0640162595

Safety Guard Upgrade Kit TM-3000 / TM4000 Safety Guard Upgrade Kit Application Tooling Specification Sheet Order No. 64016-2595 FEATURES Required to operate the 64016-2000 Taped Terminal Crimp Module in TM-3000 presses. Includes Standard “Point of Operation” safety guard insert for use with Mini-Mac, Fine Adjust, Rear Feed, and Tape applicators. Adapts to a variety of optional, easy to install “point of operation” guards. “Point of Operation” Guard adjusts with 4 screws for optimum wire to terminal alignment. Increased visibility to crimp area. SCOPE Applicable presses: Molex 63801-7200, 63801-7300, 63801-7600. New Guard Doc No: ATS-640162595 Revision: A Release Date: 05-14-12 Revision Date: 05-14-12 UNCONTROLLED COPY Page 1 of 7 Safety Guard Upgrade Kit Old Styles of the TM3000 Guards Starting in 2012 all new presses will have the 64016-2595 factory installed. For existing presses, the 64016-2595 safety guard upgrade kit can be purchased separately. This document shows the step by step procedure, for installing the upgrade kit. Installation: Removing the existing guard. Always turn off and disconnect the power supply to the press. Before installing the guards the TM3000 Press will need to be turned off. Use “POWER” switch located on the control panel to turn it off. Refer to the press operation manual TM-638017299. Tools To install the 64016-2595 Safety Guard Kit the following tools will be needed. #3 Phillips Screw Driver Doc No: ATS-640162595 Revision: A 10mm Box Open End Wrench Release Date: 05-14-12 Revision Date: 05-14-12 3mm Allen Wrench 4mm Allen Wrench UNCONTROLLED COPY Page 2 of 7 1. Before installing the kit become familiar with the upgraded components. See Figure 1. 2. Remove the existing door assembly. See Figure 2. Safety Guard Upgrade Kit 3. Remove the guard mounting frame. See figure 3. REMOVE THE GUARD MOUNTING FRAME USING A 3MM ALLEN WRENCH 3MM ALLEN WRENCH GUARD MOUNTING FRAME 3MM ALLEN WRENCH Figure 3 4. Discard the existing shim and existing guard. See figure 4. EXISTING SHIM Figure 4 EXISTING REAR GUARD USE A 4MM ALLEN WRENCH TO REMOVE Doc No: ATS-640162595 Revision: A Release Date: 05-14-12 Revision Date: 05-14-12 UNCONTROLLED COPY Page 4 of 7 Safety Guard Upgrade Kit 5. Install the new angle guard behind the existing lamp bracket as shown in figure 5. NOTE: The new angle guard (64016-2581) must be installed to ensure operator safety. EXISTING HOLES IN PRESS FRAME Figure 5 NEW ANGLE GUARD 64016-2581 PRESS LAMP ASSEMBLY EXISTING HARDWARE USE 4MM ALLEN WRENCH 6. Re-attach the guard mounting frame. See Figure 6. Use the left (Front) mounting holes that the guard mounting frame originally used. SPACER PLATE 64016-2579 GUARD MOUNTING FRAME INSTALL WITH 3MM ALLEN WRENCH M4 x 16 Long SHCS USE THESE HOLES TO REINSTALL THE GUARD MOUNTING FRAME ONLY IN CASE THE DOOR ALIGNMENT HAS ISSUES. Figure 6 7. Important Locate the new spacer plate (64016-2579) BETWEEN the guard mounting frame and the press. Note: Make sure to use the RIGHT SIDE set of mounting holes. See Figure 6. Doc No: ATS-640162595 Revision: A Release Date: 05-14-12 Revision Date: 05-14-12 UNCONTROLLED COPY Page 5 of 7 Safety Guard Upgrade Kit 8. Install the new rear guard and the new front door assembly to the hinges. See Figure 7. EXISTING HARDWARE USE 4mm ALLEN WRENCH NEW REAR GUARD 64016-2586 Figure 7 GUARD HINGE USE #3 PHILLIPS HEAD SCREWDRIVER AND A 10MM OPEN END WRENCH FOR GUARD HINGE NEW GUARD 9. Install the lower terminal guide (64016-2522) to the terminal guide (63801-7234) with (2) M4 x 8mm BHCS. See Figure 8. REFERENCE ONLY TERMINALGUDIE 63801-7234 NOT INCLUDED WITH 64016-2590 M4 X 8 LG. BHCS (2) Figure 8 LOWER TERMINAL GUIDE 64016-2522 NOTE: Clearance holes may need to be drilled into the existing terminal guide on some older TM3000 presses. Doc No: ATS-640162595 Revision: A Release Date: 05-14-12 Revision Date: 05-14-12 UNCONTROLLED COPY Page 6 of 7 Safety Guard Upgrade Kit Parts List Safety Guard Upgrade Kit 64016-2595 Order No. Engineering No. Description Quantity 63700-2342 63700-2342 Label-Caution(Eye Glasses) 1 63700-2344 63700-2344 Label-Caution(Guard In Place) 1 63801-7212 63801-7212 Handle, Guard 1 63801-7287 63801-7287 Bracket Guard 1 64016-2521 64016-2521 Guard, Front 1 64016-2522 64016-2522 Terminal Guide, Lower 1 64016-2523 64016-2523 Mounting Bracket 8 64016-2537 64016-2537 Guard, Point Of Operation 1 64016-2541 64016-2541 Guard, Right 1 64016-2579 64016-2579 Spacer Plate 1 64016-2581 64016-2581 Guard 1 64016-2586 64016-2586 Guard Rear 1 Hardware 13 N/A N/A M4 X 8 Long BHCS 10** 14 N/A N/A M4 X 10 Long BHCS 16** 15 N/A N/A M6 X 16 Long SHCS 2** ** Available from an industrial supply company such as MSC (1-800-645-7270). Item No. 1 2 3 4 5 6 7 8 9 10 11 12 4 Assembly 10 13 (2) 2 11 5 1 6 (2) 15 12 3 14 7 (8) (4) 13 8 (8) 14 (8) 9 13 (4) Figure 9 http://www.molex.com Doc No: ATS-640162595 Revision: A Release Date: 05-14-12 Revision Date: 05-14-12 UNCONTROLLED COPY Page 7 of 7