FineAdjust Applicator
FineAdjust™ APPLICATOR
Operation Manual
Order No 63800-4900
Description
Operation
Maintenance
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
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Page 1 of 50
FineAdjust Applicator
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.
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
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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FineAdjust Applicator
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
The Molex applicators are designed to operate in presses with standard shut heights of 135.80mm (5.346”).
Installation in crimp presses with other than standard shut heights can cause severe tool breakage. It is advisable that before
installation, a check of the shut height be performed. Molex will not be liable for any damages as a result of installation in a
crimp press with nonstandard or improperly set shut height.
Failure to observe these precautions may result in injury or property damage.
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
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
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FineAdjust Applicator
Table of Contents
Contents
FineAdjust™ APPLICATOR .......................................................................................................................................... 1
Order No 63800-4900.................................................................................................................................................... 1
Safety Warnings and Information .................................................................................................................................. 2
Table of Contents ........................................................................................................................................................ 4
Section 1 ................................................................................................................................................................... 6
General Description .............................................................................................................................................. 6
Principal Mechanical Parts of the FineAdjust Applicator ....................................................................................... 7
1.1 Description................................................................................................................................................. 8
1.2 Features .................................................................................................................................................... 8
1.3 Technical Specification .............................................................................................................................. 8
1.4 Delivery Check .......................................................................................................................................... 8
1.5 Tools.......................................................................................................................................................... 9
1.6 Specification Sheets .................................................................................................................................. 9
Section 2 ................................................................................................................................................................. 10
Set-Up and Operation ......................................................................................................................................... 10
2.1 Shut Height .............................................................................................................................................. 11
2.2 Set-Up ..................................................................................................................................................... 11
2.3. Adjustments ............................................................................................................................................. 13
2.4 Crimp Tooling Installation and Removal .................................................................................................. 16
Section 3 ................................................................................................................................................................. 18
Maintenance ....................................................................................................................................................... 18
3.1 Cleaning .................................................................................................................................................. 19
3.2 Lubrication ............................................................................................................................................... 19
3.3 Spare Parts.............................................................................................................................................. 20
3.4 Perishable Parts ...................................................................................................................................... 20
3.5 Storage .................................................................................................................................................... 21
Section 4 ................................................................................................................................................................. 22
Styles of FineAdjust ............................................................................................................................................ 23
4.1 STYLE A-FineAdjust Applicator ............................................................................................................... 24
4.1 STYLE A FineAdjust Applicator Assembly............................................................................................... 26
4.1 STYLE A FineAdjust Applicator Assembly (Cont.)................................................................................... 27
4.2 STYLE B-FineAdjust Applicator ............................................................................................................... 28
4.2 STYLE B FineAdjust Applicator Assembly............................................................................................... 30
4.2 STYLE B FineAdjust Applicator Assembly (Cont.).................................................................................. 31
4.3 STYLE C-FineAdjust Applicator............................................................................................................... 32
4.3 STYLE C FineAdjust Applicator Assembly .............................................................................................. 34
4.3 STYLE C FineAdjust Applicator Assembly (Cont.) ................................................................................. 35
4.4 Troubleshooting ....................................................................................................................................... 36
Appendix A .............................................................................................................................................................. 38
Crimp Terminations ............................................................................................................................................ 38
A.1
Conductor Brush and Terminal Position ................................................................................................. 39
A.2 Conductor Bell Mouth and Terminal Cutoff Tab....................................................................................... 40
A.3 Conductor Height Measurement .............................................................................................................. 41
A.4 Insulation Crimp....................................................................................................................................... 41
A.5 Pull Force Testing.................................................................................................................................... 43
Appendix B .............................................................................................................................................................. 45
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Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
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FineAdjust Applicator
Statistical Process Control (Summary) ............................................................................................................... 45
B.1 Crimp Process Control ............................................................................................................................ 46
B.2 Process Capability ................................................................................................................................... 46
B.3 Production ............................................................................................................................................... 47
Appendix C ............................................................................................................................................................. 49
Options.................................................................................................................................................................... 49
Terminal Oiler ................................................................................................... Error! Bookmark not defined.50
Order No. 63890-0719 ...................................................................................... Error! Bookmark not defined.50
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
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FineAdjust Applicator
Section 1
General Description
1.1
Description
1.2
Features
1.3
Technical Specifications
1.4
Delivery Check
1.5
Crimp Tooling Accessories
1.6
Tools
1.7
Specification Sheets
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
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FineAdjust Applicator
Principal Mechanical Parts of the FineAdjust Applicator
INSULATION
ADJUSTING CAM
PIVOT ARM
RAM
FORWARD FEED
LOCKING SCREW
FORWARD FEED
ADJUSTING KNOB
FEED FINGER
LEVER
FEED FINGER
REAR COVER
LUG BOLT
TRACK
DRAG RELEASE
DRAG FRAME
CONDUCTOR
ADJUSTING CAM
BACK STROKE
ADJUSTING KNOB
BACK STROKE
LOCKING SCREW
BASE PLATE
FRONT COVER
WIRE STOP
TRACK
ADJUSTING SCREW
ANVIL MOUNTING BLOCK
Figure 1-1
Doc. No: TM-638004900
Revision: G
CUT-OFF PLUNGER
AND RETAINER
Release Date: 09-04-03
Revision Date: 01-15-13
ANVILS
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FineAdjust Applicator
General Descrition
Directly adapts to most automatic wire processing
machines.
Quick set-up time; plus the crimp height, track and feed
adjustments can be preset in applicator.
Applicator designed to industry standard mounting and
shut height 135.80mm (5.346").
Automatic terminal feed with applicator in press.
Adjustable terminal feed with applicator in press.
Terminals are separated from carrier strip automatically
during crimping operation.
Quiet operation with low maintenance and easy to
keep clean.
The FineAdjust™ available for most Molex brand
terminals.
1.1 Description
The Molex FineAdjust™ Applicator is designed to provide
an effective method of applying a wide range of side feed
terminals to a pre-stripped discrete wire. It is the most
advanced version of a "universal" crimping tool available. It
is designed to allow for quick adjustments of crimp height,
track position, and terminal feed without taking the
applicator out of the press and without shimming. This
allows easy adjustment of crimp height to the target value
with improved process capability, even after a wire changeover.
This applicator works in the Molex TM-2000 and TM-3000
Universal Press and in most industry standard presses.
The FineAdjust™ applicator offers minimal setup time
without the need for shimming, is versatile, reliable, easy to
install, and is designed for mid-volume to high-volume,
semi or fully automatic operations.
1.3 Technical Specification
Dimensions
Width:
132mm
Depth:
101mm
Height:
152mm
Molex offers the following crimp presses for operating the
Fine Adjust Applicator™:
Weight
4.1kg
TM-2000 Press 120 V 60 Hz. 63800-8300
TM-2000 Press 240 V 50 Hz. 63800-8400
TM-3000 Press 120 V 60 Hz. 63801-7200
TM-3000 Press 240 V 50 Hz. 63801-7300
TM-4000 Press 240 V 60 Hz. 63801-7600
Guarding
The FineAdjust™ Applicator is supplied with no
guards and is intended to be used with the guards
supplied by the press manufacturer.
1.2 Features
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
(9lbs)
Press Stroke Compatibility
41.28mm (1 5/8")
28.58mm (1 1/8")
The FineAdjust Applicator is also compatible with most
OEM presses (Artos, Mecal, Komax, Megomat, Toyojamco,
etc). It also adapts to most wire processing machines.
Fine adjustment allows users to achieve target with
little effort by adjusting in increments (14 settings) of
.015mm (.0006") for conductor crimp height and (29
settings) in increments of .063mm (.0025") for
insulation height.
Independent adjustment rings allow users to quickly
adjust the conductor or insulation crimp height without
affecting each other.
Quick tooling removal with the push of a button for fast
and easy punch change.
Track adjustment for bell mouth and cut-off tab is
adjusted while the applicator is in the press for fast and
easy setup.
Compatible with the Molex TM-2000, TM-3000, TM4000 Universal Press, and most industry standard
presses. However, it does NOT fit into Molex TM40/42 press.
(5.2")
(4.0")
(6.0")
Caution: DO NOT use the applicator
without guards
1.4
Delivery Check
Carefully remove the FineAdjust Applicator from its
shipping container and determine that the following
items are included in the package.
FineAdjust Applicator
(Tooled for desired terminal)
1
11-18-4238 Short Feed Cam
Specification Sheets
TM-638004900
Operation Manual
Sample Crimped Terminals
1
1
1
5
Crimp Tooling Accessories
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FineAdjust Applicator
63890-0719
63800-2800
Terminal Oiler (Appendix C)
Digital Crimp Micrometer
The specification sheet should be filed. These are
available on the Molex website (www.molex.com).
1.5 Tools
The following tools are recommended for setup and
adjustments to the applicator:
1.
2.
3.
4.
Metric standard hex wrench set
Adjustable wrench
Wire stripper / cutter
Scissors
1.6 Specification Sheets
Molex ships specification sheets with every
applicator. The specification sheet contains the
following:
Ε
Ε
Ε
Ε
Ε
Ε
Ε
Ε
Ε
Terminal numbers
Wire AWG ranges
Insulation diameter ranges
Strip lengths
Pull force
Crimp heights
Bell mouth
Bend, twist, and roll limits
Tooling parts list and assembly
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
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FineAdjust Applicator
Section 2
Set-Up and Operation
2.1.
Shut Height
2.2.
Set-Up
2.3.
Adjustments
2.4.
Crimp Tooling Installation and Removal
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
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FineAdjust Applicator
Read the following instructions before attempting to operate the applicators.
2.1 Shut Height
The Molex FineAdjust Applicators are designed to operate in crimp
presses with standard shut height of 135.80mm (5.346").
Installation in crimp presses with other than standard shut heights
can cause severe tool breakage. It is recommended that before
installation, a check of the shut height be performed. The correct
shut height is required to prevent the punches from hitting the anvils
and the cut-off tooling from bottoming out on the base plate. It also
allows the movement of applicators from press to similar press
without adjusting the applicator or press shut height.
The shut height of the press can be checked with a shut height
gauge, which is calibrated under load to achieve the 135.80mm
(5.346") measurement. It is recommended that the shut height be
checked monthly. A shut height gauge is available from most press
manufacturers.
SHUT HEIGHT
GAUGE
PRESS QUICK
CHANGE
MOUNTING PLATE
PRESS
Figure 2-1
Measuring Press Shut Height
1. Always disconnect the power supply from the press. Remove the machine guards if necessary.
2. Remove the applicator from the press. See “Applicator Installation and Removal” (below) for additional information. Make
3.
4.
5.
6.
7.
8.
sure that the bottom of the press ram and quick change mounting plate are free from foreign material.
Place the shut height gauge into the press on the press quick change mounting plate. See Figure 2-1.
Manually cycle the press to the down stroke position. (Follow press manufacturer’s instructions on manually cycling the
press.)
Read the shut height measurement from the front of the gauge. Follow gauge manufacturers’ instruction, usually the gauge
reads “0” when set correctly.
If adjustments are necessary, refer to the press manufacturer for adjustment of the press shut height.
Repeat the above steps until the correct shut height is obtained.
Shut height gauges must be calibrated on a regular basis.
2.2 Set-Up
IMPORTANT
Power must be shut off and electrical cord disconnected. Manual press cycling is an absolutely required procedure
for safety and preventing equipment damage. Always cycle by hand when trouble shooting or changing adjustments,
tooling, applicator, or accessories.
The principal mechanical parts of the FineAdjust are illustrated in Section 4.1 Assembly Drawings.
Applicator Installation and Removal
1
2
3
4
All presses must be equipped with a common universal type quick-change mounting plate and adapter on the press.
Contact the press manufacturer for specific information.
Always turn off and disconnect the power supply to the press. Remove the press guards.
Clean the quick change mounting plate of scrap or chips that may interfere with the FineAdjust applicator installation.
For the TM-2000 and TM-3000 Presses follow the procedure below:
a. Using a 4mm hex wrench, turn the M5 SHCS clockwise until the locking clamp is fully opened.
b. Visually align the applicator base plate slots with the location clamps on the press quick-change mounting plate.
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Revision Date: 01-15-13
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FineAdjust Applicator
5
6
c. Slide the applicator onto the quick-change mounting plate
until the two notches on the left side engage against the
stops, and at the same time, guide the lug bolt into the
adapter on the press. See Figure 2-2.
d. To lock applicator, turn the M5 SHCS counter clockwise until
tight.
Some presses have locking latches on the quick change
mounting plate, which have to be flipped up to secure the
applicator. Others have knurled finger screws or "T" type latches.
Most of these are located on the right side of the quick change
mounting plate to secure the position of the applicator. These
must be in place and secured before operating the press.
Replace the press guards.
Remove the applicator by reversing the previous steps. When storing
an applicator, always leave a strip of terminals in the applicator to
prevent damage to the tooling. See Section 3.5 Storage.
LOCKING CLAMP
ENGAGE PRESS
YOKE
APPLICATOR
LOCATOR
CLAMPS
QUICK
M5 SHCS
CHANGE
MOUNTING
PLATE
Figure 2-2
Fitting Terminal Strip
1. The specified terminals are printed on the setup sheet for the
applicator. Only use the Molex terminals on the setup sheet
BASE PLATE
which is supplied with the applicator.
2. Always disconnect the power supply from the press. Remove the machine guards if necessary.
3. Rotate the drag release until the drag frame is in the upright position. This will allow the terminal to slide with ease through
the applicator track. See Figure 2-3.
4. Push the terminal strip until the first terminal comes to rest centered above the anvil.
5. Rotate the drag release to engage the terminal drag frame.
6. Cycle the press by hand so that the feed finger transfers the next terminal to a centered position over the anvil. Check that
all other parts slide and engage without any interference. It is recommended to go through this procedure several times.
TERMINAL
STRIP
Figure 2-4
DRAG RELEASE
FEED FINGER
Figure 2-3
RELEASE M4 SHCS
1ST TERMINAL
CENTERED
ABOVE ANVILS
7. When unloading the terminal strip, make sure the power is turned off and disconnected from the press. Remove the
machine guards if necessary.
8. Rotate the drag release until the drag frame is in the upright position.
9. Raise feed finger and pull terminal strip back until disengaged from applicator track. See Figure 2-3. If preferred, cut the
terminal carrier strip and pull it through the applicator with needle nose pliers.
10. Replace the machine guards before operating the press.
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
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FineAdjust Applicator
Punch and Anvil Alignments
Note: Always clean mounting surfaces of crimp tooling and tooling holders before
alignment.
APPLICATOR
1. Always disconnect the power supply from the press. Remove the machine
2.
3.
4.
5.
guards if necessary.
With a terminal in position over the anvils, slightly release anvil mounting
screw. See Figure 2-4.
Gently hand-cycle the ram of the press to bottom of its stroke. Tighten anvilmounting screws in this position to ensure perfect alignment of punches and
anvils.
Hand cycle the press ram to the highest position.
Replace the machine guards before operating the press.
6mm X 20mm
DOWEL PIN (2)
BASE PLATE
2.3. Adjustments
M6 X 10mm
BHCS (2)
Cover Plate Adjustments
1. Always disconnect the power supply from the press. Remove the machine
2.
3.
4.
5.
6.
7.
8.
Figure 2-5
guards if necessary.
Remove the applicator from the press. Refer to Applicator Installation and Removal.
Rotate the drag release until the drag frame is in the upright position. The rear cover plate should be adjusted so that the
terminal strip will slide smoothly through the track with no resistance.
Some applicators require the removal of the applicator frame from the base plate. This is done by removing the two M6
BHCS located on the bottom of the base plate. See Figure 2-5.
Loosen the two M4 BHCS to adjust the position of the rear cover. See Figure 2-6.
Slide terminal strip through the track to ensure accurate cover positioning.
After the correct position is achieved, tighten the two M4 BHCS.
Reattach the applicator frame to the base plate if needed. Locate the position of the frame using the dowel pins. Tighten
the two M6 BHCS to secure the frame to the base plate.
REAR COVER
M4 X 12mm
BHCS (2)
SCREWDRIVER
DRAG RELEASE
UP POSITION
TERMINAL
Figure 2-6
Track Position Adjustment
1.
2.
Figure 2-7
M10
LOCK SCREW
Disconnect power from the press. Remove the machine guards if necessary.
To position the terminal track in or out, first use a 6mm hex wrench to loosen the M10 lock screw located on the front of the
track.
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Revision Date: 01-15-13
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FineAdjust Applicator
3.
Put a regular screwdriver through the hole in the lock screw and turn the adjusting screw to position the terminal in the
correct location. See Figure 2-7. Turning the screw clockwise will move the track towards the operator; to move the track
towards the applicator turn the screw counterclockwise. Depending on the amount of movement, the feed finger mount may
need to be loosened and readjusted. See Feed Finger adjustment.
7 To lock the track in position, tighten the M10 lock screw.
8 If the feed finger mount was loosened during the track positioning, remember to tighten its mounting screw.
9 Replace machine guards.
10 Hand cycle the press to ensure the terminal is positioned properly on the anvils and does not have an excessive cutoff tab.
Also, verify the terminal feed operation.
11 Restore power to the press, crimp a terminal under power, and observe the quality of the termination.
12 Repeat the above steps until the desired terminal position is obtained.
PUSH DOWN
M3 SHCS
Feed Finger Adjustments
1. Position the feed finger to properly feed the next terminal in
position. Typically, terminals are fed by the carrier strip.
2. Depending on the feed cam installation (pre-feed or postfeed), move the press ram until the feed is forward (this makes
the feed finger mount more accessible), and then disconnect
power from the press. Remove the machine guards if
necessary.
3. Using a 2.5mm hex wrench, loosen the M3 SHCS located on
the feed finger mount. While holding the feed finger lever
FEED FINGER
down slightly, slide the feed finger to the desired position. See
FEED FINGER
TERMINAL
LEVER
Figure 2-8.
MOUNT
FEED FINGER
4. If the feed finger mount cannot be moved far enough, remove
Figure 2-8
the M3 SHCS completely and install it in another tapped hole
in the feed finger lever. In addition, the feed finger mount can be reversed (the feed finger must be reversed as well) to gain
additional adjustment.
5. Tighten the M3 SHCS to lock the feed finger in position.
Feed Stroke Cam Adjustments
Feed Cam
Order No.
Press Stroke
mm
In.
Feed Timing
1. The terminal feed stroke is driven by a cam mounted to the applicator
ram. Two feed cams are shipped with the applicator. The standard cam
41.28 1-5/8
Up stroke
is installed in the applicator. The spare cam is for presses with short
(terminal present
strokes (for example, 28mm). Using the standard cam with a shortover anvil)
28.58 1-1/8
stroke press may result in insufficient feed stroke or incorrect feed
63800-0305
timing.
2. Determine what feed timing is desired. Typically, when the applicator is
mounted in a wire processing machine, the feed stroke cam should be
Down stroke
assembled in the down stroke position. While the press is idle in the up
41.28 1-5/8 (terminal not present
position, a terminal will not be present over the anvil. For most bench
over anvil)
applications, the cam is installed in the up stroke position. This will leave 63800-0305
a terminal over the anvil when the press is idle in the up position. See
Figure 2-9.
Down stroke
3. Turn off and disconnect the power supply from the press. Remove the
28.58 1-1/8 (terminal not present
machine guards if necessary.
over anvil)
4. Remove the applicator from the press. See Applicator Installation and
Removal.
11-18-4238
5. Pull back on the feed pivot lever and remove the ram from the applicator.
Figure 2-9
6. Holding on to the ram, use a 3mm hex wrench to remove the M4 SHCS
holding the cam on the back of the ram.
7. Position the cam in the desired position for feeding and attach with the M4 screw. See Figure 2-9.
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
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FineAdjust Applicator
Forward Feed Adjustments
M5 SHCS
FEED LOCK
1. The forward feed position must locate the terminal that is
being crimped exactly over the anvils.
2. Disconnect the power from the press. Remove the
machine guards if necessary.
FORWARD
3. Make sure there is a terminal over the anvils and the feed
FEED
finger is fully forward (closest to the anvils).
BACK
STROKE
STROKE
4. Loosen the M5 SHCS.
ADJ. KNOB
ADJ. KNOB
5. Turn the forward feed adjusting knob to position the
terminal. To decrease the feed position, turn the forward
feed adjusting knob clockwise. To increase the feed
PIVOT CLAMP
position turn the forward feed adjusting knob
M5 FHCS
counterclockwise. See Figure 2-10.
Figure 2-10
6. When adjusting to decrease the feed position, it is
necessary to pull the terminal strip backwards until it is against the feed finger. When increasing the feed position, the feed
finger will push the terminal farther over the anvils.
7. After properly adjusting the forward feed position of the terminal, tighten the M5 SHCS with a 4mm hex wrench.
Back Stroke Feed Adjustments
INSULATION
CAM (TOP)
1. To properly feed the terminal strip, the back feed stroke should have
enough over-travel to pick up the next terminal. Too much over
travel may, in some cases, cause a double-feed.
2. Disconnect the power from the press. Remove the machine guards if
necessary.
3. To achieve the correct backstroke location, adjust the position of the
hinge bushing. First, use a 3mm hex wrench to loosen the M5 FHCS
holding the pivot clamp. Turning the backstroke adjustment knob
(which is located above the hinge bushing) clockwise will raise the
hinge bushing and will increase the backstroke. Turning the knob
CONDUCTOR
Figure 2-11
counter clockwise (CCW) will lower the hinge bushing and will
CAM (BOTTOM)
decrease the feed backstroke. When adjustment is complete, tighten
the pivot clamp securely. See Figure 2-10.
4. Since back feed stroke adjustment may not be visibly obvious, the terminal feed should be cycled (by hand, if possible) to
observe the changes.
5. Back feed stroke adjustments may affect the entire feed linkage; re-adjustment of the forward feed stroke could be
necessary. See Forward Feed Adjustments.
Conductor Crimp Punch Adjustments
1. With the guards intact, place a stripped length of suitable wire into the terminal and terminate the wire under power.
2. Inspect the quality of conductor crimp and measure the crimp height. See Appendix A.3 Conductor Crimp Height
3.
4.
5.
6.
Measurement.
If adjustments are necessary, turn off and disconnect the power supply from the press. Remove the machine guards.
The desired crimp height can be achieved by rotating the conductor-adjusting cam. See Figure 2-11. Each increment
represents approximately 0.015mm (.0006") for a total adjustment of 1.80mm (.071"). The "A" setting is the loosest crimp
height and the "N" setting is the tightest. If you find that the crimp height is not acceptable, you can rotate the adjusting cam
until the desired crimp height is obtained. See Section 2.1, Shut Height. No shimming of the applicator is required.
Replace the machine guards and repeat the previous steps until the desired crimp height is obtained. See Appendix A.3,
Conductor Crimp Height Measurement.
Perform a pull test on conductor crimp to verify the mechanical integrity of the crimp. See Appendix A.5, Pull Force Test.
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 15 of 50
FineAdjust Applicator
Insulation Crimp Punch Adjustment
1. Place a stripped length of the appropriate wire into the terminal and
crimp under power.
2. Observe quality of insulation crimp and measure the crimp height.
See Appendix A.4, Insulation Crimp.
3. If adjustments are necessary, always turn off and disconnect the
power supply from the press. Remove the machine guards.
4. Rotate the insulation-adjusting cam to achieve the desired insulation
height. Each increment represents approximately 0.06mm (.0025") for
a total adjustment of 3.00mm (.118"). The "1" setting is for the highest
(most loose) crimp height and the "29" setting the lowest (most tight)
crimp height.
5. Repeat the previous steps until the desired insulation height is
obtained.
WIRE STOP
M5 SHCS
Figure 2-12
Note: Due to the large variety of insulation wall thickness, materials, and diameter, Molex does not specify insulation crimp
height. For each different wire type, the insulation crimp height can be measured, recorded, and inspected as a quality indicator.
Wire Stop Adjustment
For automatic wire processing machines, the wire stop can be used to assist in the stripping of the terminal from the punches.
However, in certain circumstances the wire stop will need to be removed when running on an automated machine.
1.
2.
3.
4.
5.
6.
Check the setup documents to obtain the correct strip length.
Place the correct wire into the terminal and crimp the wire under power.
Observe quality of crimp and the wire position. See Appendix A.1 Conductor Brush and Terminal Position.
If adjustments are necessary, turn off and disconnect the power supply from the press. Remove the machine guards.
Use a 4mm hex wrench to loosen the M5 SHCS located on the side of the frame. See Figure 2-12.
Adjust the position of the wire stop by moving the wire stop, towards the operator decreases the brush length and towards
the press increases it.
7. Tighten the M5 SHCS.
8. Hand cycle the press to ensure the applicator is functioning properly. Then crimp a terminal under power and observe the
quality of the termination.
2.4 Crimp Tooling Installation and Removal
RAM
Installation and Removal of the Upper Tooling (Punches)
Caution: Always disconnect power supply before installing or
removing tooling.
PUNCH RELEASE
BUTTON
SCREWDRIVER
NOTE: Always clean mounting surfaces of crimp tooling and tooling holders
before installation.
1. Always turn off and disconnect the power supply from the press. Remove
PUNCHES
the machine guards if necessary.
2. Remove the applicator from the press. See Section 2.2, Applicator
Figure 2-13
Installation and Removal.
3. Pull back the feed arm and remove the ram from the applicator.
4. With a small screw driver, push in the punch release button located on the front of the ram. See Figure 2-13.
5. Pull the punches out the bottom of the ram.
6. Reverse the previous steps to reinstall the punches.
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 16 of 50
FineAdjust Applicator
Installation and Removal of the Lower Tooling (Anvils)
Caution: Always disconnect power supply before installing or
removing tooling.
NOTE: Always clean mounting surfaces of crimp tooling and tooling holders
before installation.
1. Always turn off and disconnect the power supply from the press.
Remove the machine guards if necessary.
2. Make sure the ram is all the way in the up position.
3. Remove the M4 SHCS that are holding the lower tooling in place and pull
out the tooling. See Figure 2-14.
4. Put in the new anvils, leaving the mounting screws loose. For tightening,
see Section 2.2, Punch and Anvil Alignment.
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
Figure 2-14
REMOVE M4 SHCS
UNCONTROLLED COPY
Page 17 of 50
FineAdjust Applicator
Section 3
Maintenance
3.1
Cleaning
3.2
Lubrication
3.3
Spare parts
3.4
Perishable Parts
3.5
Storage
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 18 of 50
FineAdjust Applicator
3.1 Cleaning
Caution: Always disconnect power supply before installing or removing tooling.
For efficient operation, the FineAdjust Applicator should be cleaned daily. Use a soft bristle brush to remove debris from
critical areas such as the crimp tooling. For best results, remove the crimp tooling from the press. Brush and then use a
clean cloth to wipe off the upper and lower tooling mounting areas. Before reinstalling tooling, wipe all sides of the
punches and anvils with a clean cloth.
3.2 Lubrication
WARNING: Disconnect electrical power before all maintenance.
1. Grease the ram including the cam.
2. Oil the feed finger assembly and all moving parts.
3. Lubricate with multipurpose synthetic lubricant with Teflon or an equivalent. Molex ships its applicators pregreased with Permatex multi-purpose synthetic grease with Teflon No. 82329. A SAE 30WT non-detergent oil or
light spindle oil or 3-n-1 oil should be used on pivot points.
WARNING: Never use penetrants such as WD40 for any lubrication on the machine.
4. Lubricate all points shown in Figures 3-1 with the specified oil and grease (or equivalent).
GREASE RAM
AND FEED CAM
OIL FEED FINGER
ASSEMBLY
OIL
Figure 3-1
An example of a maintenance chart is shown below. Copy and use this chart to track the maintenance of your
FineAdjust Applicator or use this as a template to create you own schedule or use your company’s standard chart, if
applicable.
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 19 of 50
FineAdjust Applicator
Preventive Maintenance Chart
Daily: Clean. See Section 3.1.
As Required: Lubricate. See Section 3.2.
YEAR _________
CHECK SHEET MONTH
Daily
Cycles
Week
1
2
3
4
Cleaning
Reapply grease 25,000
Reapply oil
Inspect all tooling,
feed fingers etc. 25,000
for wear
Daily
Clean
Days of the Week
MON TUE WED THU FRI SAT SUN
Solution
Yes
Soft Brush Industrial
Degreaser
Yes
Replace if signs
of wear.
Schedule should be adjusted up or down depending on usage. Molex recommends that a log of preventive
maintenance be kept with the press.
3.3 Spare Parts
Customers are responsible for maintaining the FineAdjust Applicator. Spare parts are available. Moving and
functioning parts can be damaged or wear out over time and will require replacement. Molex recommends that the
customer keep some or all of them in stock to reduce production down time.
3.4 Perishable Parts
Customers are responsible for maintaining the FineAdjust Applicator. Perishable parts are those parts that come in
contact with the product and will wear out over time. Molex recommends that all customers keep at least one set of the
perishable tool kits in stock at all times. This will reduce the amount of production down time. For the proper
perishable tool kit information, refer to the Crimp Tooling Specification Sheet supplied with the Applicator.
Tooling Replacement Schedule
The following is offered as a general guideline for tooling replacement. The manufacturer should monitor the process
and collect data on actual frequency as tool wear varies on different terminal materials and tool life can be increased
with good maintenance practices or decrease with lack of maintenance.
Items
Punches
Anvils
Cut-off Plungers
Feed Fingers
Cut-off Punches
Cut-off Blades
Cycles Brass Alloys
300,000/500,000
500,000/750,000
300,000/500,000
300,000/900,000
500,000/750,000
300,000/500,000
Cycles Steel
200,000/400,000
400,000/750,000
200,000/400,000
300,000/900,000
200,000/400,000
200,000/300,000
Actual
Judgment on tool replacement should be based on the attributes of the crimp they produce.
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 20 of 50
FineAdjust Applicator
See the following chart for common signs of wear.
Punches
Scoring
Tip Loss
On Terminal
Uneven Curls
Open seam
Notes
Replace
Replace
Anvils
Rounded Edges
Chipping
Worn Cut Edges
Large Extrusion
Burrs-On Tabs
Burrs
Replace
Replace
Replace
Cut-Off Plungers and Punches
Chipped or Rounded
Cut Edge
Cut-off Dies
Burr on Tab
Burr on Tab
Burrs on Cut Area
Replace
Replace
Replace
3.5 Storage
To prevent the bottoming of the ram, which can cause damage to the crimp punches and anvils leave a strip of
terminals in the applicator or place a piece of wood or rubber between the punches and the anvils.
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 21 of 50
FineAdjust Applicator
Section 4
Parts Lists, Assembly Drawings and Troubleshooting
4.1
Style A FineAdjust Applicator
4.2
Style B FineAdjust Applicator
4.3
Style C FineAdjust Applicator
4.4
Troubleshooting
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 22 of 50
FineAdjust Applicator
Styles of FineAdjust
FLAT SURFACE
NUT
KNOB
FLAT SURFACE
KNOB
FLAT HEAD
CAP SCREW
STYLE A
Figure 4-1
HEX HOLE
KNOB
FLAT HEAD
CAP SCREW
STYLE B
Figure 4-2
LEVER
FULL TRACK
STYLE C
Figure 4-3
In the effort to continually improve the FineAdjust Applicator, we have multiple styles working in the field.
To determine the style of applicator you are using, look at the pictures above. Figure 4-1, 4-2, and 4-3
point out the major differences between the styles of this applicator. Identify your applicator style and
use the appropriate parts list and assembly drawing to order replacement parts.
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 23 of 50
FineAdjust Applicator
4.1 STYLE A-FineAdjust Applicator
Parts List and Assembly Drawings (See Figure 4-4 and 4-5)
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
Order No.
11-18-4238
11-32-5346
11-41-0127
63600-0481
63800-0115
63800-0117
63800-0118
63800-0119
63800-0120
63800-0121
63800-0122
63800-0123
63800-0124
63800-0125
63800-0127
63800-0129
63800-0140
63800-0141
63800-0142
63800-0143
63800-0144
63800-0301
63800-0302
63800-0303
63800-0304
63800-0305
63800-4906
63800-0308
63800-4309
63800-0310
63800-0311
63800-0312
63800-0313
63800-0314
63800-0316
63800-0330
63800-0331
63800-0332
63800-0335
63800-0345
63800-4946
63800-0347
63800-0348
N/A
N/A
N/A
N/A
N/A
Doc. No: TM-638004900
Revision: G
STYLE A-FineAdjust Applicator
Engineering No.
Description
60700-1
Feed Cam (Short) Optional
600000Y422
M4 Ball Spring Plunger
60678-27
Compression Spring (Associated # C0180-016-0500)
63600-0481
Shoulder Screw M5 by 10mm Long
63800-0115
Spacer Tube
63800-0117
Feed Pawl Lever
63800-0118
Hinge Bushing
63800-0119
Feed Finger
63800-0120
Feed Arm
63800-0121
Lever Feed Pivot
63800-0122
Feed Adjusting Screw
63800-0123
Slider-Feed Cam
63800-0124
Pin-Feed Adjusting
63800-0125
Torsion Spring-Hinge
63800-0127
Torsion Spring-Feed Pawl
63800-0129
Washer –3.40mm Thick
63800-0140
Cylinder Pin
63800-0141
Slider
63800-0142
Roller-Cam Follower
63800-0143
Pin-Cam Follower
63800-0144
Key Stock 3mm by 3mm by 29mm Long
63800-0301
Back Frame
63800-0302
Face Plate
63800-0303
Base Plate
63800-0304
Ram-Terminator Tooling
63800-0305
Feed Cam
63800-4906
Insulation Striker
63800-0308
Terminal Track
63800-4309
Rear Support Block
63800-0310
Adjusting Screw
63800-0311
Locking Screw
63800-0312
Drag Frame
63800-0313
Drag Cam
63800-0314
Retaining Bar
63800-0316
Guide Pin-Drag Frame
63800-0330
Lug Bolt
63800-0331
Conductor Adjusting Cam
63800-0332
Insulation Adjusting Cam
63800-0335
Serial Tag
63800-0345
Retaining Plate
63800-4946
Conductor Striker
63800-0347
Retaining Rod
63800-0348
Detent Spacer
N/A
Compression Spring (Lee Spring # LC-032E-0MW)
N/A
Extension Spring (Lee Spring #LE-041C-9)
N/A
Snap Ring 3.2mm ID by 7mm OD by .62mm Thick
N/A
Washer .512" ID by 1.125" OD by 0.15” Thick
N/A
Washer .512" ID by 1.125" OD by 0.18” Thick
Release Date: 09-04-03
Revision Date: 01-15-13
UNCONTROLLED COPY
Qty
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
4**
1**
2**
1**
1**
Page 24 of 50
FineAdjust Applicator
Item
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
STYLE A-FineAdjust Applicator
Order No. Engineering No.
Description
N/A
N/A
M3 by 6mm Long FHCS
N/A
N/A
M4 Hex Nut
N/A
N/A
M4 by 8mm Long BHCS
N/A
N/A
M4 by 8mm Long SHCS
N/A
N/A
M4 by 10mm Long Set Screw
N/A
N/A
M4 by 12mm Long BHCS
N/A
N/A
M4 by 45mm Long SHCS
N/A
N/A
M5 by 6mm Long BHCS
N/A
N/A
M5 by 10mm Long SHCS
N/A
N/A
M5 by 35mm Long SHCS
N/A
N/A
M6 by 10mm Long BHCS
N/A
N/A
M6 by 8mm Long Set Screw
N/A
N/A
M12 Self Locking Hex Nut
N/A
N/A
3mm by 12mm Long Roll Pin
N/A
N/A
5mm by 20mm Long Dowel Pin
N/A
N/A
5mm by 25mm Long Dowel Pin
N/A
N/A
6mm by 10mm Long Dowel Pin
N/A
N/A
6mm by 12mm Long Dowel Pin
N/A
N/A
6mm by 20mm Long Dowel Pin
N/A
N/A
6mm by 45mm Long Dowel Pin
N/A
N/A
#2 (.098 Dia.) by .125 in. Long Drive Screw
** Available from an industrial supply company such as MSC (1-800-645-7270).
Qty
2**
1**
1**
3**
1**
2**
1**
1**
1**
4**
2**
1**
1**
2**
1**
1**
1**
2**
1**
2**
2**
Check Applicator Number Tag or Part Number on part when ordering.
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 25 of 50
FineAdjust Applicator
4.1 STYLE A FineAdjust Applicator Assembly
(2)
21
45
11
57
13
(2)
(4)
58
22
64
54
62
63
(2)
66
49
12
10
(2)
19
20
9
68
(2)
34
30
14
55
18
(2)
7
29
69
50
65
51
61
39
67
6
17
15
23
See Figure 4-5
8
24
(2) 44
59
(2)
32
44 (2)
56
28
31
5
54
33
35
(2)
STYLE A
Figure 4-4
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 26 of 50
FineAdjust Applicator
4.1 STYLE A FineAdjust Applicator Assembly (Cont.)
36
38
(4)
2
43
37
47
26
48
16
25
27
40
(2)
41
52
4
1
52
60
53
3
23
42
Reference
See Figure 4-4
STYLE A
Figure 4-5
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 27 of 50
FineAdjust Applicator
4.2 STYLE B-FineAdjust Applicator
Parts List and Assembly Drawings (See Figure 4-6 and 4-7)
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
Order No.
11-18-4238
11-32-5346
11-41-0127
63600-0481
63800-0115
63800-0120
63800-0121
63800-0123
63800-0124
63800-0127
63800-0140
63800-0142
63800-0143
63800-0144
63800-0304
63800-0308
63800-0310
63800-0311
63800-0312
63800-0313
63800-0314
63800-0316
63800-0330
63800-0331
63800-0332
63800-0345
63800-0347
63800-0348
63800-4309
63800-4902
63800-4906
63800-4946
63801-0129
63801-3202
63801-3211
63801-3225
63801-3281
63801-4462
63801-4561
63890-0817
63890-0881
63890-0883
63890-0884
63890-0885
63890-0886
63890-0887
63890-0899
63890-0999
Doc. No: TM-638004900
Revision: G
STYLE B-FineAdjust Applicator
Engineering No.
Description
60700-1
Feed Cam (Short) Optional
600000Y422
M4 Ball Spring Plunger
60678-27
Compression Spring (Associated # C0180-016-0500)
63600-0481
Shoulder Screw M5 by 10mm Long
63800-0115
Spacer Tube
63800-0120
Feed Arm
63800-0121
Lever Feed Pivot
63800-0123
Slider-Feed Cam
63800-0124
Pin-Feed Adjusting
63800-0127
Torsion Spring-Feed Pawl
63800-0140
Cylinder Pin
63800-0142
Roller-Cam Follower
63800-0143
Pin-Cam Follower
63800-0144
Key Stock 3 by 3 by 19mm Long
63800-0304
Ram-Terminator Tooling
63800-0308
Terminal Track
63800-0310
Adjusting Screw
63800-0311
Locking Screw
63800-0312
Drag Frame
63800-0313
Drag Cam
63800-0314
Retaining Bar
63800-0316
Guide Pin-Drag Frame
63800-0330
Lug Bolt
63800-0331
Conductor Adjusting Cam
63800-0332
Insulation Adjusting Cam
63800-0345
Retaining Plate
63800-0347
Retaining Rod
63800-0348
Detent Spacer
63800-4309
Rear Support Block
63800-4902
Face Plate
63800-4906
Insulation Striker
63800-4946
Conductor Striker
63801-0129
Washer 3.40mm Thick
63801-3202
Feed Cam
63801-3211
Back Frame
63801-3225
Torsion Spring
63801-3281
Base Plate
63801-4462
Feed Finger Mount
63801-4561
Feed Finger
63890-0817
Feed Pawl Lever
63890-0881
Adjusting Screw
63890-0883
Adjusting Knob Retainer
63890-0884
Adjustable Pivot
63890-0885
Slider
63890-0886
Feed Positioning Screw
63890-0887
Pivot Clamp
63890-0899
Feed Adjusting Knob
63890-0999
Serial Tag
Release Date: 09-04-03
Revision Date: 01-15-13
UNCONTROLLED COPY
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1
1
1
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1
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1
2
1
1
1
1
1
1
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1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
Page 28 of 50
FineAdjust Applicator
Item
49
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
STYLE B-FineAdjust Applicator
Order No. Engineering No.
Description
69028-0660
69028-0660
Compression Spring (Lee Spring # LC-032E-0MW)
N/A
N/A
#2 (.098 in. Diameter) by .125 in. Long Drive Screw
N/A
N/A
M3 by 5mm Long SHCS
N/A
N/A
M3 by 6mm Long FHCS
N/A
N/A
M3 by 12mm Long SHCS
N/A
N/A
M3 by 20mm Long SHCS
N/A
N/A
M4 by 8mm Long SHCS
N/A
N/A
M4 by 8mm Long Set Screw
N/A
N/A
M4 by 10mm Long Set Screw
N/A
N/A
M4 by 12mm Long BHCS
N/A
N/A
M4 by 16mm Long SHCS
N/A
N/A
M5 by 6mm Long BHCS
N/A
N/A
M5 by 8mm Long FHCS
N/A
N/A
M5 by 10mm Long SHCS
N/A
N/A
M5 by 35mm Long SHCS
N/A
N/A
M6 by 8mm Long Set Screw
N/A
N/A
3mm by 12mm Long Roll Pin
N/A
N/A
5mm by 20mm Long Dowel Pin
N/A
N/A
5mm by 25mm Long Dowel Pin
N/A
N/A
6mm by 10mm Long Dowel Pin
N/A
N/A
6mm by 20mm Long Dowel Pin
N/A
N/A
6mm by 45mm Long Dowel Pin
N/A
N/A
Extension Spring (Lee Spring #LE-041C-9)
N/A
N/A
Snap Ring 3.2mmID by 7mm OD by .62mm Thick
N/A
N/A
Washer .512” ID by 1.125” OD by 0.15” Thick
N/A
N/A
Washer .512” ID by 1.125” OD by 0.18” Thick
** Available from an industrial supply company such as MSC (1-800-645-7270).
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
UNCONTROLLED COPY
Qty
4**
2**
1**
2**
1**
2**
3**
1**
1**
3**
1**
1**
1**
1**
4**
1**
2**
1**
1**
2**
2**
2**
1**
2**
1**
1**
Page 29 of 50
FineAdjust Applicator
4.2 STYLE B FineAdjust Applicator Assembly
71
14
59
35
45
(2)
63 (4)
62
9
47
67
58
65
(2)
56
66
54 (2)
69 (2)
42
7
13
36
(2)
70
72
44
41
(2)
8
12
6
47
52
21
(2)
17
43
40
29
38
11
46
53
68 (2)
61
10
30
See
Figure 4-7
39
51
50
48
49
37
(2)
(2)
65 (2)
19
49
(2)
60
16
5
58
Doc. No: TM-638004900
Revision: G
20
18
22
(2)
Release Date: 09-04-03
Revision Date: 01-15-13
STYLE B
Figure 4-6
UNCONTROLLED COPY
Page 30 of 50
FineAdjust Applicator
4.2 STYLE B FineAdjust Applicator Assembly (Cont.)
23
25
(4)
2
28
24
73
34
74
33
15
31
26
(2)
32
55
4
1
55
64
57
3
30
27
Reference
See Figure 4-6
STYLE B
Figure 4-7
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 31 of 50
FineAdjust Applicator
4.3 STYLE C-FineAdjust Applicator
Parts List and Assembly Drawings (See Figure 4-8 and 4-9)
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
Order No.
11-18-4238
11-32-5346
11-41-0127
63443-6202
63600-0481
63600-1561
63600-2644
63800-0120
63800-0121
63800-0123
63800-0124
63800-0127
63800-0140
63800-0142
63800-0143
63800-0144
63800-0304
63800-0310
63800-0311
63800-0312
63800-0314
63800-0316
63800-0345
63800-0347
63800-4309
63800-4903
63800-4906
63800-4946
63801-3202
63801-3211
63801-3225
63801-3281
63801-4462
63801-4561
63801-5862
63801-6444
63801-6445
63801-6446
63801-6447
63890-0817
63890-0885
63890-0881
63890-0883
63890-0884
63890-0886
63890-0887
63890-0899
63890-0999
Doc. No: TM-638004900
Revision: G
STYLE C-FineAdjust ApplicatorEngineering No.
Description
60700-1
Feed Cam (Short) Optional
600000Y422
M4 Ball Spring Plunger
60678-27
Compression Spring (Associated # C0180-016-0500)
63443-6202
Terminal Track
63600-0481
Shoulder Screw M5 by 10mm Long
63600-1561
Washer 6 I.D. by 10 O.D. by 0.3mm Thick
63600-2644
Stripper Bolt 6 O.D. by 10mm Long
63800-0120
Feed Arm
63800-0121
Lever Feed Pivot
63800-0123
Slider-Feed Cam
63800-0124
Pin-Feed Adjusting
63800-0127
Torsion Spring-Feed Pawl
63800-0140
Cylinder Pin
63800-0142
Roller-Cam Follower
63800-0143
Pin-Cam Follower
63800-0144
Key Stock 3 by 3 by 19mm Long
63800-0304
Ram-Terminator Tooling
63800-0310
Adjusting Screw
63800-0311
Locking Screw
63800-0312
Drag Frame
63800-0314
Retaining Bar
63800-0316
Guide Pin-Drag Frame
63800-0345
Retaining Plate
63800-0347
Retaining Rod
63800-4309
Rear Support Block
63800-4903
Face Plate
63800-4906
Insulation Striker
63800-4946
Conductor Striker
63801-3202
Feed Cam
63801-3211
Back Frame
63801-3225
Torsion Spring
63801-3281
Base Plate
63801-4462
Feed Finger Mount
63801-4561
Feed Finger
63801-5862
Drag Cam Lever
63801-6444
Conductor Adjusting Cam
63801-6445
Insulation Adjusting Cam
63801-6446
Detent Spacer
63801-6447
Ram Adapter
63890-0817
Feed Pawl Lever
63890-0885
Slider
63890-0881
Adjusting Screw
63890-0883
Adjusting Knob Retainer
63890-0884
Adjustable Pivot
63890-0886
Feed Positioning Screw
63890-0887
Pivot Clamp
63890-0899
Feed Adjusting Knob
63890-0999
Serial Tag
Release Date: 09-04-03
Revision Date: 01-15-13
UNCONTROLLED COPY
Qty
1
5
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
Page 32 of 50
FineAdjust Applicator
Item
49
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
STYLE C-FineAdjust ApplicatorOrder No. Engineering No.
Description
69028-0660
69028-0660
Compression Spring (Lee Spring # LC-032E-0MW)
N/A
N/A
#2 (.098 in. Diameter) by .125 in. Long Drive Screw
N/A
N/A
M3 by 5mm Long SHCS
N/A
N/A
M3 by 6mm Long FHCS
N/A
N/A
M3 by 12mm Long SHCS
N/A
N/A
M3 by 20mm Long SHCS
N/A
N/A
M4 by 8mm Long SHCS
N/A
N/A
M4 by 8mm Long Set Screw
N/A
N/A
M4 by 10mm Long Set Screw
N/A
N/A
M4 by 12mm Long BHCS
N/A
N/A
M4 by 16mm Long SHCS
N/A
N/A
M5 by 6mm Long BHCS
N/A
N/A
M5 by 8mm Long FHCS
N/A
N/A
M5 by 10mm Long SHCS
N/A
N/A
M5 by 35mm Long SHCS
N/A
N/A
M6 by 8mm Long Set Screw
N/A
N/A
M6 by 10mm Long BHCS
N/A
N/A
M8 by 20mm Long FHCS
N/A
N/A
3mm by 12mm Long Roll Pin
N/A
N/A
5mm by 20mm Long Dowel Pin
N/A
N/A
5mm by 25mm Long Dowel Pin
N/A
N/A
6mm by 10mm Long Dowel Pin
N/A
N/A
6mm by 20mm Long Dowel Pin
N/A
N/A
6mm by 45mm Long Dowel Pin
N/A
N/A
Extension Spring (Lee Spring #LE-041C-9)
N/A
N/A
Snap Ring 3.2mm ID by 7mm OD by .62mm Thick
** Available from an industrial supply company such as MSC (1-800-645-7270).
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
UNCONTROLLED COPY
Qty
4**
2**
1**
2**
1**
2**
3**
1**
1**
1**
1**
1**
1**
1**
4**
1**
2**
1**
2**
1**
1**
2**
2**
2**
1**
2**
Page 33 of 50
FineAdjust Applicator
4.3 STYLE C FineAdjust Applicator Assembly
73
16
59
30
45
63 (4)
(2)
62
11
47
69
58
(2)
56
67
68
54
(2)
71
43
15
31
(2)
21
72 (2)
74
41
42
(2)
14
8
47
(2)
10
9
52
18
44
40
25
33
13
46
53
70 (2)
61
12
See
Figure 4-9
50
48
34
51
49
26
32
(2)
(2)
65
20
49 (2)
35
(2)
60
4
19
6
22
7
(2)
STYLE C
Figure 4-8
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 34 of 50
FineAdjust Applicator
4.3 STYLE C FineAdjust Applicator Assembly (Cont.)
66
39
37
2
(3)
38
2
29
(2)
36
17
28
27
23
55
5
1
(2) 55
64
57
3
24
26
STYLE C
Figure 4-9
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
Reference
See Figure 4-8
UNCONTROLLED COPY
Page 35 of 50
FineAdjust Applicator
4.4 Troubleshooting
Symptom
Cause
Terminals
not feeding
Excessive Bellmouth
Cut-off plunger does
not return to
original position
Conductor crimp is
too loose
Conductor crimp is
too tight
Insulation crimp is
too tight
Terminal sticks
during crimping
Doc. No: TM-638004900
Revision: G
Solution
Terminals bent or damaged
Feed finger worn or not properly adjusted
Drag plate not holding terminal strip back
Terminal jammed under cover plate
Conductor punch worn
Track out of position
Cut-off plunger adjusted too tight against anvil
Cut-off plunger spring damaged or broken
Cut edges worn, plunger sides or
plunger retainer scored
Wrong tooling
Tooling worn or damaged
Wrong cam setting
Press shut height too high
Wrong tooling
Cam out of adjustment
Press shut height is too low
Cam out of adjustment
Wrong tooling
Press shut height is too low
Wrong tooling
Tooling worn or damaged
Gold plating and/or some high tensile materials
Release Date: 09-04-03
Revision Date: 01-15-13
Replace terminals
Check proper finger setting
Check compression springs
Clear and reinsert terminals
Replace
Adjust base and track for proper
alignment with the punches and anvil
Readjust
Replace spring
Remove scoring marks. If problem not
solved, replace with new cut-off parts
Replace with proper tooling
Replace tooling
Back off one setting
Calibrate press shut height
Replace with proper tooling
Readjust conductor cam
Calibrate press shut height
Readjust insulation cam
Replace with proper tooling
Calibrate press shut height
Replace with proper tooling
Replace tooling
Install a terminal oiler.
See Appendix C
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Page 36 of 50
FineAdjust Applicator
For more information use the Quality Crimping Handbook
There is no charge for this book, which can be found on the Molex Website (www.molex.com) or contact your
local Molex sales engineer
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 37 of 50
FineAdjust Applicator
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
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 38 of 50
FineAdjust Applicator
BEND UP
Terminal Terminology
BELL
MOUTH
BRUSH
CONDUCTOR
CRIMP
ROLLING
SEAM
INSULATION
CRIMP
TWISTING
STRIP
LENGTH
BEND
DOWN
CUT-OFF
TAB
CRIMP HEIGHT
A.1 Conductor Brush and Terminal Position
Figure A-1
A-1
Optimum crimp setup
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
(with a 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,
(with a long conductor brush length)
Cause:
Wire stop position incorrect.
Solution: Adjust wire stop to center the insulation in the transition area.
Figure A-4
Figure A-5
Figure A-6
A-4
Insulation under conductor crimp,
(with a 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,
(with the 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 under insulation grip,
(with the conductor brush too short)
Cause: Strip length too long.
Solution: Verify strip length specification and adjust as necessary.
Readjust wire stop for bench applications.
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 39 of 50
FineAdjust Applicator
Figure A-7
Figure A-8
A-7
Insulation edge under insulation crimp,
(with a good or wrong conductor brush length)
Cause:
Strip length too long.
Solution: Verify strip length specification and adjust as necessary.
Adjust the wire stop.
A-8
Insulation edge under insulation crimp,
(with a short or no conductor brush length)
Cause:
1) Wire stop position incorrect.
2) Operator not consistently using the wire stop.
Solution: 1) Adjust the wire stop to center the insulation in the transition area.
2) Operator training, reduce crimping rate.
A.2 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, cut-off tab flush with Insulation crimp
Figure A-2.2
1) Wrong conductor crimp tooling used.
2) Camber in the terminal strip.
Solution: 1) Verify that correct tooling is installed.
2) Adjust terminal track into the applicator.
A-2.3
No or small bell mouth, long cut-off tab
Cause:
Figure A-2.3
1) Wrong conductor crimp tooling used.
2) Camber in the terminal strip.
Solution: 1) Verify that correct tooling is installed.
2) Adjust terminal track towards the operator.
A-2.4
Excessive Bell mouth, good cut-off tab
Cause:
Figure A-2.4
1) Worn conductor punch tooling.
2) Incorrect 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) Worn cutoff tooling.
2) Incorrect cut-off tooling.
Solution: Replace tooling if necessary.
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 40 of 50
FineAdjust Applicator
A.3 Conductor 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 diameter.
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.
Solution: Adjust tooling back to target
(Refer to Section 2)
CALIPER
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) 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
MICROMETER
EXTRUSION
POINTS
Figure A-3.1
CRIMP HEIGHT MEASUREMENT
A.4 Insulation Crimp
A.4.1 Preferred Insulation Crimp
It is preferred that the insulation crimp completely
surrounds the outside diameter of the insulation. 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.
A.4.2
Figure A-4.1 Preferred Insulation Crimp
Figure A-4.2 Acceptable Insulation Crimp
Acceptable Insulation Crimp
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 41 of 50
FineAdjust Applicator
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) Troubleshooting of marginal insulation crimp that covers
in case of 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 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, or for thin-walled
insulations, 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
Figure A-4.4 Marginal Insulation Crimp
terminal grips will push the strands to the side. Yet, there is
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.
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 42 of 50
FineAdjust Applicator
A.5 Pull Force Testing
A.5.1 Pull Force Procedure
Wire connectors and soldering lugs for use with copper conductors. (Per UL486A November 15, 2003) 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 connectors 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.
6.
7.
8.
9.
10.
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.
Knot the non-terminated end of the wire.
Regardless of pull tester type, both wire and terminated end must be securely clamped. (Note: When clamping the
terminated end, do not clamp the conductor crimp.)
Activate pull test.
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.
Compare lowest reading to minimum pull force specification.
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. Change wire, if
necessary.
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.
A.5.2.2 Wire pulls out of conductor grip, crimp height good
Test Values For Pullout Test UL486A
Conductor Size
Pullout Force
AWG
mm2
N
LBF
30
0.05
6.7
1.5
28
0.08
8.9
2
26
0.13
13.4
3
24
0.20
22.3
5
22
0.324
35.6
8
20
0.519
57.9
13
18
0.823
89.0
20
16
1.31
133.5
30
14
2.08
222.6
50
12
3.31
311.5
70
10
5.261
356.0
80
9
8.367
400.5
90
Material Evaluation
Cause: 1) Terminal material thickness too small.
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 43 of 50
FineAdjust Applicator
2) Terminal serration depth/form wrong.
3) Terminal plating thickness wrong.
4) Gold plating application.
Solution: 1) Evaluate a new terminal.
2) Or Contact terminal manufacturer.
3) Evaluate selective Gold application.
Stripping Evaluation
Cause: Wrong strip length, poor conductor brush.
Solution: Adjust strip length.
Figure A-5.0 Pull Force Testing
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 44 of 50
FineAdjust Applicator
Appendix B
Statistical Process Control (Summary)
B.1
Crimp Process Control
B.2
Process Capability
B.3
Production
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 45 of 50
FineAdjust Applicator
B.1 Crimp Process Control
The crimp process is the interaction of a terminal, wire,
tooling, personnel, methods and procedures, and
environmental attributes that, when controlled, produce a
quality termination. Quality control is an important aspect
of quality crimping. It should not take excessive setup or
inspection time to implement, and can save a harness
manufacturer thousands of dollars in potential rework or
re-manufacturing.
The key to quality is to target nominal specifications while
continuously reducing variability. Achieving target is
determined by the adjustability of the tooling. The
FineAdjust applicator allows crimp height adjustment to
.005mm (.0002”) of target.
Variability is the slight changes that occur from crimp to
crimp. There are two types of variability, common and
special. Common sources of variation are those causes
that affect the process uniformly, and are created from
numerous small sources. Common variability is inherent
tolerances within a reel of wire or terminals. In addition,
common variability is created by the natural tolerances of
the stripping and crimping machines. Reduction of
variability at the common level normally has to come from
changes at the wire, terminal, and tooling manufacturer.
The second source of variability is referred to as special
cause. Unlike common cause, special sources of
variation occur irregularly and unpredictably. Without
checks throughout a run, a tool becoming loose after the
first hundred crimps, or a damaged tool from a jam, may
be undetected until thousands of crimps are made.
This section assumes that crimp height is being
measured with a resolution of .0025 mm (.0001”), and
pull force is measured with a resolution of 1 N (.25 lbf).
B.2 Process Capability
Molex qualifies each FineAdjust Applicator design for pull
force and crimp height.
This qualification is performed on a common wire
stranding, and is targeted at 2.0 Cpk. Before a new
crimping tool is put in production, it is recommended that
the customer using their specific wire in their process
should do a capability study. A capability study is based
on the assumption of a normal distribution (bell-type
curve). It provides an estimate on the probability of a
measurement being outside of specification.
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
Cpk
0.67
1
1.33
1.67
2
+/- Sigma
2
3
4
5
6
% Yield
95.45
99.73
99.99
99.99+
99.99++
PPM
45,500
2,699
63
0.57
0
PPM - Parts per million – number of potential defects
per million crimps produced.
A minimum of a 25-piece sample should be run off
the crimping process. The average and standard
deviation should be calculated for each specification.
A capability index (Cp) is defined by the formula
below. Cp may range in value from 0 to infinity, with
a larger value indicating a more capable process. A
value greater than (>) 1.33 is normally considered
acceptable.
Tolerance
6*Standard Deviation
The Cpk index indicates whether the process will produce
units within the tolerance limits. Cpk has a value equal to
Cp if the process is centered on the mean of specification;
if Cpk is negative, the process mean is outside the
specification limits; if Cpk is between 0 and 1 then some of
the 6 sigma spread falls outside the tolerance limits. If
Cpk is larger than 1, the 6 sigma spread is completely
within the tolerance limits. Cpk is calculated with the
lesser of the following formulas:
(USL - MEAN)
(LSL - MEAN)
3*Standard Deviation 3*Standard Deviation
USL = Upper Specification Limit, LSL = Lower
Specification Limit
Six sigma is a goal of many companies because it
represents virtually zero defects. The ability of a
company to achieve a six-sigma level is dependent on
the amount of common variability in their process. Hand
stripping of the wire will produce more variability than a
stripping machine.
A crimping hand tool will produce more variability than a
press and die set. Bench terminations will produce more
variability than a wire-processing machine.
A portion of the variability in crimping will come from what
instruments are used to measure the parts and the ability
of an operator to repeat the measurement. A crimp
micrometer will measure more accurately than a dial
caliper. An automatic pull force system will measure
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FineAdjust Applicator
better than a hook type scale. It is important that the
measurement gauge has enough resolution. Two
operators may measure the same part differently, or the
same operator may measure the part different when
using two types of gauges. A gauge capability study is
recommended to identify what part of the variability is
coming from measurement error. Micro-terminals
crimped to small wire sizes need a tight crimp height
range to maintain pull force. The variability from
measurement error can keep Cpks low.
Production (Control Charting)
It should be normal procedure for the operator to visually
fan each bundle of crimped wires and visually check bell
mouth, conductor brush, insulation position, and cut-off
tab length and insulation crimp height. Crimp height
should be checked throughout the run. The frequency
of each check is determined by the risk
you wish to
take for scraping parts. A check every 250 to 500 parts is
recommended.
Control Charting
Crimp height is normally control charted since it is a quick
nondestructive measurement and is critical for the
electrical reliability of the termination.
The capability of the crimping tools should be reconfirmed if the production data is significantly different
from the capability study.
There are three primary purposes for control charting.
First, the numbers of setup samples are normally small,
and its statistical value is limited. Second, since special
cause effects on a process are irregular and
unpredictable, it is necessary to have a means of
catching changes in the process as soon as they occur.
This prevents thousands of terminations from being
scrapped after the run is over. Third and most important,
this data is necessary to assess and improve the crimp
process.
B.3 Production
Once the level of capability is established, the tool is
ready for production.
Many harness manufacturers run only a few hundred or
few thousand wires at one time. In this case, it is not
practical or economical to run a twenty-five-piece
capability with every set-up.
Setup Confirmation
Once the tooling process is set-up and the wire size is
not changing, keep one control chart for wire color
changes, wire length changes, terminal material changes,
or setup adjustments. Record the data point on the chart
before a crimp height adjustment is made. If data is
recorded after each adjustment, the process most likely
will assume control and provide little data for improving
the process. Write as many notes on the chart as
possible.
The only truly effective and economically sensible
manner of managing a manufacturing process is to
understand, monitor, and reduce sources of variability
inherent to the process itself. Every minute the process
is down for setup or adjustment is unproductive.
After the setup of the crimping process, crimp five
terminals with a loose insulation crimp. Visually inspect
or measure bell mouth, cut-off tab length, conductor
brush, insulation position, and conductor crimp height.
Make the appropriate adjustments to the machine.
(Refer to trouble shooting sections if needed). After all
adjustments have been made, crimp five more samples
for pull force evaluation. The pull force is a good
indicator for cut or nicked strands, short conductor brush,
small bell mouth, or incorrect crimp height. Calculate the
average. Compare the average and minimum reading
with the capability study data.
After the pull force has been confirmed, set the insulation
crimp to the appropriate setting. Re-check crimp height
and make the proper adjustments if necessary.
The range is considered the maximum reading minus the
minimum reading. With a crimp micrometer and an
experienced operator, the range for crimp terminations is
normally only a few ten thousandths of an inch. This data
becomes the first point on the control chart.
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
Thousandths
Crimp Height
Crimp five more samples and document the average
crimp height, the maximum reading, and the minimum
reading.
Example Control Chart
31.5
Sample
30.5
Contol Limit
Control Limit
Upper Specification
29.5
Lower Specification
28.5
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
Measurements
X and R Chart
Control Limit for sample of 5 = Avg (Avg. of 5 readings)
+ .577 x Avg (Ranges)
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FineAdjust Applicator
What does this sample chart tell us? A process shift
occurred between measurement 12 and 13. This type
of shift could occur due to a change in wire, a change in
terminal lots, a jam in the machine that damaged the
tooling, a change in operators, or an adjustment to the
insulation crimp. Since the measurements are still
within specification, would you stop production to adjust
crimp height?
A shift in the process due to a change in material may
arrant a crimp height adjustment. A shift after a jam
would not indicate an adjustment, but a close evaluation
of the tooling. A shift in the process between operators
would not indicate an adjustment, but an evaluation of
measurement capability.
FineAdjust Control Chart
31.5
The idea of the control chart is to identify what caused
the shift to justify if an adjustment to the process is
warranted.
The FineAdjust Applicator is extremely easy to adjust. It
is just as important to chart and document process
control with the FineAdjust applicator.
If the process shift is due to a jam or a change in
operators, more evaluation may be necessary than an
adjustment.
Many crimping processes have been producing product
within specification for decades. Today, with statistical
process control, the philosophy of quality is being within
specification is being replaced by being on target with
continuous reduction in variability. Control charting is a
tool that truly allows a company to understand their
process.
Thousandths
Crimp Height
31
Sample
30.5
Contol Limit
30
ATTENTION
Control Limit
Upper Specification
29.5
Lower Specification
29
Reference must always be made to product application /
crimp specification to determine crimp parameters.
28.5
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
Measurements
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
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Page 48 of 50
FineAdjust Applicator
Appendix C
Options
1
Oiler
Doc. No: TM-638004900
Revision: F
Release Date: 09-04-03
Revision Date: 10-15-09
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Page 49 of 50
FineAdjust Applicator
Terminal Oiler
For FineAdjust and
Mini-Mac Applicators
Application Tooling
Information Sheet
Order No. 63890-0719
Terminal Oiler
To install a Terminal Oiler (Order No. 63890-0719) to any
FineAdjust or Mini-Mac Applicator, use the following
procedure.
1. Remove lid assembly from the oiler jar.
2. Remove upper oiler nut from lid assembly.
3. Place oiler mtg. bracket over tube, replace upper nut,
and tighten securely.
FRAME
M5 X 12LG
BHCS
4. Place lid assembly with mtg. bracket on the oiler jar
and turn until hand tight. Do not over tighten.
5. Mount terminal oiler assembly with bracket on the
frame of the FineAdjust or Mini-Mac Applicator.
APPLICATOR
6. Recommended lubricant oil:
NUT-UPPER
Product Name: 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
63890-0713
MTG. BRACKET
LID
ASSEMBLY
JAR
7. For replacement wicks use part no. 63890-0727 (package of 25).
Visit our Web site at http://www.molex.com
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
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Page 50 of 50
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