY Page 12 of 16 Molex Standard Manual Assembly Press Section 4 4.1 Parts List 4.2 Assembly Drawings Order No: TM-011316356 Revision: D Release Date: 02-05-99 Revision Date: 10-08-09 UNCONTROLLED COPY Page 13 of 16 Molex Standard Manual Assembly Press 4.1 Parts List Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 Order No: TM-011316356 Revision: D Molex Standard Manual Assembly Press 11-31-6356 (AM-60026-50) Order No. Engineering No. Description 11-31-7100 AM-60026-1 Base 11-31-7101 AM-60026-2 Frame Right Hand 11-31-7102 AM-60026-3 Frame Left Hand 11-31-7103 AM-60026-4 Tension Column 11-31-7104 AM-60026-5 Frame Spacer 11-31-7105 AM-60026-6 Ram 11-31-7106 AM-60026-7 Ram Adjustment Screw 11-31-7107 AM-60026-8 Ram Guide Plate 11-31-7110 AM-60026-11 Ram Cam 11-31-7111 AM-60026-12 Ram Cam Shaft 11-31-7113 AM-60026-14 Cam Follower Nut 11-31-7114 AM-60026-15 Anti-Backup Sprocket 11-31-7115 AM-60026-16 Anti Backup Pawl 11-31-7117 AM-60026-18 Anti-Backup Release 11-31-7118 AM-60026-19 Anti-Backup Release Pivot 11-31-7119 AM-60026-20 Frame Handle 11-31-7120 AM-60026-21 Handle Support 11-31-7121 AM-60026-22 Ram Arm 11-31-7122 AM-60026-23 Ram Arm Handle 11-31-7123 AM-60026-24 Handle Shaft 11-31-7124 AM-60026-25 Front Cover 11-31-7125 AM-60026-26 Compression Spring .240” OD 11-31-7126 AM-60026-27 Washer 7/32” ID 11-31-7128 AM-60026-29 Spacer 11-31-7132 AM-60026-33 Flat Washer .260” ID 11-31-7133 AM-60026-34 Flat Washer .340” ID 11-31-7134 AM-60026-35 Ram Cam Hub 11-31-7135 AM-60026-36 Spring Anchor 11-31-7313 AM-60026-37 Hub Spacer 11-32-4494 AM-60026-98 #8-32 Socket Head Set Screw 11-32-5278 AM-60026-38 E-Ring .168 ID 11-32-5279 AM-60026-39 E-Ring .281 ID 11-32-5280 AM-60026-40 E- Ring .238 ID Spare Parts 11-31-7108 AM-60026-9 Roller 11-31-7109 AM-60026-10 Bearing 1/4” ID 11-31-7112 AM-60026-13 Cam Follower 11-31-7116 AM-60026-17 Extension Spring .187” OD 11-31-7127 AM-60026-28 Bearing 5/8” ID 11-31-7131 AM-60026-32 Detent Hardware N/A N/A #8-32 by 3/8” Long FHCS N/A N/A #8-32 by 1/4” Long BHCS N/A N/A #8-32 by 3/4” Long SHCS N/A N/A #10-32 by 1/4” Long SSS N/A N/A #1/4-20 by 1.0” Long SHCS N/A N/A #1/4-28 by 3/8” Long SSS Half Dog N/A N/A #5/16-18 by 1-1/2” Long SHCS N/A N/A 1/8 by 5/8” Long Dowel Pin N/A N/A 3/16 by 3/4” Long Dowel Pin Release Date: 02-05-99 Revision Date: 10-08-09 UNCONTROLLED COPY Quantity 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 2 1 1 1 1 2 2 2 8 2 1 2 1 1 1 1 8 8 8 1 1 2 1 4** 2** 2** 1** 16** 2** 6** 1** 3** Page 14 of 16 Molex Standard Manual Assembly Press Item No. 49 50 Order No: TM-011316356 Revision: D Molex Standard Manual Assembly Press 11-31-6356 (AM-60026-50) Order No. Engineering No. Description Quantity N/A N/A 5/16 by 1.0” Long Dowel Pin 2** N/A N/A 1/4 by 1-1/2” Long Dowel Pin 8** ** Available from an industrial supply company such as MSC (1-800-645-7270). Release Date: 02-05-99 Revision Date: 10-08-09 UNCONTROLLED COPY Page 15 of 16 Molex Standard Manual Assembly Press 4.2 Assembly 24 14 31 44 (2) (2) 44 (2) 16 15 2 13 17 (2) 45 (2) 48 26 (2) 28 (2) 37 32 25 39 (8) 47 19 20 (2) 3 18 8 (8) (8) 34 (10 44 35 (8) (8) 50 44 (2) 48 4 33 43 (2) 42 29 23 (2) 49 (2) 11 36 22 (2) 27 10 12 30 9 38 40 1 (2) 41 (4) 6 (2) 46 5 (6) Americas Headquarters Lisle, Illinois 60532 U.S.A. 1-800-78MOLEX amerinfo@molex.com 7 Figure 4-1 Far East North Headquarters Yamato, Kanagawa, Japan 81-462-65-2324 feninfo@molex.com Far East South Headquarters Jurong, Singapore 65-6-268-6868 fesinfo@molex.com European Headquarters Munich, Germany 49-89-413092-0 eurinfo@molex.com 21 Corporate Headquarters 2222 Wellington Ct. Lisle, IL 60532 U.S.A. 630-969-4550 Fax: 630-969-1352 Visit our Web site at http://www.molex.com Order No: TM-011316356 Revision: D Release Date: 02-05-99 Revision Date: 10-08-09 UNCONTROLLED COPY Page 16 of 16