TM42 Termination Press
Tm42 Termination Press
Use with Molex T2, and all Terminator Dies
Operation Manual
Order No.69002-5099
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Description
Operation
Maintenance
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 1 of 49
TM42 Termination Press
Safety Warnings and Information
Read and understand all of the instructions and safety information in this manual before
operating or servicing this tool.
Keep this manual available when using this tool.
Replacement manuals are available for download at no charge at www.molex.com.
SAFETY ALERT SYMBOL
This symbol is used to call your attention to hazards or unsafe practices which could result in an injury
or property damage. The signal word, defined below, indicates the severity of the hazard. The message
after the signal word provides information for preventing or avoiding the hazard.
DANGER:
DANGER
Indicates an imminently hazardous situation which, if not avoided, could result in death or serious injury.
WARNING:
WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION:
CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
CAUTION may also be used to alert against unsafe practices associated with events that could lead
to personal injury.
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.
WARNING
Never wear clothing or jewelery that is loose or
That could potentially hang into the equipement
and get caught.
Failure to observe this warning could result in
Severe Injury or death.
WARNING
Never operate, service, install, or adjust this
machine without proper instruction and without
first reading and understanding the instructions
in this manual and all applicable press and/or
wire processing machine.
manuals.
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
WARNING
Heavy Object
To avoid muscle strain or back injury, use lifting
aids and proper lifting techniques when removing
or replacing.
Failure to observe these precautions may result in
injury or property damage.
WARNING
Never install or service this machine while
connected to any electrical power source.
Disconnect power by unplugging the press
from its power source.
Failure to observe this warning could result
In severe injury or death.
WARNING
Always hand cycle the applicator in the equipment
to ensure the tooling is properly aligned.
Failure to observe these precautions may result in
Injury or property damage.
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TM42 Termination Press
WARNING
WARNING
Do not use compressed air to clean
this equipment.
The forces created by compressed
air can force debris into the tool.
Never use this press or wire processing machine
without guards or safety devices that are intended
to prevent hands from remaining in the die space.
Failure to observe this warning could result in
Severe injury or death.
Failure to observe these precautions may
result in injury or property damage.
WARNING
Always wear proper ear protection when Operating or servicing this applicator.
CAUTION
NEVER install or remove terminator dies with the flywheel in motion or the motor running.
Never install or remove terminator dies or service this machine without manually cycling the press to verify that the clutch control
collar is in the locked position (past top dead center) block the press ram in the full up position if a defective clutch is suspected.
Caution the TM42 press is shipped from the factory for operation with US standard tooling. When using European Standard tooling,
the spacer shim (69002-5560) supplied with the unit must be added between the bolster plate and the press frame
Failure to remove this shim before installing US standard tooling may result in severe damage to the tooling and/or press.
CAUTION
Never perform any service or maintenance other than as described in this manual.
Never modify, alter or misuse the 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 and asking for the Molex Tooling Group.
Call Toll Free 1-800-786-6539 (US) 1-630-969-4550 (Global).
This assistance is limited to the operation and set-up of a customer’s Molex Press. Questions with regard to Molex connector
products or how to identify the proper tooling and/ or tooling documentation should be directed to your local Molex personnel or
Customer Service Representative.
When calling for service on the press a copy of the Tooling Manual and Specific Applicator Tooling Specification Sheet should be
present and a person that is familiar with the applicator should be present. Be sure the following information is supplied:
1.
2.
3.
4.
5.
6.
7.
8.
Customer name
Customer address
Person to contact such as (name, title, e-mail, and telephone number
Applicator order number (Lease number also if applicable)
Serial number (Lease number also if applicable)
Molex Connector product order number
Urgency of request
Nature of problem
Molex Application Tooling Group
2200 Wellington Court
Lisle, IL 60532, USA
Tel: +1 (630) 969-4550
Fax:+1 (630) 505-0049
Visit our Web site at http://www.molex.com
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
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TM42 Termination Press
Table of Contents
Contents
Tm42 Termination Press ............................................................................................................................................... 1
Order No.69002-5099.................................................................................................................................................... 1
Safety Warnings and Information .................................................................................................................................. 2
Table of Contents .......................................................................................................................................................... 4
Section 1 ................................................................................................................................................................... 6
General Description .............................................................................................................................................. 6
1.1 Description................................................................................................................................................. 7
1.2 Features .................................................................................................................................................... 7
1.3 Technical Specifications ............................................................................................................................ 7
1.4 Delivery Check .......................................................................................................................................... 7
1.5 Tools.......................................................................................................................................................... 8
Section 2 ................................................................................................................................................................... 9
Installation............................................................................................................................................................. 9
2.1 Lifting/Mounting ....................................................................................................................................... 10
2.2 Reel Support Assembly ........................................................................................................................... 11
2.3 Foot Pedal and Power Connection .......................................................................................................... 11
2.4 Hand Rest................................................................................................................................................ 11
2.5 Safety and Work Area Check .................................................................................................................. 11
2.6 Bolster Shim Installation and Removal .................................................................................................... 12
Section 3 ................................................................................................................................................................. 14
Setup and Operation........................................................................................................................................... 14
3.1 Termination Die Set Installation and Removal ......................................................................................... 15
3.2 Loading the Terminal Strip....................................................................................................................... 16
3.3 Punch and Anvil Alignment ...................................................................................................................... 18
3.4 Feed Finger Adjustment .......................................................................................................................... 18
3.5 Forward Feed Adjustment ....................................................................................................................... 18
3.6 Back Stroke Feed Adjustment ................................................................................................................. 19
3.7 Manually Cycling the Press ..................................................................................................................... 19
3.8 Conductor Crimp Punch Adjustment ....................................................................................................... 20
3.9 Insulation Crimp Punch Adjustment......................................................................................................... 20
3.10 Operation ................................................................................................................................................. 21
Section 4 ................................................................................................................................................................. 22
Maintenance and Clutch Unit Service ................................................................................................................. 22
4.1 Cleaning .................................................................................................................................................. 23
4.2 Lubrication ............................................................................................................................................... 23
4.3 Perishable Orders.................................................................................................................................... 24
4.4 Spare Orders ........................................................................................................................................... 24
4.5 Clutch Unit Service Adjust/Repair............................................................................................................ 24
4.6 Oiler ......................................................................................................................................................... 27
Section 5 ................................................................................................................................................................. 29
5.1 Parts List ................................................................................................................................................. 30
5.2 Assembly Drawings ................................................................................................................................. 33
5.3 Electrcal Parts List ................................................................................................................................... 37
5.3 Electrcal Schematic ................................................................................................................................. 38
5.4 Troubleshooting ....................................................................................................................................... 39
Appendix A .............................................................................................................................................................. 41
A.1 Conductor Brush and Terminal Position .................................................................................................. 42
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
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TM42 Termination Press
A.2 Conductor Bell Mouth and Terminal Cutoff Tab....................................................................................... 43
A.3 Crimp Height Measurement.......................................................................................................................... 44
A.4 Insulation Crimp....................................................................................................................................... 44
A.5 Pull Force Testing.................................................................................................................................... 46
Appendix B .............................................................................................................................................................. 48
EC Declaration of Conformity ............................................................................................................................. 49
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
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TM42 Termination 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-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
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TM42 Termination Press
1.3
General Description
1.1
Dimensions with reel mounted
Width: 540.00mm (21.30”)
Depth: 330.00mm (13.00”)
Height: 1,150.00mm (45.00”)
Description
The 69002-5000 (240V AC Version) and the 690025001(120V AC Version) TM42 Termination Machine is
an electrically operated, single-cycle, flywheel press.
It is designed to provide an effective method of
terminating a wide range of Molex side-feed crimp
terminals to pre-stripped discrete wire and cable.
(Without reel mounted)
Width:
Depth:
Height:
Production flexibility is obtained through the use of
interchangeable modular terminator dies. These dies
are inexpensive because, unlike a modular applicator,
all crimp height and terminal feed adjustments are
located in the press. The TM42 is ideally suited for
mid-volume, semi-automatic operation.
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Power Requirements
69002-5001 120V AC, 1Ph, 60 Hz, 5.8/2.9 Amp
Note: Press shipped setup for 120V service.
69002-5000 240V AC, 1Ph, 50 Hz, 3.8 Amp
European CE Rated.
Features
Utilizes Molex TM40, TM42, T2, and FFC
Terminator Dies.
Independent conductor and insulation adjustments
with position reference indicators.
Bench-mounted unit requires electrical power
only. Meets OSHA safety and noise standards.
European CE rated.
Quick-release tooling for fast and simple
changeover. Ability to remove upper crimp tooling
without removing lower die.
Ideal for mid-volume and semi-automatic
applications.
38.1 mm Stroke, No ram adjustment required.
Meets ISO Standards.
Flexible external work light.
Universal feed adjustment to accept Molex sidefeed terminals.
Totally enclosed for operator safety, including a
power interlock switch for the front guard with
“GUARD OPEN” indicator light.
Resettable counter for accurate batch-counting.
Modular solid-state controls. Power cord and foot
pedal plug in easily.
Order No: TM-690025099
Revision: H
330.00mm (13.00”)
330.00mm (13.00”)
914.00mm (36.00”)
Weight
100kg (220 lbs.) Unpacked
110kg (242 lbs.) Gross
The TM42 will complete one crimping cycle with each
depression of the foot pedal. Safe operation is
provided by an interlock switch that renders the press
inoperative if the safety guard is removed.
1.2
Technical Specifications
Release Date: 08-08-02
Revision Date: 01-15-13
Production Rate
Depending on the operator skill and the wire
length, 2500 terminations per hour maximum.
Flywheel rotation: 210 RPM.
Processing Capability
Up to 4.0mm² of copper conductor in solid or
stranded wire.
Sound Level
Operator will be exposed to less than 85 DB.
1.4
Delivery Check
After removing the packaging band, the top and
sides of the box should lift off easily. Make sure
the following items are included in this package.
Description
Main press body
Reel support assembly
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1
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TM42 Termination Press
Two cartons are included that contain the
following;
Carton 1
69002-5715 Foot switch assembly
Carton 2
Power cord
69018-6237 (for 69002-5001)
OR
62500-0113 (for 69002-5000)
69002-5547 Hand rest
TM-690025099 TM42 Operation Manual
69002-5560 Shim
69001-0106 Feed finger crank
69018-8235 10mm hex wrench
1.5
Tools
The following tools may be needed for setup and
adjustment of the TM42 press and terminator die.
1
1
1
1
1
1
1
Ε
Ε
Ε
Ε
Ε
Ε
Ε
Ε
Metric hex wrench set
English hex wrench set (for older terminator die
set designs)
Large and small standard screwdriver
Adjustable wrench
Needle nose pliers
Crimp micrometer
Eye loupe (10x)
Wire stripper/cuter
* For International applications, the power cord/plug
may need to be replaced or adapted with the
appropriate connection.
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
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TM42 Termination Press
Section 2
Installation
2.1
Lifting/Mounting
2.2
Reel Support
2.3
Foot Pedal and Power Connection
2.4
Hand Rest
2.5
Safety and Work Area Check
2.6
Bolster Shim Installation and Removal
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 9 of 49
TM42 Termination Press
CAUTION: To avoid serious injury support the ram in the upper position with a hardwood wedge (approximately 1 7/8”
high).
When changing tooling or working on the clutch, a block
should be inserted under the ram (See Illustration). This
also pertains when the guards are taken off. The block
supports the ram and the tooling, if block is not inserted the
Ram can fall suddenly and cause serious injury.
When procedure is complete be sure to remove the block
prior to cycling the Press.
2.1
PLACE BLOCK
HERE
(WITH PRESS
RAM IN
THE UP
POSTION)
Lifting/Mounting
WARNING: The TM42 press weighs over 100 kg. (220
lbs.) and is NOT intended to be lifted by an individual. The
guarding is not attached to provide support for lifting
purposes. Mechanical lifting devices should be used. A person lifting the press can sustain severe back or other
injuries.
TERMINAL GUIDE
ASSEMBLY (INSTALLED)
WORK BENCH
REEL SUPPORT
ASSEMBLY
MAIN PRESS BODY
LIFTING HOOKS
PRESS CONTROL
ASSEMBLY
POWER CORD
FOOT PEDAL CORD
HAND REST
FOOT PEDAL
ASSEMBLY
Figure 2-1
Lifting hooks are provided on each side of the press. See Figure 2-1. 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 12.0mm (0.50”) and verify that the
press is well balanced. Upon verification, the press can be lifted onto a sturdy workbench. Access to the back of the
machine is required for manual cycling. A minimum 25.00mm (1.00”) thick wooden bench top will offer quiet vibrationOrder No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
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TM42 Termination Press
free operation. TM42 should be attached to the table with
(2) 12.0mm bolts and washers. For marking the tabletop
(See Figure 2-2), or use the removable template at the
back of the manual. Drill the clearance holes for the
12.0mm bolts and secure the press to the table. Bolts are
not supplied by Molex.
2.2
Reel Support Assembly
155.58mm
6.12”)
76.96mm
(3.03”)
25.4mm (1.0”) DIA. OR
SQUARE HOLE FOR
SCRAP
PIPE IF USED (4)
212.73mm
(8.38”)
15.9mm
(.625”) DIA. (4)
76.2mm
(3.0”)
Install the reel support assembly by inserting the support
tube in the hole located on the left side of the top cover.
2.3
0
28.58mm
(1.12”)
Foot Pedal and Power Connection
DIA.
0 (4)
FRONT OF PRESS
1. Connect the 4-pin plug for the foot pedal in the rear of
the press control assembly.
Figure 2–2
2. Turn the Locking Ring clockwise until tight.
Table Top Mounting Pattern
3. Connect the power cord plug to the socket in the back
of the control assembly. Use a grounded electrical outlet as the power source.
4. Two fuses are located in the fuse drawer directly above the power socket. To replace the fuses, use a small
screwdriver to open the fuse drawer, remove damaged fuses and replace.
2.4
Hand Rest
Attach the hand rest with one M6 x 10.0mm BHCS located at the front center of the press.
See Figure 2-1.
2.5
Safety and Work Area Check
1. Check that the work area is well lighted. Adjust the work
light for best visibility.
2. Check that the work area is clean and free of debris.
3. Check that no tools have been left in the machine or
work area.
“E-STOP”
BUTTON
“GUARD OPEN”
INDICATOR
LIGHT
Never operate in areas of excess moisture or water.
Check that all safety guards are in place. NEVER
operate this press without press guards in place. The
guard indicator light is located on the front of the press
control assembly. See Figure 2-3.
“RUN”
INDICATOR
LIGHT
RUN “ON”
BUTTON
4. 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
Figure 2- 3
allows both feet to rest on the floor. The foot pedal
should be placed in a comfortable position.
5. Check that the press position is located approximately 150.00mm (6 .00“) from the edge of the bench. A chair or
stool with adjustable height and backrest should be provided for maximum comfort and back support for the
operator. Observe where the emergency stop button is on the control panel. See Figure 2-3.
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
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Page 11 of 49
TM42 Termination Press
CAUTION: Molex recommends that the operator and observers wear eye protection when the press is in
operation or being serviced.
2.6
Bolster Shim Installation and Removal
CAUTION: Before installing any tooling in this press, determine the presence or absence of the .50mm (.020”) shim.
This shim is in addition to the .25 mm (.010”) that should always be present. The TM42 is shipped from the factory for
operation with U.S. designed terminator dies (order numbers 11-40-2XXX, 6384X-XXXX, or 6385X-XXXX.
When using European designed tooling (order number 69001-XXXX), an additional .50mm (.020”) Shim (P.N. 690025560), supplied with the unit must be added between the bolster plate and the press frame to set the shut height. Do
not remove the .25.00mm (.010”) shim.
WARNING: Failure to install the shim 69002-5560 for European tooling may result in a nonfunctional terminator die
set. Failure to remove the .50mm (.020”) shim before installing U.S. terminator dies may result in damage to the
tooling and/or press.
GUARD
69025506
(BOLSTER PLATE)
638004205
(.25mm SHIM)
LIFTING
SLOTS (2)
“E-STOP”
BUTTON
PUSH ROD
M6 JAM NUT
M10 X 16LG
SHCS (2)
690025560
(.50mm SHIM)
M10 X 16LG
BHCS (4)
Order No: TM-690025099
Revision: H
M6 X 25LG BHCS
Release Date: 08-08-02
Revision Date: 01-15-13
(1) ON EACH SIDE
REQUIRES LOOSENING ONLY
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Figure 2-4
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TM42 Termination Press
Refer to Section 3 for setup, manual cycling, and operation before attempting any crimp terminations under power. If
the press is running, push the emergency stop button located on the front of the press control assembly. The motor
and flywheel will stop. The work light will still operate.
1. Remove the press guards by removing the (2) M10 BHCS (See Figure 2-4) located on the front bolster plate,
and loosen (1) on each side. Once removed, the guard interlock switch will disconnect power to both the motor
and clutch.
2. Remove the push rod from the hole on the right side of the bolster plate. If necessary, remove any tooling, and
then remove (2) M10 SHCS attaching the bolster plate to the press frame.
3. Lift the bolster plate away from the locating dowels by placing a screwdriver in the (2) lifting slots on the underside
of the bolster plate. Remove or install the .50mm (.020”) spacer and verify the presence of the .250mm (.010”)
spacer.
4. Position the bolster plate on the locating dowels and refasten with the (2) M10 SHCS. Replace the push rod.
Follow the tooling setup procedures in Section 3.
CAUTION: Always manually cycle the press before restoring power to the machine.
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
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TM42 Termination Press
Section 3
Setup and Operation
3.1
Termination Die Set Installation and Removal
3.2
Loading the Terminal Strip
3.3
Punch and Anvil Alignment
3.4
Feed Finger Adjustment
3.5
Forward Feed Adjustment
3.6
Back Stroke Adjustment
3.7
Manually Cycling Press
3.8
Conductor Crimp Punch Adjustment
3.9
Insulation Crimp Punch Adjustment
3.10
Operation
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
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TM42 Termination Press
3.1
Termination Die Set Installation and Removal
Always turn off and disconnect the power supply to the press. Power down the press by pressing the emergency
stop button located on the front of the control panel.
PUNCH PLATE
PUNCH
RELEASE PIN
LEFT LOCATING PLATE
BOLSTER
PLATE
CONDUCTOR
PUNCH
INSULATION
PUNCH
FRONT STRIKER
RIGHT
LOCATING PLATE
COVERS
REAR STRIKER
WIRE STOP
NOSE HOLDDOWN
ANVILS
DRAG
PLATE
TRACK
SCRAP CHUTE
FRONT CUT-OFF
TOOLING
CENTER CARRIER
CUT-OFF
Figure 3–1 TM42 PRESS AND TERMINATION DIE
Termination Die Removal
1. Remove the press guards by removing the (2) M10 BHCS (See Figure 1-4) located on the front bolster plate, and
loosen (1) on each side.
NOTE: Once removed, the guard interlock switch will disconnect power to both the motor and clutch. The work light
will still operate if the unit is still connected to the power source.
2.
3.
4.
5.
6.
Set both the conductor and insulation indicators to a reference setting of “1”. See Figure 3-3.
Loosen the M5 BHCS and remove the right locating plate.
Lift the feed finger clear and slide the terminator die out of the press.
Remove the punches, nose hold-down, rear striker, and center carrier cutoff tooling.
The terminator die is best stored in its original container.
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
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TM42 Termination Press
Termination Die Installation
GUARD
Before any die is installed make sure the cover
alignment procedure and the track adjustment
procedure, (when applicable) have been completed. See
the appropriate terminator die instruction manual for
these procedures.
PUSH ROD
M6 HEX NUT
1. Power down the press and remove the guards as
(THIN)
described in Section 3.1.1, steps 1 and 2.
2. Not all terminator dies have contact nose hold down,
rear strikers, or center carrier cutoff tooling. If
M10 X 16LG
M6 X 25 LG BHCS
present on the terminator die, attachment points are
BHCS (4)
located behind the punches either in the front of or
Figure 3-2 GUARD REMOVAL
on the bottom of the ram See Figure 3-1. Refer to
the assembly drawing supplied with each individual terminator die for parts supplied with that terminator.
3. Fit the (2) punches in the opening on the underside of the ram. The conductor punch should be positioned in the
rear See Figure 3-1. A click will be heard when
the punch retaining/release pin engages.
FACE PLATE
4. Set both the conductor and insulation indicators to
a reference setting of “1”. See Figure 3-3.
INSULATION
ADJUSTMENT
5. The front striker slides in front of the punches and
INDICATOR
is attached with a screw through the hole in the
punch plate.
CONDUCTOR
6. Make sure the bolster plate is clean and free of
ADJUSTMENT
debris.
INDICATOR
7. Lift the feed finger clear and slide the terminator
die onto the left locating plate.
INSULATION
ADJUSTMENT CAM
8. Attach the right locating plate and tighten the M5
BHCS.
3.2
Loading the Terminal Strip
CAUTION: The specified terminal is printed on the
setup sheet supplied with the terminator die. Do not
use any terminal not indicated on that setup sheet.
CONDUCTOR
ADJUSTMENT LOCK
CONDUCTOR
ADJUSTMENT
SETTING 1 IS MAXIMUM HEIGHT
SETTING 6 IS MINIMUM HEIGHT
PUNCH
RELEASE PIN
Figure 3-3 HEIGHT SETTING
1.
2.
3.
4.
5.
Power down the press and remove the guards as described in Section 3.1.1, steps 1 and 2.
Remove the pull pin and outer hub on the press reel support.
Remove all tape on the edge of the reel.
Place the terminal reel on the exposed shaft so the terminal strip comes off the reel in proper orientation.
Place the outer hub back on the shaft and lock in position so there is enough tension so that the reel does not freely
rotate and unwind the terminals. The tension should be loose enough that a light pull on the terminals will rotate the
reel.
6. Place the pull pin back on the end the shaft. This will prevent the hub from falling off should the hub locking screw
become loose.
7. Unwind the terminal strip under the terminal guide. See Figure 3-4. Be careful not to distort the terminals or the
strip while feeding the terminals into the terminator die.
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
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TM42 Termination Press
8. Most terminator dies do not have any track adjustment features.
For this type, lift both the drag and anti-back-up pins located on
the front of the terminator die. This will allow the terminals to
slide freely through the terminator die track. See Figure 3-5.
9. For track adjustment type terminator dies rotate the drag cam
until the drag frame is fully raised. See Figure 3-6. This will
allow the terminal to slide freely through the terminator die
track.
HUB
LOCKING
SCREW
REEL
PULL PIN
OUTER HUB
REAR COVER
WIRE STOP
TERMINAL
GUIDE
DRAG PIN
CORRECT
TERMINAL FEED
ANTI-BACKUP
PIN
TRACK
Figure 3–4 REEL INSTALLATION
ANVILS
FRONT CUT-OFF
TOOLING
Figure 3–5 NON-ADJUSTABLE TRACK
10. Load the terminal strip under the rear cover plate until the first terminal comes to rest centered above the anvil.
See Figure 3-7.
11. Release the terminal drag and anti-backup pins for non-adjustment terminators, or rotate the drag cam to engage
the terminal drag frame on the track adjustment style dies.
CAUTION: Terminals and terminal carrier strips may have sharp edges that can scratch or cut. Use caution while
handling terminals.
COVERS
TERMINAL
ANVILS
COVER
WIRE STOP
DRAG
CAM
SCRAP
CHUTE
DRAG
PLATE
TRACK
FRONT CUT-OFF
TOOLING
Figure 3–7 TERMINAL AND COVER
Figure 3-6 ADJUSTABLE TRACK
12. To remove the terminal strip, raise the terminal drag and/or anti-back-up finger. Lift the feed finger and pull the
terminal carrier strip back using needle nose pliers until disengaged from the terminator track. If preferred, cut the
terminal carrier strip and pull it through the terminator die.
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
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Page 17 of 49
TM42 Termination Press
3.3
Punch and Anvil Alignment
The following procedure will align the punch and anvil profiles.
1. Power down the press and remove the guards as described in
Section 3.1.1, steps 1 and 2.
2. With a terminal in position over the anvils, slightly loosen the front
and/or back anvil mounting screws (See Figure 3-8) and center
carrier cut-off tooling when applicable. See Figure 3-1.
3. Slowly hand cycle the ram of the press to the bottom of its stroke.
4. In this position, tighten the anvil mounting screws and center
carrier cut-off tooling when applicable to ensure proper alignment
of punches, anvils, and cut-off tooling.
3.4
Figure 3-8 PUNCH AND ANVIL ALIGNMENT
M4 X 10LG LOCKING
SET SCREW
Feed Finger Adjustment
1. Power down the press and remove the guards as
FEED FINGER SHAFT
described in Section 3.1.1, steps 1 and 2.
2. Loosen the terminal feed finger shaft locking screw
(M4) and slide the feed finger shaft in or out. See
Figure 3-9.
3. Position the feed finger to pick up the best feeding
position. This may differ from terminal to terminal.
Typically, terminals are fed via carrier strip holes or by
the tab between the insulation terminal section and the
carrier strip.
4. With a small screwdriver, rotate the feed finger shaft
CW to increase or CCW to decrease spring tension on
the feed finger. Tighten the feed finger shaft locking
Figure 3-9 FEED FINGER SHAFT
screw to lock the feed finger in position. See Figure 310.
5. Cycle the press by hand (See Section 3.7) to be certain that the feed finger transfers the next terminal to be aligned
over the anvil.
6. Check that all other parts slide and engage without any
interference.
7. Repeat this procedure several times.
8. If a manual cycle cannot be completed, or the terminal is not
MAKE SURE LOCKING
positioned over the anvil, refer to Sec 3.4 to 3.7.
3.5
SCREW IS LOOSENED
BEFORE TURNING SHAFT
Forward Feed Adjustment
A forward or backstroke feed adjustment may be necessary if the
terminal is not centered over the anvil during the manual cycle.
1. Power down the press and remove the guards as described in
Section 3.1.1, steps 1 and 2.
2. To check the forward feed position, the terminal being crimped
should be positioned exactly over the anvil and the ram in the
up position.
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
DECREASE
(COUNTER
CLOCKWISE)
INCREASE (CLOCKWISE)
Figure 3–10 FEED FINGER ADJUSTMENT
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TM42 Termination Press
3. Loosen the M6 forward feed adjustment lock screw
located on the top of the punch plate. See Figure 3-11.
4. Rotate the forward feed adjustment wheel to center the
terminal over the anvil.
5. After adjusting the forward feed position of the terminal,
tighten the M6 forward feed adjustment lock screw.
6. For future reference, document the feed position on the
forward feed adjustment indicator
M6 FORWARD
FEED ADJ.
LOCK SCREW
FORWARD FEED
ADJ. WHEEL
PUNCH PLATE
3.6
Back Stroke Feed Adjustment
FORWARD FEED
ADJ. INDICATOR
Figure 3–11 FORWARD FEED ADJUSTMENT
BACK FEED
ADJ. SCREW
M6 JAM NUT
Figure 3–12 BACK STROKE ADJUSTMENT
Figure 3–13 MANUAL CYCLE CLUTCH RELEASE
1.
2.
3.
4.
5.
6.
3.7
The feed finger requires over-travel on the backstroke to pick up the next position on the loaded terminal strip.
Manually cycle the press 180 degrees to the bottom dead center position.
With the press in the down position, loosen the M6 hex jam nut. See Figure 3-12.
Adjust the M6 back feed adjustment screw to change the backstroke position of the feed finger.
After the stroke is adjusted, tighten the M6 hex jam nut.
Verify the forward stroke position readjust if necessary.
Manually Cycling the Press
CAUTION: By disengaging the actuator (See Figure 4-2) the ram
will be free to move. The weight of the ram can result in downward
motion. Use caution to ensure that the area under the ram is clear
of fingers and hand tools. The machine guard should be in place.
1. Power down the press by pressing the emergency stop button located
on the front of the control panel.
2. Release the clutch by inserting a screwdriver through the access hole
to trip the locked actuator.
See Figure 3-13.
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
Figure 3–14 MANUAL CYCLING
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TM42 Termination Press
3. Insert the 10mm hex wrench through the hole in the center of the rear cover and engage it in the socket in the
press flywheel. See Figure 3-14.
4. Rotate the press flywheel to move the ram as desired.
WARNING: Never insert anything through this hole while the press is under power.
3.8
Conductor Crimp Punch Adjustment
1. With the guards in place, insert a stripped length of specified wire into the terminal and terminate the wire under
power. Refer to the terminal specification sheet supplied with the terminator die.
2. Examine the quality of the initial conductor crimp and measure the crimp height (See Appendix A: Crimp
Terminations).
3. Power down the press and remove the guards as described in Section 3.1.1, steps 1 and 2.
CONDUCTOR
ADJ. INDICATOR
INSULATION
ADJ. INDICATOR
CONDUCTOR ADJ.
LOCK SCREW
CONDUCTOR
ADJ. SCREW
SETTING 1 IS MAXIMUM HEIGHT
SETTING 6 IS MINIMUM HEIGHT
INSULATION
ADJ. CAM
PUNCH
RELEASE PIN
PUNCH RELEASE PIN
Figure 3-16 INSULATION CRIMP
HEIGHT ADJUSTMENT
Figure 3-15 CONDUCTOR CRIMP HEIGHT ADJUSTMENT
4. Loosen the M6 conductor adjustment lock screw located on the front of the punch plate. See Figure 3-15.
5. With a screwdriver, turn the conductor adjusting screw located on the right side of the punch plate. Rotating the
adjusting screw clockwise one full turn will lower the crimp height approximately .03mm (.001"). Each increment in
the reference window represents approximately .13.00mm (.005") for a total adjustment of .65.00mm (.026"). The
"1” setting, on the Conductor Adjustment Indicator, equates to the largest crimp height and the “6” setting is the
smallest.
6. Tighten the M6 locking screw.
7. Replace the machine guards and repeat the above steps until the desired crimp height is obtained (See Appendix
A, Crimp Terminations).
8. Perform a pull force test to verify the mechanical integrity of the crimp. (See Appendix A, Crimp Terminations).
3.9
Insulation Crimp Punch Adjustment
1. Place a stripped length of wire into the terminal and terminate under power.
2. Examine the quality of the initial insulation. See Appendix A, Crimp Terminations.
3. Power down the press and remove the guards as described in Section 3.1.1, steps 1 and 2.
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
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Page 20 of 49
TM42 Termination Press
4. Rotate the insulation adjusting screw to obtain the required insulation crimp height. Each increment in the reference
window represents approximately .2.00mm (.0078") for a total adjustment of 1.60mm (.063"). The "1" setting, on
the Insulation Adjustment Indicator, equates to the largest crimp height and the "8" setting is the smallest. See
Figure 3- 16.
5. Repeat the above steps until the desired insulation crimp height is obtained.
NOTE: Due to the large variety of insulation wall thickness, material, and durometers, Molex does not specify
insulation crimp height. The insulation crimp height should be inspected, measured, and documented as a quality
indicator for all wire types and sizes.
PRESTRIPPED WIRE
3.10 Operation
1. Check that all setup procedures were followed and that the
terminations are meeting specification.
2. Verify the machine was manually cycled before operating
under power.
3. With guards in place, turn on the press by pressing the run
button on the front of the press control assembly. The motor
starts and the run light comes on. Pressing the Emergency
Stop button disconnects power to the motor and the clutch.
The run light goes off.
WIRE STOP
Figure 3–17 WIRE POSITIONING
NOTE: To fully remove power to the press, unplug the power cord from the press control assembly.
4. Place the pre-stripped wire through the slot in the guard above the terminal and touch the wire stop. See Figure 317.
5. Press the foot pedal down once and release. The press will cycle once. Keep the foot raised or remove it from the
foot pedal to prevent unwanted crimp cycles.
CAUTION: Call maintenance immediately if the press cycles more than once. Do not operate the press. See
Section 4.5 Clutch Unit.
6. The press is set up to have a terminal over the anvil before beginning the crimp cycle. During the crimp cycle, but
after the wire is terminated, the operator should make a slight rightward motion of the crimped wire/terminal. This
rightward motion should take place during the upward cycle of the press. This will prevent the next indexing terminal
from being tangled during the upward cycle of the press.
7. Be sure to remove the crimped terminal out of the slot in the guard before the next termination.
8. Periodically check the terminations for crimp height and visual attributes described in Appendix A: Crimp
Terminations, and Appendix B: Statistical Process Control.
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
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TM42 Termination Press
Section 4
Maintenance and Clutch Unit Service
4.1
Cleaning
4.2
Lubrication
4.3
Perishable Orders
4.4
Spare Orders
4.5
Clutch Unit Service/Adjust and Repair
4.6
Oiler
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 22 of 49
TM42 Termination Press
4.1
Cleaning
WARNING: Disconnect the power cord from the power source during all maintenance operations.
For efficient operation, the TM42 press should be cleaned daily with a soft bristle brush to remove any carrier strip
debris and terminal plating dust from the tooling area. For continuous operation, this may have to be done more
frequently.
When it is necessary to change a terminator die, use caution removing any debris from tapped holes in the press
base where the applicator mounts. Debris can prevent tooling from being properly locked into position.
CAUTION: Cleaning using compressed air is not recommended. Chips can wedge in the tooling and/or cause
injury.
NOTE: Do not use solvents to clean the guards. Window cleaner and a soft cloth should be used. If the
guarding becomes scratched or scuffed, replacement may be necessary.
4.2
Lubrication
(Excluding clutch assembly) All bearing areas are pre-lubricated and sealed for life.
An example of a maintenance chart is shown below. Copy and use this chart to track the maintenance of your TM42
Press or use this as a template to create you own schedule or use your company’s standard chart, if applicable.
Preventive Maintenance Chart
Daily: Clean. See Section 4.1.
As Required: Lubricate. See Section 4.2)
CHECK SHEET MONTH__________ YEAR _________
Days of the Week
Daily
Daily
Week
Cycles
Clean MON TUE WED THU FRI SAT SUN
1
2
3
4
Cleaning
Reapply grease
Reapply oil
Inspect all tooling,
Feed fingers etc.
for wear
Solution
25,000
Yes
Soft Brush
Industrial
Degreaser
25,000
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.
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
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Page 23 of 49
TM42 Termination Press
4.3
Perishable Orders
Perishable parts are those parts that come into contact with the product and may wear over time. The customer is
responsible for maintaining these parts and Molex recommends that they keep at least one set in stock at all times.
There are no perishable parts on the TM42 press. However there are perishable parts on the termination die sets.
Refer to the instructions that come with the dies.
M6 X 40LG SSS W/NUT
4.4
Spare Orders
RAM
Spare parts are available to support the TM42
Termination Machine. Moving and functioning
parts can be damaged or malfunction. Molex
recommends that the customer keep some or all
of them in stock to reduce down time. These parts
are identified in the Orders List in Section 5.
4.5
CLUTCH
COLLAR
BLACK
HOUSING
Clutch Unit Service Adjust/Repair
CAUTION: Disconnect power cord from
power source during all maintenance.
FLYWHEEL
INSERT 10mm
HEX WRENCH HERE
Operational Check 1
1. Remove the rear cover of the TM-42 unit. Verify
Figure 4-1
INPUT HUB
that the clutch control collar is in the locked
position (See Figure 4-2). Insert the 10mm hex wrench into the socket head cap screw. This screw is located in the
center of the flywheel (See Figure 4-1). This screw is spring loaded to prevent 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 hub/flywheel clockwise by hand.
The input hub/flywheel should be free to rotate. During
this portion of the operational check, the black spring
INPUT HUB
housing should not rotate. See Figure 4-1.
CLUTCH COLLAR
4. If the unit fails operational check 1, the clutch unit has
failed internally or the actuator is not functioning properly
UNLOCKED POSITION
and the clutch unit must be replaced.
CAUTION: By disengaging the actuator (See Figure 42) the ram will be free to move. The weight of the ram
can result in downward motion. Use caution to ensure
that the area under the ram is clear of fingers and hand
tools. The machine guard should be in place.
ACTUATOR
LOCKED
POSTION
Figure 4-2
Operational Check 2
1. Verify that the clutch control collar is unlocked. See Figure 4-2. The crankshaft, input hub/flywheel, and black
spring housing should rotate freely with the 10mm wrench moving the ram down and up.
2. After 360 degrees of clockwise rotation, the actuator will engage the clutch control collar and rotation will stop.
This is normal operation.
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
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Page 24 of 49
TM42 Termination Press
3. If rotation with the 10mm wrench is not possible and the actuator is disengaged, the clutch unit is demonstrating
early signs of failure and must be replaced.
Removing the Clutch Unit
WARNING: This procedure should be followed to ensure compliance with safety instructions. Molex cannot
accept liability in the event of a subsequent accident caused by clutch failure when improperly serviced by the
customer.
See Figure 4-4 for the following steps.
1. Power down the press and remove the guards as
described in Section 3.1.1, steps 1 and 2.
PLACE BLOCK
2. Support the ram in the upper position with a
HERE (WITH PRESS
hardwood wedge (approximately 1 7/8” high). See
RAM IN THE “UP”
Figure 4-3.
POSITION)
3. Remove the terminal reel support arm and the top
and rear covers, separate connector from counter.
Figure 4-3
4. Disconnect leads from solenoid.
5. Leave the V-belt in a position to support weight when removing and replacing the flywheel.
6. Remove the Flywheel Bearing Retainer Screw and washer from the end of the crankshaft.
7. Remove (3) M6 x 40 Long SHCS from the Flywheel.
8. Remove the flywheel. The inner race of the flywheel may stay on the crankshaft when the flywheel is removed.
9. Remove the 5.0mm x 35 Long spiral pin from the clutch and crankshaft using a drive punch.
10. Remove the (3) M6 x 16 Long SHSS (socket head shoulder screw) from the clutch plate.
11. Pull the clutch/solenoid assembly from the crankshaft. This may require pry bars to push from the rear side of the
clutch plate. If the inner race of the flywheel remained on the crankshaft, it will be pushed off before the
solenoid/clutch assembly.
RETAINER SCREW
12. Determine if the inner race for the flywheel can be
WASHER
reused or be replaced.
FLYWHEEL
Installing the Clutch Unit
Note: The (3) M6 x 16 Long 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 rigidly attached to the clutch plate and any
restrictions could result in malfunction and possible
damage to the springs.
M6 X 16LG SHSS (3)
M6 X 40LG
SHCS (3)
CLUTCH
V-BELT
FLYWHEEL
BEARING
INNER RACE
5MM X 35LG
SPIROL PIN
Figure 4-4
See Figure 4-4 for the following steps.
1. Slide the solenoid/clutch assembly onto the crankshaft.
2. Replace (3) M6 x 16 Long SHSS
3. Secure the clutch to the crankshaft by inserting a new 5mm x 35 Long spiral pin.
4. Adjust the clutch timing. See Section 4.5.5, Solenoid/Clutch Assembly Adjustment.
5. Slide the inner race onto the crankshaft followed by the flywheel.
6. Replace the (3) M6 x 40 Long SHCS in the flywheel.
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
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Page 25 of 49
TM42 Termination Press
7.
8.
9.
10.
11.
12.
Replace the Flywheel Bearing Retainer Screw and washer in the end of the crankshaft.
Reconnect the leads for the clutch solenoid.
Replace the V-Belt.
Replace rear and top covers and the reel support assembly.
Remove the hardwood wedge from under the ram.
Replace front guard.
Adjustment for the Solenoid/Clutch Assembly
CAUTION: By disengaging the actuator (See Figure 4-2) the ram will be free to move. The weight of the ram can
result in downward motion. Use caution to ensure that the area under the ram is clear of fingers and hand tools.
The machine guard should be in place.
1. Remove the rear cover of the TM-42 unit.
2. Locate the retaining ring in front of the clutch control collar. See Figure 4-1. Using a regular tip screwdriver,
unseat the ring from its groove and slide it towards the flywheel.
3. Insert the 10mm hex wench into Flywheel Bearing Retainer Screw. Hold the wrench firmly and release the clutch
control collar by lifting up the actuator. See Figure 4-5. The crankshaft, input hub/flywheel, and black spring
housing are now free to rotate.
4. Rotate the 10mm hex wrench clockwise observing the rams down and up motion. When the ram has traveled a
complete down and up motion, hold the position of the ram just past top dead center (this is when the ram has
traveled to the full up position and starts its descent downward).
5. Now observe the relationship of the control collar to the actuator (See Figure 4-5), if the control collar is butted up
against the actuator, no adjustment is required.
INPUT HUB
M6 NUT
M6 X 40LG SSS
(CUP PT)
CLUTCH COLLAR
M6 X 16LG
SHSS (3)
UNLOCKED
POSTION
.25mm (.010”)
GAP
PUSH
ACTUATOR
RADIAL
MOVEMENT
LOCKED
POSITION
ACTUATOR
Figure 4-5
ACTUATOR
LOCKED POSITION
Figure 4-6
6. If the control collar stops short of the actuator, pull the control collar back towards the flywheel and reposition the
collar to the new setting. The control collar use spline teeth to control the engagement.
7. Replace the retaining ring to lock the control collar in position.
8. Verify proper clearance for radial movement of the solenoid/clutch assembly. Check the gap between the
solenoid/clutch mounting plate and the M6 stop screw located on the upper left hand corner. If the gap is more or
less than the recommended .25.00mm (.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.
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 26 of 49
TM42 Termination Press
Solenoid/Clutch Assembly Lubrication
The clutch has sintered metal components that have been impregnated with bearing infusion oil No. 33 for permanent
lubrication, by the manufacturer. When the machine is subjected to continuous heavy duty operation, operates in high
temperature, or in less than clean environments, the bearing oil may be washed out or the assembly may become
polluted with foreign matter. Flushing in a lighter bearing infusion oil as used in manufacturing can restore efficiency.
If this process proves ineffective, the solenoid/clutch assembly should be replaced.
CAUTION: Never use solvents to clean sintered metal parts.
4.6
Oiler
Description
The wick action oiler is included as an option to lubricate the
products as they enter and are fed through tooling to ensure
smooth, trouble free operation. The oiler applies a thin coat of
oil to the terminals for proper feed and better release from
termination punches. The oiler is primarily used for terminals
with gold plating. To avoid contamination when shipped and
during setup, the oiler is shipped from the factory with no
lubricant oil.
LID
TUBE
MOUNTING
BRACKET
WICK
(PKG OF (25)
#638900727)
JAR
(OIL RESERVOIR)
Adjustments
Figure 4-7 OILER ASSEMBLY
Oiler Position
Adjust the position of the oiler unit using the mounting screw
that attaches the oiler to the guard assembly. Simply loosen the screw and slide the unit to the desired position and
tighten the screw. The unit can be removed and placed on the right side of the guard assembly for rear feed
applications.
Oiler Wick
Adjust the height of the oiler wick by pulling up or pushing down on the wick to the appropriate height. The wick can be
moved using pliers or 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 top end of the tube and replace the lid.
Package of (25) Wicks:
Molex Order No: 63890-0727
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
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Page 27 of 49
TM42 Termination Press
Lubricant Oil
Recommended oil: 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
Adding a New Oiler to an Older Press
If your TM42 Presses was produced before 1996, it
did not include provisions to mount an oiler.
To install a Terminal Oiler Order No. 63890-0720 to
your press you will need to add a mounting hole.
Locate this hole on the left side of the frame, with the
front of press facing you, under the track.
1. Use the following procedure to install the oiler.
2. Drill 4.20mm (.165”) diameter x 17.00mm (.62”)
deep in location shown in the figure below.
3. Tap M6-1.0 x 12.00mm (.47”) deep.
4. Use a M6 BHCS and M6 flat washer to secure
oiler onto frame.
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
DRILL AND
TAP HERE
M6 X 10LG
BHCS
35.0mm (1.38”)
M6 WASHER
19.0mm (.75”)
Figure 4-8
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TM42 Termination Press
Section 5
5.1
Parts List
5.2
Assembly Drawings
5.3
Electical Schematics
5.4
Toubleshooting
The following pages contain the Orders Lists and Assembly Drawings for the TM42 Terminator Machine. Here are
several tips to help you better understand and use this material.
1. The “Item” number in the Orders List matches the number in the balloon on the assembly drawing
immediately following that list.
2. The “Order No.” is the number to use if ordering that particular item.
3. The “RSP” appearing at the end of some description columns means this item is a Recommended Spare
Order.
4. The “Req’d.” number is the quantity of that particular part required per assembly and is also the quantity
Molex recommends the user keep on hand if this is a Recommended Spare Order
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
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Page 29 of 49
TM42 Termination Press
5.1
Parts List
Item
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
49
Order No.
Engineering No.
11-40-0185
11-40-0218
REF
11-41-0264
63800-4201
63800-4205
69002-5012
69001-0105
69001-0106
69002-5004
69002-5005
69002-5013
69002-5073
69002-5074
69018-6052
69002-5099
69002-5504
69002-5505
69002-5507
69002-5510
69002-5511
69002-5512
69002-5518
69002-5520
69002-5521
69002-5523
69002-5524
69002-5525
69002-5526
69002-5527
69002-5531
69002-5532
69002-5533
69002-5537
69002-5539
69002-5540
69002-5541
69002-5546
69002-5547
69002-5548
69002-5550
69002-5552
69002-5555
69002-5556
69002-5557
69002-5560
69002-5563
69002-5604
69002-5605
TM40-68
TM40-100
REF
KM241
63800-4201
63800-4205
69002-5012
69001-0105
69001-0106
69002-5004
69002-5005
69002-5013
69002-5073
69002-5074
69018-6052
69002-5099
69002-5504
69002-5505
69002-5507
69002-5510
69002-5511
69002-5512
69002-5518
69002-5520
69002-5521
69002-5523
69002-5524
69002-5525
69002-5526
69002-5527
69002-5531
69002-5532
69002-5533
69002-5537
69002-5539
69002-5540
69002-5541
69002-5546
69002-5547
69002-5548
69002-5550
69002-5552
69002-5555
69002-5556
69002-5557
69002-5560
69002-5563
69002-5604
69002-5605
Order No: TM-690025099
Revision: H
RSP / PP Parts
Quantity
and notes
Lifting Hook
2
Locating Plate
1
Domestic Orders Kit (TM42)
REF
Molex Logo 3 Inch
1
Serial Number Plate CE Name Plate
1
Bolster Plate Shim (USA) (Shipped with Press)
1
Support Tube Weldment
1
Straight Feed Finger
RSP
1
Angled Feed Finger
RSP
1
Bolster Plate Assembly
1
Adjusting Cam Assembly
1
Disc Assembly
2
TM42 Main Wiring Harness
1
Counter Assembly (Resettable With Leads)
1
Limit Switch
RSP
1
Instruction Manual – TM42
1
Ram Wear Plate
2
Leader Pin
2
Guide Block
1
Adjusting Cam – Conductor Punch
1
Adjusting Wheel – Conductor Cam
1
Punch Lock Pin
1
Eccentric Bearing Retainer
1
Crankshaft Bearing Retainer
1
Flywheel
1
Flywheel Bearing Retainer
1
Feed Lever
1
Feed Arm Shaft
1
Feed Arm
1
Feed Arm Spring
RSP
1
Top Cover
1
Top Cover Plate
3
Die Guard
RSP
1
Limit Switch Mounting Bracket
1
Push Rod
RSP
1
Trip Rod
1
Plunger
1
Feed Adjusting Thumb Nut
1
Hand Rest
1
Punch Plate Label
1
Threaded Insert
1
Flywheel ROT/RPM Label
1
Flywheel Bearing Retainer Screw
1
Terminal Guide
1
Mounting Bracket
1
Bolster Plate Shim (For European Press)
1
Bushing
1
Punch Face Plate
1
Feed Adjusting Rod
1
Release Date: 08-08-02
Revision Date: 01-15-13
Description
UNCONTROLLED COPY
Page 30 of 49
TM42 Termination Press
Item
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
Order No.
Engineering No.
Description
69002-5606
69002-5607
69002-5608
REF
63800-4210
63800-8394
69002-5717
69002-5718
69018-5044
69018-6219
69018-6237
69018-6241
69018-6271
69018-7029
69018-7031
69018-7032
69018-7033
69018-7034
69018-7035
69018-7036
69018-7037
69018-7038
69018-8089
69018-8135
69018-8136
69018-8235
69018-9500
69018-9542
69018-9594
69901-0203
69002-5606
69002-5607
69002-5608
REF
63800-4210
63800-8394
69002-5717
69002-5718
69018-5044
69018-6219
69018-6237
69018-6241
69018-6271
69018-7029
69018-7031
69018-7032
69018-7033
69018-7034
69018-7035
69018-7036
69018-7037
69018-7038
69018-8089
69018-8135
69018-8136
69018-8235
69018-9500
69018-9542
69018-9594
69901-0203
Crankshaft
Front Bearing Retainer
Rear Cover
Label – Box (Domestic Orders Kit)
Control Assembly
Foot Switch Assembly
Painted Frame
Painted Ram
110/V AC 60 Hz Motor **
Fuse (8 – AMP) **
Power Cord (120V) **
Solenoid/Clutch Assembly
Light Bulb (120V) 50 Watt **
Ball Sealed Bushing
Crankshaft Bearing
Main Inner Ring
1.625 OD Outer Ring Flywheel Bearing
1.1241 OD Inner Race
Eccentric Outer Ring Assembly
Eccentric Inner Ring
V-Belt
Pulley
Ball Plunger
Knurled Knob
Pip Pin
Hex Wrench – 10mm
Compression Spring
Eject Pin Spring
Feed Lever Spring
External Retaining Ring
RSP / PP Parts
Quantity
and notes
1
1
1
REF
RSP
1
RSP
1
1
1
1
RSP
2
1
1
RSP
1
4
1
1
1
1
3
3
RSP
1
1
1
1
1
1
RSP
1
RSP
1
RSP
1
2
**Components for 240Volt Version
Item
1
2
3
4
Order No: TM-690025099
Revision: H
Order No.
62500-0113
69018-5021
69018-6238
69018-6239
RSP / PP Parts
Quantity
and notes
Power Cord (240V)
1
240V AC 50 Hz Motor
1
Light Bulb (240V) 25 Watt
RSP
1
Fuse (5.0 – AMP)
RSP
2
Description
Release Date: 08-08-02
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 31 of 49
TM42 Termination Press
Hardware
Item
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
Description
1/8 by 1/2Long Dowel Pin
3/8 by 3/8Long BSP Plug
5mm by 35 Long Spiral Pin
6mm by 16Long Shoulder Screw
M10 by 16Long BHCS
M10 by 16Long SHCS
M3 Hex Nut - Full
M3 by 10Long FHCS
M3 by 10Long Roll Pin
M3 by 20Long Spiral Pin
M3 by 25Long Dowel Pin
M3 by 35Long SHCS
M3 by 6Long SHCS
M4 Hex Nut
M4 by 10Long Set Screw
M4 by 12Long SHCS
M4 by 30Long SHCS
M4 by 8Long BHCS
M4 by 8Long Set Screw
M5 by 10Long BHCS
M5 by 10Long FHCS
M5 by 10Long SHCS
M5 by 12Long BHCS
M5 by 16Long SHCS
M5 by 20Long BHCS
M5 by 20Long SHCS
M6 Hex Nut - Full
M6 Jam Nut
M6 by 10Long BHCS
M6 by 12Long BHCS
M6 by 12Long Set Screw
M6 by 16Long Dowel Pin
M6 by 16Long FHCS
M6 by 20Long Dowel Pin
M6 by 25Long BHCS
M6 by 40Long Set Screw
M6 by 30Long Set Screw
M6 by 60Long Set Screw
M6 by 40Long SHCS
M8 Flat Washer
M8 Hex Nut - Full
M8 by 12Long BHCS
M8 by 25Long SHCS
M8 by 50Long Stud
Pop Rivet – 1/8” Aluminum
Required
2
1
1
3
4
2
2
2
1
1
1
1
1
2
1
4
2
4
3
6
1
2
2
1
1
4
2
1
4
1
5
1
4
1
1
1
1
1
3
8
8
8
4
4
9
Available from an industrial supply company such as MSC (1-800-645-7270).
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 32 of 49
TM42 Termination Press
5.2
Assembly Drawings
M6 X 12LG
SET SCREW
M8 HEX NUT (2)
73
M8 WASHER (2)
74
58
81
M6 HEX NUT
M6 X 60LG
SET SCREW
7
12
M8 X 50LG
STUD (4)
M5 X 12LG
BHCS (2)
M6 X 30LG
SET SCREW
M6 JAM NUT
33
5
M6 X 12LG
SET SCREW
78
3/8 X 3/8LG
BSP PLUG
M6 HEX NUT
56
M6 X 40LG
SET SCREW
M10 X 16LG
BHCS (4)
M6 X 25LG BHCS
Figure 5-1
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 33 of 49
TM42 Termination Press
5.2
Assembly Drawings (continued)
52
44
POP RIVET
1/8 – ALUM (9)
M5 X 10LG
BHCS (4)
1
31
(2)
42
32
75
(3)
M4 X 8LG
BHCS (4)
M5 X 20LG
SHCS (4)
45
M3 X 10LG
FHCS (2)
M6 X 10LG
BHCS (4)
M5 X 10LG
BHCS (2)
4
14
M3 HEX NUT (2)
59 (2)
15
83
36
54
39
M5 X 10LG
BHCS (2)
M6 X 12LG
BHCS
M4 X 12LG
SHCS (2)
62
34
82
60
80
M4 HEX NUT (2)
55
Figure 5-2
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
63800-8397: CONVERSION CABLE REQUIRED
WHEN USING FOOTSWITCH 63800-8394 WITH
CONTROL ASSEMBLY 69002-5710
UNCONTROLLED COPY
Page 34 of 49
TM42 Termination Press
5.2 Assembly Drawings (continued)
64
68
50
69
65
51
77
M6 X 16LG
FHCS (4)
71
68
5mm DIA. X 35LG
SPIROL PIN
43
26
23
37
66
67
69
M6 X 40LG
SHCS (3)
M5 X 10LG
FHCS
70
25
M6 X 16LG
SHSS (3)
Figure 5-3
61
24
____________________________________________________________________________________
19
M10 X 16LG
SHCS (2)
M4 X 10LG
SET
M5 X 20LG
47
BHCS
**
2
**
27
28
10
30
6mm X 20LG
DOWEL PIN
46
(2) 79
6mm X 16LG
DOWEL PIN M3 X 6LG
SHCS
8
9
56
35
6
Figure 5-4
Order No: TM-690025099
Revision: H
29
Release Date: 08-08-02
Revision Date: 01-15-13
** THESE PARTS ARE INCLUDED IN
ASSEMBLY
BUT CAN BE ORDER SEPERATELY
UNCONTROLLED COPY
10
Page 35 of 49
TM42 Termination Press
5.2 Assembly Drawings (continued)
18
(2)
17
(2)
M4 X 8LG
SET SCREW
1/8 X 1/2LG
DOWEL PIN (2)
M3 X 25LG
M6 X 12LG
DOWEL PIN
SET SCREW (2)
M4 X 30LG
SHCS (2)
11
57
20
48
40
M4 X 12LG
SHCS (2)
38
63
(4)
M5 X 16LG
SHCS
21
M8 X 25LG
SHCS (4)
72
M8 X 12LG
BHCS (8)
22
49
76
41
M3 X 10LG
ROLL PIN
M3 X 35LG
SHCS
M4 X 8LG
SET SCREW
M3 X 20LG
SPIROL PIN
Figure 5-5
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 36 of 49
TM42 Termination Press
5.3
Electrcal 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
37
39
40
43
44
51
52
Order No.
63800-4210
69002-5712
69018-6271
69018-6238
69018-5044
69018-5021
69018-6240
69002-5074
63800-8394
69018-6239
69018-6219
69018-6237
69018-6251
69018-6052
63800-4213
69002-5073
69018-6223
69018-6222
69018-6252
69018-6226
69018-6231
69018-6227
69018-6234
69018-6235
69018-6233
69018-6228
69018-6242
69002-5713
69002-5534
69018-6221
69018-6220
11-32-2733
62500-1055
69018-6230
69018-6229
69018-6232
63800-4216
69018-6262
62500-0113
62500-1613
62500-1615
63800-4214
Order No: TM-690025099
Revision: H
Engineering No.
63800-4210
69002-5712
69018-6271
69018-6238
69018-5044
69018-5021
69018-6240
69002-5074
63800-8394
69018-6239
69018-6219
69018-6237
69018-6251
69018-6052
63800-4213
69002-5073
69018-6223
69018-6222
69018-6252
69018-6226
69018-6231
69018-6227
69018-6234
69018-6235
69018-6233
69018-6228
69018-6242
69002-5713
69002-5534
69018-6221
69018-6220
AM63190-E207
62500-1055
69018-6230
69018-6229
69018-6232
63800-4216
69018-6262
62500-0113
62500-1613
62500-1615
63800-4214
Release Date: 08-08-02
Revision Date: 01-15-13
Description
Controls Assembly (TM-42)
Control PCB Assembly
120V 25 Watt Bulb
240V 50 Watt Bulb
120V 1/3 HP Motor
240V 1/3 HP Motor
24V Clutch Soleniod
Counter Assembly (Resetable with Leads)
Foot Switch Assembly
5 Amp (240V) 5 x 20mm SB Fuse
8 Amp (120V) 5 x 20mm SB Fuse
Power Cord 120V - 9’-10”, 16 AWG
Guard Open Red LED Assembly
Guard Switch
Jumper Wire Assembly (Remote E-Stop)
Harness Assembly
E-Stop Button Assembly
Run Button Assembly
Run Green LED Assembly
Transformer 10VA 24 VCT
Diode
Positive Adjustable Regulator
Resistor 221 Ohm 1/10W 1%
Resistor 5.11K Ohm 1/4W 1%
Capacitor 1200MFD 35V
Counter - 7 Digit (Non-Resetable)
Relay 3PDT
Blank-PCB
Enclosure - Control Assembly
Power Voltage Selector (115/230VAC)
Power Entry Module
Fuse Drawer (2-Pole)
Micro –DC Series (4-Pin) (Female)
Relay Hold Down Spring
Relay Socket - PCB
Metal Oxide Varistor
Power Entry Sub-Assembly
Ground Wire Assembly
Power Cord 240V (International)
Ferrite Core
Work Lamp Assembly
Foot Switch Connector Assembly
UNCONTROLLED COPY
Quantity
REF
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
7
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Page 37 of 49
TM42 Termination Press
Electrcal Schematic
TM42 ELECTRICAL SCHEMATIC
5.3
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 38 of 49
TM42 Termination Press
5.4
Troubleshooting
Symptom
Cause
Solution
Power/Power cord failure.
Loose connection.
Motor will not run.
Flywheel fails to rotate
(motor runs).
Flywheel rotates press
will not cycle.
Excessive clutch noise.
Press double/multi-cycles.
No termnial feed.
Ram drops from
top dead center.
Broken tooling
Order No: TM-690025099
Revision: H
Check power supply.
Refer to control schematic.
Check condition of cord and repair or replace
Power cord not properly plugged
as required. Check to be sure it is securely
in or cord damaged.
plugged in on both ends.
Guard interlock switch disengaged. Install guard.
Fuse blown.
Replace
On/Off switch failure.
Replace
Motor thermal overload.
Push reset button on motor.
Belt too tight.
Adjust motor mount.
Motor Failure.
Replace
Belt slipping/broken.
Adjust/Replace
Drive pulley loose.
Tighten
Loose electrical connection.
Refer to control schematic and repair.
Foot switch connection.
Check/Replace.
Faulty Foot switcg
Check connection/Replace.
Faulty counter.
Check connection/Replace.
Clutch/Solenoid failure.
See Section 4.5
Press Control Assembly failure.
Unplug counter.
Out of adjustment
See Section 4.5.
Clutch component failure
Adjust/Replace.
Solenoid sticks
Check/Replace. See Section 4.5.
Shorted leads in foot switch.
Replace
Broken clutch screw
Check/Replace.
Replace.
Spirol pin broken.
See Ram assembly in Section 5.
Broken clutch pin.
Check/Replace.
Faulty clutch spring.
Check/Replace
Replace and refer to Section 2.
Improper tooling installation.
Make necessary corrections.
Release Date: 08-08-02
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 39 of 49
TM42 Termination Press
For more information use the Quality Crimping Handbook (Order No. 63800-0029)
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 40 of 49
TM42 Termination Press
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
A.6
EC Declaration of Conformity
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 41 of 49
TM42 Termination Press
BEND UP
Terminal Terminology
BELL
MOUTH
BRUSH
CONDUCTOR
CRIMP
ROLLING
SEAM
INSULATION
CRIMP
TWISTING
STRIP
LENGTH
BEND
DOWN
CUT-OFF
TAB
A.1
CRIMP HEIGHT
Conductor Brush and Terminal Position
A-1
Optimum Crimp Setup
Figure A-1
The insulation edge should be centered in the middle of the transition
area. The conductor brush should extend past the conductor crimp
and not extend into the contact area.
Figure A-2
A-2
Insulation Under Conductor Crimp
Good Conductor Brush Length
Cause:
Strip length too short.
Solution: Verify strip length specification and adjust as necessary.
Figure A-3
A-3
Insulation Under Conductor Crimp,
Long Conductor Brush Length
Cause:
Wire stop position incorrect.
Solution: Adjust wire stop to center theinsulation in the transition area.
A-4
Figure A-5
Figure A-6
Insulation Under Conductor Crimp,
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 Centered in the Transition Area,
Conductor Brush Too Long
Cause:
1) Strip length too long.
2) Irregular wire cut-off or wire strands pulled from insulation
bundle.
Solution: 1) Verify strip length specification and adjust as necessary.
Readjust wire stop for bench applications
2) Check for worn stripping blades
A-6
Insulation Edge in the Center of Transition Area,
Conductor Brush Too Short
Cause:
Strip length too short.
Solution: Verify strip length specification and adjust as
necessary. Readjust wire stop for bench applications.
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 42 of 49
TM42 Termination Press
A-7
Insulation Edge Under Insulation Crimp Form,
Good or ong Conductor Brush Length
Cause:
Strip length too long.
Solution: Verify strip length specification and adjust as necessary.
Adjust the wire stop.
Figure A-8
A.2
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 crimping rate.
Conductor Bell Mouth and Terminal Cutoff Tab
Figure A-2.1
A-2.1
Optimum Crimp Setup
Tooling was set up 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, Cutoff Tab Flush With Insulation Crimp
Figure A-2.2
1) Terminal tooling position.
2) Camber in the terminal strip.
1) Verify pull force.
2) Adjust terminal track into the applicator.
Cause:
Solution:
A-2.3
No or Small Bell mouth, Long Cutoff Tab
Figure A-2.3
1) Terminal to tooling position.
2) Camber in the terminal strip.
Solution: 1) Verify pull force.
2) Adjust terminal track towards operator.
Cause:
Figure A-2.4
A-2.4
Excessive Bell mouth, Good Cutoff Tab
1) Check for worn conductor punch tooling.
2) Check for correct conductor punch tooling.
Solution:
Replace tooling if necessary
Cause:
A-2.5
Excessive Cutoff Tab, Good Conductor Bell mouth
Figure A-2.5
Cause: 1) Check for worn cutoff tooling.
2) Check for correct cutoff tooling.
Solution:
Replace tooling if necessary.
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 43 of 49
TM42 Termination Press
A.3 Crimp Height 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) Changed tooling set-up.
8) Damaged or worn tooling.
CALIPER
Solution: Adjust tooling back to target
(Refer to Section 2.8 and 2.9)
A.3.2 Crimp height variability too high
Cause: 1) Wire variability.
2) Terminal variability.
3) Damaged, loose, or worn tooling.
4) Measurement error *.
5) Terminal spring back too great **.
6) Cut or missing wire strands.
Solution: 1 or 2) Inspect incoming 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
MICROMETER
EXTRUSION
POINTS
Figure A-3.1
CRIMP HEIGHT MEASUREMENT
Insulation Crimp
A.4.1 Preferred Insulation Crimp
It is preferred that the insulation crimp completely
surrounds the outside diameter of the insulation.
Figure A-4.1 Preferred Insulation Crimp
The terminal should hold on to the wire as firmly as
possible without cutting through to the conductor strands. It should be noted that a preferred crimp only occurs in
a small portion of the full insulation range a terminal
can accommodate. A preferred insulation crimp is
recommended for high vibration or movement
applications.
An overlap insulation crimp is normally only
developed for high vibration or movement
applications where the wire diameter is near the
lower terminal specification limit.
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
Figure A-4.2 Acceptable Insulation Crimp
UNCONTROLLED COPY
Page 44 of 49
TM42 Termination Press
A.4.2
Acceptable Insulation Crimp
A terminal is normally specified to cover a wide range of insulation wall thickness over a range of wire sizes.
Within this specified range, an insulation crimp may not completely surround the wire or fully hold the full
diameter of the wire. This condition will still give an acceptable insulation crimp for most applications.
a) A large insulation crimp should firmly grip at least 88% of the wire.
b) A smaller insulation crimp should firmly grip at least 50% of the wire and firmly hold the top of the wire.
A.4.3
Marginal 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.
Figure A-4.3 Marginal Insulation Crimp
Cause: Not enough terminal grip length.
Solution: 1) Evaluate if the same terminal 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 a housing for acceptability
b) An insulation crimp that covers less than 50% of a small insulation diameter.
Cause: Too much terminal grip.
Solution: 1) Find out if the same terminal is available in a different wire range.
2) Find out if overlap crimp tooling is available.
A.4.4
Marginal Insulation Crimp
For insulation diameters that are small, thin-walled
insulated wire. A loose crimp ensures no strand
damage and offers insulation containment. Insulation
crimps that pierce through the insulation will offer
more strain relief. In some cases insulation terminal
grips will push the strands to the side. Yet, there is
Figure A-4.4 Marginal Insulation Crimp
always the possibility that a wire strand could be
nicked. In severe cases, a wire strand may be cut. Careful application evaluation is needed for both of these
cases.
Cause: 1) Crimp tooling adjustment.
2) Wire diameter variability.
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
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TM42 Termination Press
A.5
Pull Force Testing
A.5.1 Pull Force Procedure
Wire connectors and soldering lugs for use with copper conductors. (Per UL486A October 8, 1991) UL Section
12 Pullout Test.
12.1 The connectors subjected to the static heating test or secureness test shall be subjected to a direct pull of
the value specified for one minute. Only those conductors that have been subjected to the secureness test
are to be subjected to the pullout test. The connector is acceptable if it does not become separated from the
conductor or conductors after completion of the test.
12.2 For an insulated connector in which the insulation is assembled to the connector 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 equivalent, so that there will be no sudden application
of force or jerking during the test.
The following is the procedure Molex uses for the qualification of pull force:
1.
2.
3.
4.
5.
Cut wire length approximately 150mm (6.0”) long.
Strip one end to 13mm (.50”), or long enough so no wire insulation is under the insulation grip.
Terminate the appropriate terminal to the wire to the nominal crimp height.
Visually inspect the termination for bell mouth, wire brush and cut strands.
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 tester type, both wire and terminated end must be securely clamped. (Note: If Clamp
terminal contact interface, do not clamp conductor crimp.)
8. Activate pull test.
9. Record a minimum of 25 readings of maximum pull force. After the application has been qualified, a
minimum of 5 pull force measurements should be done to confirm each setup.
10. Compare lowest reading to minimum pull force specification.
Test Values For Pullout Test UL486A
A.5.2 Pull Test Problems
A.5.2.1 Wire breaks before conductor grip pull force low
Material Evaluation
Cause:
Wire material properties, and/or coatings.
Solution: Test non-terminated wire for breaking strength.
Stripping Evaluation
Cause: Cut or nicked strands from stripping operation.
1) Wire being manually stripped.
2) Poor automatic stripping cutoff.
3) Worn strip tooling.
Solution: 1) Switch to semiautomatic or automatic wire stripping machine.
2) Correct stripping machine setup.
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
Conductor Size
AWG
mm2
30
0.05
28
0.08
26
0.13
24
0.20
22
0.324
20
0.519
18
0.823
16
1.31
14
2.08
12
3.31
10
5.261
9
8.367
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Pullout Force
N
LB
6.7
1.5
8.9
2
13.4
3
22.3
5
35.6
8
57.9
13
89.0
20
133.5
30
222.6
50
311.5
70
356.0
80
400.5
90
Page 46 of 49
TM42 Termination Press
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 strip length, poor conductor brush.
Solution: Adjust strip length.
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
Figure A-5.0 Pull Force Testing
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TM42 Termination Press
Appendix B
Options
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 48 of 49
TM42 Termination Press
EC Declaration of Conformity
We hereby declare that the following product is in conformity with the requirements of the following EC
Directives:
Product: TM42 Crimp Machine
Type:
69002-5001, 69002-5000
Title and No. of Directive: EMC Directive 89/336/EEC, 92/31/EEC
Machine Directive 89/392/EEC
This product is designed and manufactured in accordance with the following standards:
EMC:
EMI (Electromagnetic Interface): EN50081-1
Conducted/Radiated: EN 55011 level B
EMS (Electromagnetic Susceptibility):
Immunity EN 50082-1 EN 50082-2
Electrical Safety: EN 292-1:1991/ EN 292-2:1991/EN 60204-1:1993
Manufacturer:
Name:
Address:
Molex Application Tooling Group
2200 Wellington Court
Lisle, IL 60532 USA
April 4 1996
Date:
Signed:
Typed Name:
Title:
___________________________
Director of Engineering
Representative in EU:
Name:
Address:
Molex Interconnect AG
Luchthavenweg 38
5657 EB Eindhoven,
The Netherlands
Visit our Website at http://www.molex.com
Order No: TM-690025099
Revision: H
Release Date: 08-08-02
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 49 of 49
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