0638018600

TM-3000™ and TM-4000™ Adapter for JST* Applicators TM-3000™ and TM-4000™ Press Adapter Kit for JST* Applicators *JST* is a registered trademark of Japan Solderless Terminal Mfg. Co., LTD Application Tooling Specification Sheet Order No. 63801-8600 FEATURES


This Press Adapter Kit is used to install a specific version of a JST* applicator in the Molex TM-3000™ or TM-4000™ presses. Positive applicator clamping to the press bolster plate. Minimal installation time with common metric hex wrenches. JST* APPLICATOR DESCRIPTION
This Press Adapter Kit is designed for a specific version of a JST* applicator. This Molex adapter kit allows the JST* applicator to be installed in the Molex TM-3000™ or TM4000™ presses. See Figure 1. TM-4000™ PRESS Figure 1 Always turn off and disconnect the power supply to the press when installing or removing the Press Adapter Kit or the applicator. Refer to the Molex TM3000™ / TM-4000™ press manual, order number 63801-7299 found at www.molex.com. Note: When the press guard is open or the hand cycle wrench is in the motor, the guard interlock switch will disconnect power to the motor. NOTES


After installing this Adapter Kit, the press shut height may require adjustment in order for the JST* applicator to achieve proper crimp height. See the TM-3000/TM-4000 press manual for shut height adjustment procedure. When re-installing the original TM-3000™ or TM-4000™ press components, make sure that the shut height is 135.8mm (5.346 in.). Use Molex shut height gauge 63800-7900 to measure shut height. Do not use the Molex shut height gauge in the TM-3000 or TMBOLSTER PLATE M6 SCREW 4000 press when the JST* adapter is installed. (The JST* applicator does not use a 135.8mm shut height.) Preparation for Adapter Kit Installation 1. Using a 5mm hex wrench, remove the (2) M6 screws holding the TM-3000 bolster plate to the press frame. Remove the bolster plate from the press. See Figure 2. M6 SCREW Figure 2 Doc No. ATS-638018600 Revision: B Release Date: 02-29-12 Revision Date: 03-29-12 UNCONTROLLED COPY Page 1 of 5 TM-3000™ and TM-4000™ Adapter for JST* Applicators *JST* is a registered trademark of Japan Solderless Terminal Mfg. Co., LTD 2. Put the hand-cycle wrench in the back of the press motor. Turn the wrench until the press ram is about halfway down. Next, using a 5mm hex wrench, remove the (2) M6 screws holding the TM-3000 yoke and yoke adapter to the press ram. See Figure 3. The yoke and yoke adapter come out toward the back of the press. M5 SCREW M6 SCREW RAM HALFWAY DOWN YOKE ADAPTER LEFT SIDE GUARD M6 SCREW Figure 4 Figure 3 TM-3000 YOKE 3. Using a 4mm hex wrench, remove the (3) M5 screws holding the left side guard to the press. See Figure 4. Adapter Kit Installation 1. Add the (3) spacers to the inside of the left side guard and install the guard using the (3) M5 x 20mm long screws furnished with the Adapter Kit. See Figure 5. ADD SPACERS Figure 5 Note: The left side guard must be installed for safe press operation. 2. Assemble the JST* yoke and JST* yoke adapter. The notched side of the yoke shoulder is oriented towards the side of the adapter that has the threaded hole. The yoke is held in the adapter with (2) M6 set screws (doubled). See Figures 6 and 7. Doc No. ATS-638018600 Revision: B Release Date: 02-29-12 Revision Date: 03-29-12 UNCONTROLLED COPY Page 2 of 5 TM-3000™ and TM-4000™ Adapter for JST* Applicators *JST* is a registered trademark of Japan Solderless Terminal Mfg. Co., LTD NOTCH YOKE INSTALL DOUBLE M6 SET SCREWS Figure 6 Figure 7 THREADED HOLE IN YOKE ADAPTER 3. Install the JST* yoke adapter in the press ram. Use a 5mm hex wrench to tighten the (2) M6 screws securely. See Figure 8. SHAFT SIDE OF PLATE M6 SCREW Figure 9 Figure 8 M6 SCREW 4. Install the JST* bolster plate on the press frame. The side of the bolster plate with the shaft goes towards the left side of the press. Use a 5mm hex wrench to tighten the (2) M6 screws securely. See Figure 9. JST* Applicator Installation 1. Put the hand-cycle wrench in the back of the press motor. Turn the wrench until the press ram is fully up. See Figure 10. YOKE Figure 10 Doc No. ATS-638018600 Revision: B RAM FULLY UP Release Date: 02-29-12 Revision Date: 03-29-12 Figure 11 UNCONTROLLED COPY LUG BOLT (STARTED INTO YOKE) Page 3 of 5 TM-3000™ and TM-4000™ Adapter for JST* Applicators *JST* is a registered trademark of Japan Solderless Terminal Mfg. Co., LTD 2. Put the lug bolt of the JST* applicator into the slots of the yoke and slide the applicator into the press until the lug bolt is centered in the yoke. See Figure 11. 3. Pull down the lower section of the JST* applicator until its base plate rests on the press bolster plate. Install the JST* front clamp using (2) M5 screws and a 4mm hex wrench. Make sure the front of the applicator base plate is against the front clamp. See Figure 12. BASE PLATE AGAINST CLAMP Figure 12 M5 SCREW (2) FRONT CLAMP Figure 13 REAR CLAMP M5 SCREW 4. Install the rear clamp using an M5 screw and a 4mm wrench. The rear clamp goes against the angled edge of the applicator base plate. See Figure 13. 5. Use the hand cycle wrench to manually cycle the TM-3000 or TM-4000 press through one complete cycle. If it becomes difficult to turn the wrench, stop and investigate the cause. 6. Turn the hand cycle wrench until the press ram is fully up. Remove the hand cycle wrench from the press motor. The applicator is now ready for terminals to be loaded. 7. After loading terminals, close the guard door and restore electrical power to the press. 8. Make several sample crimps and evaluate the crimp dimensions. If necessary, adjust the applicator cams first. The press shut height should be changed only if the applicator cams do not provide enough adjustment. Contact Information For more information on Molex® application tooling please contact Molex® at 1-800-786-6539. Doc No. ATS-638018600 Revision: B Release Date: 02-29-12 Revision Date: 03-29-12 UNCONTROLLED COPY Page 4 of 5 TM-3000™ and TM-4000™ Adapter for JST* Applicators *JST* is a registered trademark of Japan Solderless Terminal Mfg. Co., LTD Parts List 63801-8600 JST* Press Adapter Kit Engineering No. Description Qty 63600-4046 Base Plate 1 63600-4047 Yoke Holder (JST) 1 63600-4048 Yoke (JST) 1 63600-4049 Front Clamp (JST) 1 63600-4050 Rear Clamp (JST) 1 63600-4051 Metal Washer 3 63600-4108 Yoke Adapter Clamp 1 Hardware 8 N/A N/A M5 by 20 Long SHCS 6** 9 N/A N/A M6 by 6 Long Set Screw Cup 2** 10 N/A N/A M6 by 16 Long SHCS 2** 11 N/A N/A M6 by 20 Long SHCS 2** ** Replacements available from an industrial supply company such as MSC® (1-800-645-7270). Item 1 2 3 4 5 6 7 Order No. 63600-4046 63600-4047 63600-4048 63600-4049 63600-4050 63600-4051 63600-4108 2 7 (2) 9 10 (2) 3 (2) 8 11 8 (3) (3) 5 6 4 (3) Figure 14 1 http://www.molex.com Doc No. ATS-638018600 Revision: B Release Date: 02-29-12 Revision Date: 03-29-12 UNCONTROLLED COPY Page 5 of 5