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tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 1 of 47 revision: d revision date: 12-0-02-09 tm-3000 universal press tm-4000 universal press use with molex fineadjust, mini-mac applicators and the molex tape terminal crimp module instruction manual order no.63801-7299 description operation maintenance
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 2 of 47 revision: d revision date: 12-0-02-09 warning never use this machine without the guards or safety devic es that are intended to prevent hands from remaining in the die space. run ning this machine without guards, under any circumstances, can cause serious injury. never lift this press without the aid of mechanical lift ing devices. never operate, service, or adjust this machine or instal l applicator dies without proper instruction and without first reading and un derstanding the instructions in this manual. never service this machine while it is connected to any electrical power source. disconnect power by unplugging the press from its p ower source and from the compressed air supply. never install or remove applicator dies with the motor running, or air supply connected. caution this press is shipped from the factory at a shut h eight of 135.80mm (5.346). failure to hand cycle the press when installing app licators can cause severe damage to the tooling and/or press. caution molex crimp specifications are valid only when use d with molex terminals, applicators and tooling. work safely at all times for service, contact your local molex sales office molex application tooling group 2200 wellington court lisle, illinois 60532 tel: 630-969-4550 fax: 630-505-0049
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 3 of 47 revision: d revision date: 12-0-02-09 table of contents section 1 general description 2 installation 3 setup - operation 4 maintenance and troubleshooting 5 parts list, assembly drawings, electrical schematic s 6 ec declaration of conformity appendix a options 1. taped terminal crimp module
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 4 of 47 revision: d revision date: 12-0-02-09 section 1 general description 1.1 description 1.2 features 1.3 technical specifications 1.4 delivery check 1.5 tools
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 5 of 47 revision: d revision date: 12-0-02-09 general description 1.1 description the 63801-7200 (120v ac version), the 63801- 7300 (240v ac version) tm-3000 universal press and the 63801-7600 (240v ac version) tm-4000 universal press are economical, electrically- operated, single-cycle and split cycle direct drive presses. they are designed to provide an effective method of applying a wide range of side-feed and rear-feed terminals to a pre-stripped discrete wire or cable. both the tm-3000 and the tm-4000 are suited to mid-volume semi-automatic operations. production flexibility is obtained using interchangeable fineadjust or mini-mac applicators and most industrial standard applicators. these presses will complete one crimping cycle with each depression of the foot pedal and two depressions for split cycle. safe operation is provided by an interlock switch that renders the press inoperative if the safety guard is opened or removed. 1.2 features utilizes both fineadjust and mini-mac applicators side and rear feed, and most industry standard applicators press is shipped set to industry shut height of 135.80mm (5.346) ideal for mid-volume, semi-automatic applications meets o.s.h.a. safety standards is ansi- z535.2-2002 compliant totally enclosed for operator safety, including a power interlock switch for the front guard resettable counter for accurate batch counting modular solid state controls with an easy plug in power cord and foot switch. ce certified 1.3 technical specifications dimensions with reel mounted height 1210mm (47.60) width 648mm (25.50) depth 559mm (22.00) unpacked weight 100kg (220 lb) power requirements voltage: 63801-7200-120v ac 60 hz voltage: 63801-7300-240v ac 50 C 60 hz voltage: 63801-7600-240v ac 50 C 60 hz note: if 240v power is not available, then 120v power may be used with an appropriate (1000va minimum) step-up transformer. recommended step-up transformer: allied electronics #836-0181 (phone: 1-800-433-5700). pneumatic requirements (air feed applicators only) 75 psi min. (366 kn/cm 2 ) min. 1.0 scfm (28.3 l/min) ? npt inlet 12.7mm (1/2) supply pipe minimum. production rate 2400 terminations per hour maximum, depending on operator skill and wire length. processing capability tm-3000 press output = 4000 lbf (18kn). copper conductors up to 10 awg (5.0mm2) in solid or stranded wire. tm-4000 press output = 7000 lbf (31kn). copper conductors up to 4 awg (21.0mm2) in solid or stranded wire. sound level operator will be exposed to less than 85 dba. 1.4. delivery check after removing the packaging band, the top and sides of the box should lift off easily. the follow ing items are included in this package : quantity main press body 1 reel support assembly 1 t wrench for manual cycling 1
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 6 of 47 revision: d revision date: 12-0-02-09 carton contents quantity 69018-6237 powercord (for 63801-7200) 1 or 62500-1774 power cord 220v 10a (for 63801-7300 and 63801-7600) 1 63801-7271 foot pedal 1 tm-638007299 instruction manual 1 1.5 tools the following tools are recommended for setup and adjustments to the applicator in this press metric hex wrench set small standard screwdriver adjustable wrench needle nose pliers crimp micrometer eye loupe (10x) wire stripper/cutter english hex wrench set for some non-metric applicators
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 7 of 47 revision: d revision date: 12-0-02-09 section 2 installation 2.1 lifting/mounting 2.2 reel support 2.3 foot pedal and power connection 2.4 pneumatic supply hook-up 2.5 terminal feed guide 2.6 function test 2.7 safety and work area check
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 8 of 47 revision: d revision date: 12-0-02-09 2.1 lifting/mounting warning : this press weighs over 100 kg (220 lb); it should not attempt to be lifted by one individual. mechanical lifting devices should be used. a person lifting the press can sustain severe back or other injuries. a lifting hook is provided on the top of the press. 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 12mm (.50) and verify that the press is well balanced. upon verification, the press can be lift ed onto a sturdy workbench. access to the back of the machine is required for manual cycling. a wooden bench that is a minimum of 25mm (1.00) thick will offer quiet vibration-free operation. f or thinner or sheet metal tops, the tm-3000 can be attached to the table with two 12mm bolts. bolts are not supplied by molex. 2.2 reel support install the reel support in the hole located on the top of machine frame. for rear feed, rotate the reel supp ort as required. see figure 2-3. loosen the m10 set screw that holds the reel support. pull up from th e hole and rotate for the proper feeding orientation. then slide down back into the hole and tighten the m10 set screw. 2.3 foot pedal and power connection connect the 3-pin plug for the foot pedal in the re ar of the press control assembly. turn the locking ring clockwise until tight. connect the power cord plug to the socket in the back of the control assembly. use a grounded electrical outlet as the power source. see figure 2-2. foot pedal assembly press control assembly figure 2-1 oiler assembly motor reel support assembly terminal guide power cord work bench lift hook work light
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 9 of 47 revision: d revision date: 12-0-02-09 2.4 pneumatic supply hook-up a compressed air supply is required if air feed or other air powered applicators will be used. the press comes equipped with an air supply system, which consists of filter, regulator, lubricator and a val ve to actuate the air feeds at the proper time in the pre ss cycle. due to the considerable types of air connection and quick connect fittings available; molex only suppli es the press with a 1/4 npt female threaded fitting. the customer may attach whatever type of air connection s that are commonly used in their plant to this port. the minimum flexible tube size used to connect the press should be 8mm or 5/16 to assure adequate flo w rate. a filter-regulator-lubricator unit is supplied to p roperly condition the incoming air. the filter will remove particulate and moisture from the air that can dama ge or reduce the life of cylinders and valves. this f ilter and bowl should be serviced on a regular schedule. (see section 4.1) the filter has an automatic drai n at the bottom of the bowl that will automatically open and expel fluid when the bowl is getting full. it is recommended that, a 6mm or 1/4 flexible tube, be attached to the drain hose barb and run to a contai ner if the air system contains excessive moisture. the regulator adjusts the pressure of the incoming air to what the applicators require usually 60-80 psi ( refer to the applicator manual for recommended pressures. ) adjustment is accomplished by pulling up on the kno b, rotating it until the gauge indicates the desired pressure, then pushing it down to lock the setting. a lubricator is supplied for those applicator air f eeds that need lubrication. molex air-feed applicators do not require lubrication. the lubricator is shipped without lubricant in it. to use, fill the lubricat or (make sure the main air supply is disconnected or that th e slide valve provided is in the off position before adding lubricant) through the fill plug on the top of the unit, with high quality sae 10 w oil. the lubricator has a graduated dial on top, turn the dial to the 1 or 2 setting. caution: do not over lubricate. only a very small amount of lubricant is required to assure smooth operation. excess lubricant is exhausted to the atmosphere. if lubrication is not required set the dial to 0 to turn off the lubricator. 2.5 terminal feed guide depending on side or rear-feed applications, the terminal guide plate and bracket must be reposition ed. the press is set for side-feed applicators when shipped from the factory. when rear-feed applicato rs are used, the two m6 bhcs from the terminal guide- mounting bracket are to be removed. see figure 2-3 . the guide bracket is rotated 180 degrees and the assembly is then mounted on the two standoffs in th e pull up from hole, rotate and slide down into hole reposition terminal guide figure 2-3 remove m6 bhcs and remove terminal guide loosen m10 sss in front of press power cord plug figure 2-2 footswitch cord
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 10 of 47 revision: d revision date: 12-0-02-09 shut height gauge press quick change mounting plate figure 2-4 press figure 2-5 fuse holder rear of the press with the two m6 shcs. see figure 2-3. 2.6 function test when the press is shipped from the factory, it is s et to the industry shut height of 135.80 mm (5.346) w ith a calibrated load gauge. the press shut height gauge is spring loaded to give an accurate reading on the press shut height. see figure 2-4. molex recommends hand cycling the press each time an applicator is installed. see section 3-3. caution: always manually cycle the press before restoring power to the machine. 2.6.1 verification of press shut height this press comes factory set at an industry standar d shut height of 135.80mm (5.346). a label is attached to the front of each press indicating the factory settings. this press has an adjustable shu t height, see section 3.4.3 for crimp height adjustme nt. always return the press to the factory setting on t he label before installing applicators to avoid toolin g damage. check the factory setting periodically wit h a calibrated shut height gage. shut height gauges may be purchased from: artos eng. 602-581-0070 komax corp. 847-537-6640 2.7 safety and work area check check that the crimping position is ergonomic for the operators size. a bench height of 762.00 to 813.00mm (30.00 to 32.00) will provide operator comfort, and allows both feet to rest on the floor. the foot pedal should be placed in a comfortable position. check that the press position is located approximately 150mm (6) 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. caution: molex recommends that the operator and observers wear eye protection when the press is in operation or being serviced. the fuse is located on the control panel. to replace the fuse (10amp on 110 v models and 5amp on 220v models), turn the holder in the direction as shown. turn clockwise to secure holder in place when replaced. see figure 2-5.
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 11 of 47 revision: d revision date: 12-0-02-09 section 3 setup and operation 3.1 applicator installation 3.2 air feed applicator installation 3.3 manually cycling the press 3.4 operation
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 12 of 47 revision: d revision date: 12-0-02-09 3.1 applicator installation power down the press by turning off the power switch located on the control panel. note: once the press guard is open the guard interlock switch will disconnect power to the motor . steps 1. swing the press guard open. 2. verify that the applicator is correctly tooled for the terminal being used. (reference specification sheets supplied with the applicator). 3. clean the press quick change mounting plate of scrap or chips that may interfere with the applicator installation. 4. using a 4mm hex wrench, turn the m5 shcs clockwise until the locking clamp is fully opened. 5. locate the applicator lug bolt in the press yoke. see figure 3-1. 6. align the applicator base plate slots with the locator clamps on the press quick change plate. 7. to lock applicator, turn m5 shcs counter clockwise until tight. 8. confirm that the applicator is secured properly. 3.2 air feed applicator installation power down the press by turning off the power switch, located on the control panel. note: once the press guard is open the guard interlock switch will disconnect power to the motor . warning: when using air feed applicators, always use the slide valve supplied to shut-off and vent a ir pressure to the air feed before servicing. the gua rd interlock switch does not remove air pressure. if an air feed is jammed and air pressure is not removed before servicing, the feed could move unexpectedly and cause injury. steps 1. swing the press guard open. 2. verify that the applicator is correctly tooled for the terminal being used. (reference specification sheets supplied with the applicator). 3. clean the press quick change mounting plate of scrap or chips that may interfere with the applicator installation. 4. using a 4mm hex wrench, turn the m5 shcs clockwise until the locking clamp is fully opened. 5. locate the applicator lug bolt in the press yoke. see figure 3-1. 6. align the applicator base plate slots with the locator clamps on the press quick change mounting plate. quick change plate locator clamps locking clamp use 4mm hex wrench figure 3-1 engage press yoke base plate lug bolt to main air supply shut-off sleeve figure 3-2 filter-reg-lubricator slide left to shut off
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 13 of 47 revision: d revision date: 12-0-02-09 figure 3-4 foot switch cord motor turn clockwise t-handle wrench power cord port b figure 3-3 air-feed applicator port a advances retracts filter-reg. lubricator to main air supply 7. to lock applicator, turn m5 shcs counter clockwise until tight. 8. confirm that the applicator is secured properly. 9. disconnect the air supply from the filter-regulator - lubricator supplied with the press, by sliding the shutoff valve sleeve to the left, as shown in figur e 3-2. remove the plugs from the fittings on the air valve. do not discard the plugs; when the air applicator is not being used, the fittings should b e plugged. note : when not using an air feed applicator always shutoff the air supply to the filter-regulator-lubr icator by sliding the shutoff valve sleeve to the left, th e opposite direction of the airflow, as shown in figu re 3-2. note : some applicators feed terminals in the retracted position, for those air tubes must be reversed. in addition, some applicators are air advance and spring return, on these applicators one port will need to be plugged. 10. insert the a port of the air valve with the tube that retracts the feed mechanism of the applicator. see figure 3-3. 11. insert the b port of the air valve with the tube that advances the feed mechanism of the applicator. see figure 3-3. note : when using the 64016-2000 crimp module, set the feed selector on the control panel to single or double, depending on the spacing of the taped terminals. see figure 3-5. 12. connect the main air supply to the filter reg- lubricator. (custumer supplied fitting) 13. adjust the regulator to 75-80 psi (366-390 kn/cm 2 ). 14. check that the tubing for the applicator is properl y connected by dry cycling the press and observing the feed motion. 3.3. manually cycling the press turn off the power switch which is located on the control panel to power down the press. note: once the press guard is open the guard interlock switch will disconnect power to the motor . hand cycling the press is necessary to confirm correct tool alignment and terminal feed adjustment. it also gives the setup person the ability to step through the press cycle manually. steps 1. insert the 8mm square socket t-handle wrench through the access hole in the center of the rear cover on the motor and locate it in the shaft motor . see figure 3-4.
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 14 of 47 revision: d revision date: 12-0-02-09 toggle switch to full cycle push motor on figure 3-5 power on feed selector wire stop pre-stripped wire figure 3-6 guard 2. rotate the wrench clockwise. this turns the motor and moves the ram down and up. 3. always return the press back to top dead center insuring that the ram is in the start up position. 4. remove the t-handle wrench. note: when the t-handle is put into the motor shaft the motor turns off automatically. 3.4. operation 3.4.1 full cycle operation caution: make sure the press guard is in position and all setup procedures are followed. follow the safety and work area instructions. steps: 1. push the toggle switch on the control panel to ful l cycle. see figure 3-5. 2. turn the power switch on, the power indicator li ght will light up. 3. press the motor on push button, the motor indicator light will light up. after a 5 second de lay the press will be ready to cycle. 4. place the prestripped wire through the slot in the press guard and push until it contacts the wire sto p. see figure 3-6. 5. press the foot pedal down once. use a sweeping motion to the right with the crimped wire and remove. 6. check the crimped wire and confirm that it meets th e applicator specifications and visual inspection. 7. repeat steps 4 and 5 for the next crimp. 3.4.2 split cycle operation desription: the split cycle is used mostly for closed barrel terminals. this makes it easier to locate the term inal before crimping the wire. the punch/ram will close partially to assist in locating the terminal for th e termination. then the wire can be placed into the terminal and be terminated. to setup the machine for split cycle push the toggle switch on the contr ol panel to split cycle. see figure 3-5. steps: 1. depress the foot switch once, the ram will lower partially, positioning the terminal for termination . 2. place the prestripped wire into the terminal. 3. depress the foot switch a second time. the ram wil l complete its downward stroke and return to the top position to complete the cycle of terminating the crimp. caution: make sure the press guard is in position and all setup procedures are followed. follow the safety and work area instructions.
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 15 of 47 revision: d revision date: 12-0-02-09 adjustable dial loosen m6 shcs figure 3-8 loosen m6 shcs 1.52mm (.06) max. gap m4 jam nut figure 3-7 prox sensor m12 jam nut prox bracket toggle switch to split cycle split cycle ram adjustment when setting up an applicator for split cycle opera tion it may be necessary to adjust the ram for a partially closed position (1 st position), so the terminal will be captivated in the punch and not terminated. for adjustment, t he prox sensor located on the left side of the ram cov er, needs to be adjusted. see the following steps: steps : 1. depress the foot switch once, with the terminals in the applicator. see where the punch is located in the 1 st position of the cycle. 2. if the punch is too high and does not center the terminal so that the prestripped wire can be insert ed in the closed barrel or the punch is too low partia lly crimping the terminal, the prox sensor needs to be adjusted. 3. open the press guard. 4. loosen the two m12 jam nuts on the split cycle prox , located on both sides of the prox bracket. then loosen the m4 jam nut holding the m4 x 25 shcs. turn the screw clockwise to raise the prox or counter-clockwise to lower the prox. see figure 3- 7. raise the prox if the punch is partially crimping t he terminal; or lower the prox if the ram is not closi ng far enough and not centering the terminal punch. 5. retighten the m4 shcs and the (2)m12 jam nuts positioning the prox for the 1 st position of the split cycle. see figure 3-7. 6. close the press guard. 7. repeat step 1 to check for the correct position of the ram. (be sure ram is at top-dead-center first.) note: the gap between the prox and the ram should be 1.52mm (.06) max. see figure 3-7. caution: always return the ram to the top dead center position or start position of the cycle befo re recycling the press. this is done by manually cycling the press. see section 3.3. 3.4.3 crimp adjustment see section 2.6.1 for industry standard shut height . crimp adjustment full and split cycle if crimp adjustment is required and cannot be made by the cam adjustment on the applicator, the fine adjustment dial on the press ram can be adjusted by following the steps below. steps: 1. open the press guard. 2. loosen the four m6 shcss on the front of the press. 3. rotate the adjustment dial to the right to raise cr imp height or to the left to decrease. dial indicator lines represent increments of .05mm (.002). see figure 3-8.
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 16 of 47 revision: d revision date: 12-0-02-09 4. when adjustment is complete, retighten the four m6 shcss. 5. close the guard. 6. place a prestripped wire into the terminal and terminate under power. examine the quality of the crimp. 7. repeat steps 1 thru 6 if the desired crimp is not achieved. use caution adjusting the ram downward. over adjustment in this direction may cause tooling damage or breakage. always return the adjustment to the factory setting before installing another applicator, or recalibrat ing shut height. see section 2.6.1.
molex taped terminal crimp module order no: ats-638017299 release date: 06-06-05 uncontrolled copy page 17 of 47 revision: b revision date: 10-06-08 section 4 4.1 maintenance 4.2 oiler 4.3 troubleshooting
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 18 of 47 revision: d revision date: 12-0-02-09 oil cup grease fitting figure 4-8 4.1 maintenance power down the press by pressing the power button to off o located on the control panel. for efficient operation the press should be cleaned daily with a soft bristle brush to remove any carrier strip debris an d terminal plating dust from the tooling area. maintenance schedule the following is offered as a general guideline for maintenance. tool life can be increased with good maintenance practic es or decrease with lack of maintenance. item frequency cycles frequency time materials air filter 100,000 weekly clean bowl and sintered filter with denatured alcohol air lubricator 100,000 weekly sae 10w oil. check and refill if used ram 25,000 daily sae 10w oil oil cup (top of ram) main bearing 25,000 daily grease fitting right side of press bearing lube cleaning 25,000 daily use soft bristle brush on applicator mounting plate 4.2. oiler description the wick action oiler is included with the press. the oiler applies a thin coat of lubricant to the terminals, which helps with feeding and better release from terminat ion 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. the oiler should only be used on applicators that require lubrication for smooth tro uble- free operation. oiler position adjust the position of the oiler unit using the mou nting screw that attaches the oiler to the quick ch ange mounting plate. simply loosen the screw, slide the unit to the desired position, and tighten the screw. the u nit can be removed and placed on the rear side of the quick change mou nting plate for rear-feed applications. lid tube wick (pkg of 25 #638900727) mounting bracket jar (oil reservoir) figure 4-9 oiler assembly
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 19 of 47 revision: d revision date: 12-0-02-09 oiler wick adjust the height of the oiler wick by pulling up o r pushing down on the wick to the appropriate heigh t. the wick can be moved using pliers or simply grab it with your f ingers. filling the reservoir while firmly holding the lid, screw the jar (oil re servoir) counter clockwise until it is removed. fi ll the jar with the desired lubricant oil and replace the lid. replacing the wick while firmly holding the lid, screw the jar oil res ervoir) counter clockwise until it is removed. fee d 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 lubricant oil recommended oil: transdraw b-19 vendor: sure lubricants inc. 356 south lively boulevard elk grove village, il 60007-2010 phone: 888-787-3582 fax: 847-956-6655 e-mail: surelub@aol.com 4.3 troubleshooting symptom cause solution power/power cord failure check supply loose connection refer to control schematic guard interlock switch disengaged re-install guard fuse blown replace on/off switch failure replace motor failure replace t-wrench not removed from motor removed t-wrench fr om motor control pcb not working replace solid state relay not working replace motor will not run control board for motor repair or replace guard interlock switch disengaged re-install guard faulty footswitch check connection. repair or repl ace control pcb not working replace press will not cycle fuse blown replace press partially cycles toggle switch set to split cycle reset the toggle s witch to full cycle
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 20 of 47 revision: d revision date: 12-0-02-09 section 5 5.1 parts list 5.2 assembly drawings 5.3 electrical and pnuematic schematics
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 21 of 47 revision: d revision date: 12-0-02-09 5.1. parts list tm-3000 main assembly (figure 5-1 and 5-2) item no. order no. ref. no. description quantity 1 63801-7200 fe-2tc (110vac) universal press (110vac) see notes below 2 63801-7300 fe-2tc (220vac) universal press (220vac) see notes below 3 63801-7201 a01 press frame 1 4 63801-7202 a02 ram 1 5 63801-7203 a03 follower 1 6 63801-7204 a04 front cap 1 7 63801-7205 a05 press face plate 1 8 63801-7206 a06 switch-tdc 1 9 63801-7207 f05 flag pickup 1 10 63801-7208 a08 access cover 1 11 63801-7209 f17 oil fill cap 1 12 63801-7210 a10 flag-position 1 13 63801-7211 (m) b01 split cycle prox 1 14 63801-7212 (m) b03 guard handle 1 15 63801-7213 b02 yoke adapter 1 16 63801-7214 b03 mounting block cover 1 17 63801-7215 b04 mounting block 1 18 63801-7216 (m) a01 press yoke 1 19 63801-7217 b01 press shaft 1 20 63801-7218 a021-r80 shaft e-ring 1 21 63801-7219 a007-na6911 front bearing 1 22 64016-2501 --- guard slide 2 23 64016-2502 --- guard front 1 24 64016-2503 --- front guard insert 1 25 63801-7281 (m) rear guard 1 26 63801-7222 (m) a02 quick change plate 1 27 63801-7283 (m) side guard 1 28 63801-7224 (m) name plate (universal press) 1 29 63801-7284 (m) hinge mounting bracket 1 30 63801-7285 (m) guard hinge 2 31 63801-7286 (m) a06 guard sensor bracket 1 32 63801-7287 (m) guard bracket 1 33 63801-7288 (m) stand-off, guard side 3 34 63801-7631 --- control panel 1 35 63801-7232 f12 eye bolt 1 36 63801-7233 c04 stand off 2 37 63801-7234 c01 terminal guide 1 38 63801-7235 c03 guide 2 39 63801-7236 c02 terminal guide bracket 1 40 63700-3845 (m) rotor magnet 1 41 63801-7237 f06 press lamp 1 42 63801-7238 e05 lamp mounting bracket 1 43 63801-7239 (m) b02 guard switch prox 1 44 63801-7240 (m) oiler assembly (figure 5-3) 1 45 63801-7241 f07a * ** * bulb-110 vac 1 46 63801-7242 f07b * ** ** ** * bulb-220 vac 1 47 63801-7243 (m) a03 alignment block 2 48 63801-7244 (m) a04 locking clamp 1 49 63801-7245 (m) a05 clamp retainer 1
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 22 of 47 revision: d revision date: 12-0-02-09 tm-3000 main assembly (figure 5-1 and 5-2) item no. order no. ref. no. description quantity 50 63801-7246 a021-r68 e-ring 2 51 63801-7247 a007-a6909zz rear bearing 2 63801-7248 (m) f01 motor with gear reducer 1 52 63801-7648 (m) f01 * ** ** ** ** ** * motor with gear reducer 1 53 63801-7249 a021-s45 small e-ring 1 54 63801-7250 f02 * ** * motor controller 110vac 1 55 63801-7251 f02a * ** ** ** * motor controller 220 vac 1 56 63801-7252 f03 relay - motor on 1 57 63801-7253 f04 transformer (18v) 1 58 63801-7254 (m) e04 pcb-machine 1 59 63801-7256 e03 sensor flag -motor 1 60 63801-7257 f08 motor shutoff prox 1 61 63801-7258 e02 prox motor shutoff bracket 1 62 63801-7259 a09 rear cover 1 63 63801-7260 d01 reel support 1 64 63801-7261 d02 reel boss 2 65 63801-7262 d03 reel disc 2 66 63801-7263 d04 reel-spring 1 67 63801-7269 (m) filter-regulator-lubricator 1 68 63801-7270 (m) air valve-3 way 1 69 63801-7271 (m) foot switch with cord 1 70 69018-6237 --- * ** * power cord (110vac) 20 amp 1 71 62500-1774 --- * ** ** ** * power cord (220vac) 10 amp 1 72 63801-7272 (m) slide valve 1 73 63801-7273 (m) label (lightning bolt) 1-1/2 triangle 1 74 63801-7274 (m) label (eye-glasses) 1 75 63801-7275 (m) label (caution) 2 76 63801-7276 (m) plug (1/4 tube) 2 77 63801-7277 (m) elbow male (1/4 tube) for filter-reg.-lubricat or 1 78 63801-7278 (m) elbow male (1/4 tube) for 3-way valve 3 79 63801-7279 (m) terminal guide standoff 4 80 63801-7600 --- universal press (220vac) see notes below note: 1. for tm-3000 press 220vac use assembly no. 63801-730 0. 2. for tm-4000 press (220vac only) use assembly no. 63 801-7600. 3. all parts for both 63801-7200 and 63801-7300 presse s unless otherwise specified. 4. * ** * indicates parts for 63801-7200 (110vac) press only. 5. * ** * * ** * indicates parts for 63801-7300 (220vac) press only. 6. * ** * * ** ** ** * indicates parts for 63801-7600 (220vac) press only.
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 23 of 47 revision: d revision date: 12-0-02-09 72 14 figure 5-1 (3) 77 67 29 22 31 74 40 79 m12 jam nut (2) (ref) 26 43 13 44 76 30 32 35 23 (2) (4) 33 25 78 (3) (2) 34 (2) 24 27 75 28 68 5.2. assembly
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 24 of 47 revision: d revision date: 12-0-02-09 26 7 61 11 4 5 20 19 21 49 6 16 15 17 18 47 12 3 37 55 36 38 46 65 62 64 63 45 39 51 10 48 9 60 59 50 52 8 56 57 53 70 69 29 42 41 figure 5-2 (2) (2) (2) (2) (2) (2) (2) 110v 220v 110v 220v 54 58 110v 220v ref 71 66 73 5.2 assembly (continued)
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 25 of 47 revision: d revision date: 12-0-02-09 1 3 4 2 3 6 5 assembly (continued) figure 5-3 oiler assembly item no. 43 (63801-7240) item no. description quantity 1 oiler wick 1 2 oiler lamp tube 1 3 oiler lamp tube nut 2 4 wide mouth glass jar 1 5 oiler glass jar lid 1 6 oiler bracket 1
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 26 of 47 revision: d revision date: 12-0-02-09 5.3. electrical schematic
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 27 of 47 revision: d revision date: 12-0-02-09 5.3. pnuematic schematic americas headquarters lisle, illinois 60532 u.s.a. 1-800-78molex amerinfo@molex.com far east north headquarters yamato, kanagawa, japan 81-462-65-2324 feninfo@molex.com far east south headquarters jurong, singapore 65-6-268-6868 fesinfo@molex.com european headquarters munich, germany 49-89-413092-0 eurinfo@molex.com corporate headquarters 2222 wellington ct. lisle, il 60532 u.s.a. 630-969-4550 fax: 630-969-1352 visit our web site at http://www.molex.com figure 5-5
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 28 of 47 revision: d revision date: 12-0-02-09 section 6 6.1 ec declaration of conformity
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 29 of 47 revision: d revision date: 12-0-02-09 6.1 ec declaration of conformity
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 30 of 47 revision: d revision date: 12-0-02-09 for more information use the quality crimping handb ook and industrial crimping handbook there is no charge for these books, they can be fou nd on the molex website (www.molex.com) or contact you local molex sales engineer
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 31 of 47 revision: d revision date: 12-0-02-09 appendix a options 1. taped terminal crimp module
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 32 of 47 revision: d revision date: 12-0-02-09 taped terminal crimp module order number 64016-2000 instruction manual description operation maintenance
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 33 of 47 revision: d revision date: 12-0-02-09 warning never use this crimp module in a press without guards or safety devices that are intended to prevent hands from remaining in the die space. never operate, service, install, or adjust this crimp mo dule without proper instruction and without first reading and understan ding the instructions in this manual and all applicable press manuals. never install or service this crimp module while connecte d to any electrical power source. disconnect power by unplugging the p ress from its power source. caution the molex crimp module is designed to operate only in the molex tm-3000 or tm-4000 presses. installation in other crimp press es can cause severe tool damage. it is advisable that before installation, a check of the press shut height be performed. molex will not be liable for any damages as a result of installation in a press with an improperly set s hut height. caution molex crimp specifications are valid only when use d with molex terminals and molex application tooling. work safely at all times for service, contact your local molex sales office molex application tooling group 2200 wellington court lisle, il 60532 tel: (630) 969-4550 fax: (630) 505-0049 visit our web site at http://www.molex.com
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 34 of 47 revision: d revision date: 12-0-02-09 table of contents section 1 general description 2 setup, adjustments, and operation 3 maintenance 4 parts list, assembly drawings, troubleshooting, a nd guard upgrade appendix a pull force testing
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 35 of 47 revision: d revision date: 12-0-02-09 section 1 general description 1.1 description 1.2 features 1.3 technical specifications 1.4 delivery check 1.5 tools 1.6 specification sheets
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 36 of 47 revision: d revision date: 12-0-02-09 ram tape guide cover anvil mount press yoke atp-301 punch holder wire stop/ stripper unit carrying handle storage for wire stop/ stripper storage for punch holder and p ress yoke figure 1-1 feed cylinder principal mechanical parts of the taped terminal cr imp module
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 37 of 47 revision: d revision date: 12-0-02-09 general description description the taped terminal crimp module provides an effective method of applying a wide range of side feed tape-mounted terminals to pre- stripped discrete wire(s) from 4 to 30 awg. the crimp module and press combination replaces the molex atp-301 press (19228- 0030) and the molex atp-201 press (19047- 0001). this crimp module operates only in the molex tm-3000 and tm-4000 universal presses. the crimp module uses quick-change modular tooling, requires little or no adjustments, and is intended for mid-volume to high-volume, semi- automatic operations. molex offers the following crimp presses for operating the crimp module: tm-3000 universal press 120v 50-60 hz. 63801-7200 tm-3000 universal press 240v 50-60 hz. 63801-7300 the tm-3000 should be used for 10-30 awg terminals. tm-4000 universal press 240v 50-60 hz. 63801-7600 the tm-4000 should be used for 4-30 awg terminals. general features independent adjustment of insulation crimp height. tooling is accessed from the front of the module, simplifying change over. no track adjustment is required. compatible with the molex tm-3000 and tm-4000 universal presses only. it does not fit into molex tm-40, tm-42, or tm-2000 presses. no terminal feed adjustment is required. uses crimp tooling from existing molex atp-201 and atp-301 crimp presses. technical specification dimensions crimp module only width: 140mm (5.5") depth: 136mm (5.3") height: 175mm (6.9") (ram down) weight 4.1kg (9lb) guarding the crimp module is intended to be used with the guards supplied on the tm-3000 or tm- 4000 universal press. a special retrofit guard kit is available when the crimp module is installed on earlier tm-3000 press models. see section 4.3. caution: do not operate the crimp module without press guards in place. delivery check carefully remove the crimp module from its shipping container and determine that the following items are included in the package. crimp module 1 air line kit 1 press guard kit (if required) 1 instruction manual 1 note: terminal crimp tooling is not included with the crimp module and must be ordered separately.
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 38 of 47 revision: d revision date: 12-0-02-09 tools the following tools are recommended for setup and adjustments to the crimp module: 1. metric standard hex wrench set 2. inch standard hex wrench set 3. wire stripper / cutter 4. crimp micrometer or caliper specification sheets specification sheets are available for all crimp tooling. the specification sheet contains the following: applicable terminal numbers wire awg ranges insulation diameter ranges pull force specification strip lengths slug height specification tooling parts lists and assembly drawings the specification sheet is available on the molex website (www.molex.com).
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 39 of 47 revision: d revision date: 12-0-02-09 section 2 set-up and operation 2.1 shut height 2.2 setup 2.3 crimp height adjustments 2.4 crimp tooling installation and removal 2.5 specific crimp module adjustments 2.6 operation
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 40 of 47 revision: d revision date: 12-0-02-09 shut height gauge press quick change mounting plate figure 2-1 press adjustable dial loosen m6 shcs figure 2 - 2 loosen m6 shcs read the following instructions before attempting to operate the crimp module. 2.1. shut height the molex taped terminal crimp module operates only in the tm-3000 and tm-4000 presses with standard shut height of 135.80mm (5.346"). installation in crimp presses with other than standard shut heights can cause sev ere tool damage. before installing the crimp module, the press shut height must be verified. the correct shut height is required for proper crimping without caus ing tool damage. the shut height of the tm-3000 and the tm-4000 pres ses are preset at the factory and labeled on the front of the press. over time, however, the press may wear caus ing a change in the shut height. the shut height of the press can be checked with a shut height gauge, which is calibrated under load to ach ieve the 135.80mm (5.346") measurement. it is recommended that the shut height be checked monthly. a shut he ight gauge is available from most press manufacturers. measuring press shut height 1. disconnect the power supply from the press. remove the machine guards if necessary. 2. remove the applicator from the press. make sure that the bottom of the press ram and quick change mounting plate are free of foreign material. 3. place the shut height gauge into the press on the press quick change mounting plate. see figure 2- 1. 4. manually cycle the press to the full down stroke position. (see the tm-3000 press instructions on manually cycling the press.) 5. read the shut height measurement from the front of the gauge. follow gauge manufacturers instructions; usually the gauge reads 0 at the correct shut height. 6. if shut height adjustment is necessary: a. loosen the four m6 shcs on the front of the press. b. rotate the adjustment dial to the right to raise shut height or to the left to decrease. dial indicator lines represent increments of .05mm (.002). see figure 2-2. c. when adjustment is complete, retighten the four m6 shcs. 7. repeat the above steps until the correct shut heigh t is obtained. 8. shut height gauges must be calibrated on a regular basis. 2.2. set-up the principal mechanical parts of the crimp module are illustrated in the assembly drawings (section 4-1).
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 41 of 47 revision: d revision date: 12-0-02-09 quick change plate locator clamps locking clamp m5 shcs figure 2-2 ram adapter base plate press yoke crimp module installation and removal 1. turn off the press and disconnect the power. open the press guard. 2. clean the quick-change mounting plate of scrap or chips that may interfere with the crimp module installation. 3. using a 3mm hex wrench, loosen the set screw holding the press yoke. pull the press yoke straig ht down and remove it from the press. (note: a storag e hole is provided on right side of the crimp module frame to keep the press yoke) 4. install the press yoke furnished with the crimp mod ule in the press ram. tighten the set screw securely. 5. using a 4mm hex wrench, turn the m5 shcs clockwise until the locking clamp is fully opened. 6. visually align the crimp modules base plate slots with the location clamps on the press quick-change mounting plate. 7. slide the crimp module onto the quick-change mounting plate until the two notches on the left si de engage against the stops, and at the same time, guide the ram adapter into the press yoke. see figure 2-2. 8. to lock the crimp module, turn the m5 shcs counterclockwise until tight. 9. connect the air lines from the feed cylinder to the press air valve. the cylinder port closest to the module frame must be connected to the normally open valve port. the other cylinder port (with th e flow control valve) must be connected to the normally closed valve port. 10. close the press guard. 11. remove the crimp module by reversing the previous steps. when storing the crimp module, always leave a strip of terminals in the module on the anv ils to prevent damage to the tooling. see section 3.5 storage. punch and anvil alignments note: always clean mounting surfaces of crimp tooling and tooling holders prior to alignment. 1. disconnect power from the press and open the machine guard. 2. using a 5/32 hex wrench, slightly loosen the anvil mounting screw. see figure 2-3. 3. slowly hand-cycle the ram of the press to bottom of its stroke. with the punches engaging the anvils, securely tighten the anvil mounting screw to ensure alignment of punches and anvils. 4. hand cycle the press ram to its up position. 5. close the machine guard and restore power to the press. 2.3. crimp height adjustments conductor crimp height adjustment 1. obtain a piece of solder, approximately 40mm (1.5) long and approximately 0.5mm (.02) larger in diameter than the crimped slug height. if the sold er anvil figure 2-3 loosen the #10 shcs
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 42 of 47 revision: d revision date: 12-0-02-09 figure 2-5 #10 shcs punch holder punches o-ring loosen the #10 shcs figure 2-4 insulation cam punches diameter is too large the crimped slug will have la rge extrusions, making it difficult to measure the over all slug height. 2. with no terminals in the applicator, lay the solder across the anvils and cycle the press (by hand or under power). 3. using a crimp micrometer or dial caliper, measure t he solder slug height and compare to specification. 4. if adjustments are necessary, turn off the press an d open the machine guard. 5. the conductor crimp height is based on the conducto r punch contacting the conductor anvil. if the press shut height was correctly set prior to crimp module installation (see section 2.1) there should be no n eed to adjust conductor crimp height. however, some of the larger terminal crimps may cause minor press frame deflection which can be compensated by adjusting the press shut height. see section 2.1 f or shut height adjustment. note: crimp height adjustments for closed-barrel industrial terminals are always based on solder slu g heights, not terminal crimp heights. 1. load the terminals, close the machine guard, and crimp several wires under power. 2. perform a pull test on the conductor crimp to verif y the mechanical integrity of the crimp. see appendi x a-pull force test. insulation crimp height 1. place a stripped length of the appropriate wire int o the terminal and crimp under power. 2. observe quality of insulation crimp. 3. if adjustments are necessary, turn off the press. open the machine guard. 4. using a 5/32 hex wrench, loosen the #10 shcs holding the punches. 5. rotate the insulation adjusting cam to achieve the desired insulation height. there are three cam positions (marked l, m, and s) for large, medium, a nd small diameter wires. the cam must be in one of th e three positions; do not adjust it between positions . see figure 2-4. 6. while holding the punches up against the punch holder, securely tighten the #10 shcs. 7. close the machine guards, restore power, and crimp a wire under power. inspect the insulation crimp a nd make further adjustments if needed. note: due to the large variety of insulation wall thickness, materials, and durometers, molex does no t specify insulation crimp height. 2.4. crimp tooling removal and installation caution : always disconnect power before installing or removing tooling. removal and installation of atp-301 style punches note: always clean mounting surfaces of crimp tooling and tooling holders prior to installation.
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 43 of 47 revision: d revision date: 12-0-02-09 ram set screw visible in the hole ram in the full up position figure 2-7 atp-201 punch #10 shcs note the side plate position o-ring figure 2-6 anvils anvil mount 1. disconnect power from the press. open the machine guard. 2. if the ram is down, move it manually to the full up position. 3. to remove the punches, use a 5/32 hex wrench to remove the #10 shcs holding the punches to the punch holder. see figure 2-5. 4. remove the screw, punches, and o-ring together. some tool kits may include a spacer plate (behind t he conductor punch). 5. to install, place the punches with the spacer (if u sed) and o-ring against the punch holder and securely tighten the #10 shcs. the conductor punch (e2) goes against the punch holder and the insulation punch (i2) is stacked on the conductor punch. ma ke sure the etched e2 or i2 on each punch faces outward. note: the press should be hand-cycled after installing punches to insure a free fit between pun ch and anvil. if excessive resistance is felt, check for an incorrectly installed punch and/or anvil misalignme nt. removal and installation of atp-301 style anvils note: always clean mounting surfaces of crimp tooling and tooling holders prior to installation. 1. disconnect power from the press. open the machine guard. 2. if the ram is down, move it manually to the full up position. 3. to remove the anvils, use a 5/32 hex wrench to remove the #10 shcs holding the anvils to the anvil mount. see figure 2-6. 4. remove the screw, anvils, and o-ring together. some tool kits may include a spacer plate (behind the conductor anvil). 5. to install, place the anvils with the spacer (if us ed) and o-ring against the anvil mount, leaving the mounting screw slightly loose. the conductor anvil (e1) is installed first and the insulation anvil (i1) is stacked onto it. make sure the etched e1 or i1on each anvil face outward. warning : use the mounting screws that are furnished with the atp tool kit. the feed mechanism may become damage when using screws that are too long. 6. the side plates must be a close fit to the width of the anvils. for the atp-301 style anvils, the step on the side plates must be toward the outside. if it is not, loosen the m4 shcs and reverse the side plate. 7. the anvils must be aligned to the punches before tightening the screws. see section 2.2 (set up; punch and anvil alignments). removal and installation of atp-201 style punches
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 44 of 47 revision: d revision date: 12-0-02-09 figure 2-8 flat face of the atp-201 punch facing forward ram figure 2-9 #10 shcs note the side plate position o-ring anvil anvil mount 1. disconnect power from the press. open the machine guard. 2. if the ram is down, move it manually to the full up position. 3. to remove the punch assembly, use a 3mm hex wrench to loosen the set screw on the front of the ram. this screw is accessible through the modules front cover. see figure 2-7. 4. with the set screw loosened, pull the punch assembly straight down. 5. to install the punch assembly, orient the assembly so the flat on the round stub faces forward. put the stub into the hole in the bottom of the ram and push the punch assembly up against the bottom of the ram. see figure 2-8. 6. with the punch assembly in the ram, tighten the set screw securely. note: the press should be hand-cycled after installing the punch assembly to insure a free fit between punch and anvil. if excessive resistance is felt, check for an incorrectly installed punch and/ or anvil misalignment. removal and installation of atp-201 style anvils note: always clean mounting surfaces of crimp tooling and tooling holders prior to installation. 1. disconnect power from the press. open the machine guard. 2. if the ram is down, move it manually to the full up position. 3. to remove the anvils, use a 5/32 hex wrench to remove the #10 shcs holding the anvils to the anvil mount. see figure 2-9. 4. remove the screw, anvil(s), and o-ring together. 5. to install, place the anvil(s) and o-ring against t he anvil mount, leaving the mounting screw slightly loose. the conductor anvil (e1) is installed fir st and the insulation anvil (i1) is stacked onto it. make sure the etched e1 or i1on each anvil face outward. warning : use the mounting screws that are furnished with the atp tool kit. screws that are t o long may damage the feed mechanism. 6. the side plates must be a close fit to the width of the anvils. for the atp-201 style anvils, the step on the side plates must be toward the inside. if it i s not, loosen the m4 shcs and reverse the side plate. 7. the anvils must be aligned to the punches before tightening the screws. see section 2.2 (set up; punch and anvil alignments). 2.5. crimp module adjustments terminal feed adjustments the tape feed mechanism is a ratcheting wheel and h as no adjustable features.
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 45 of 47 revision: d revision date: 12-0-02-09 knob locking ring figure 2-10 feed cylinder adjust figure 2-11 adjust m5 shcs m5 shcs adjust wire stop terminal m5 shcs figure 2-12 feed speed adjustments terminal feed speed is controlled by the flow contr ol valve on the feed cylinder. loosen the locking rin g, then turn the adjustment knob clockwise (cw) to reduce t he feed speed or counterclockwise (ccw) to increase th e feed speed. see figure 2-10. adjustments to the feed speed should be made gradually. when adjustment is complete, turn the locking ring until it is finger-tight. terminal stripper adjustment some terminals have a tendency to stick in the conductor punch after being crimped. the terminal stripper is used to shed the terminal away from the retracting punches. 1. disconnect power from the press. open the machine guard. 2. if the ram is down, move it manually to the full up position. 3. to adjust the stripper in and out, use a 4mm hex wrench to loosen the m5 shcs on the side of the stripper. move the stripper toward the punches, bu t not too close or it could interfere with the ram stroke. see figure 2-11. tighten the m5 shcs when adjustment is complete. 4. to adjust the stripper up and down, use a 4mm hex wrench to loosen the m5 shcs on the front of the stripper. move the stripper down until it is just above the taped terminal on the anvils. see figure 2-11. tighten the m5 shcs when adjustment is complete. note: if the stripper is adjusted down too far it m ay interfere with the terminal feed motion. wire stop adjustment the wire stop is used when the terminal being crimp ed does not have an internal wire stop tab. some larg er ring terminals fall into this category.
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 46 of 47 revision: d revision date: 12-0-02-09 track cover closed track cover open hole pull knob out lift knob up figure 2-14 figure 2-15 terminal on anvil tape slot terminal 1. disconnect power from the press. open the machi ne guard. 2. if the ram is down, move it manually to the full up position. 3. to adjust the wire stop, loosen the m5 shcs on t he side of the stripper. move the wire stop in or out until it is near the end of the terminal barrel. see figure 2-12. tighten the m5 shcs when adjustment is complete. note : since they are mounted to the same block, adjustments to the wire stop will also influence th e terminal stripper. to achieve full adjustment of t he wire stop, the stripping tool may need to be removed fro m the block. 2.6 operation loading and unloading tape 1. applicable terminals are listed on the crimp toolin g specification sheet. do not crimp terminals that a re not listed on the specification sheet. 2. disconnect power from the press. open the machine guard. 3. the tape will be easier to start in the track if the corner of the tape is trimmed as shown in figure 2- 13. 4. open the tape track cover by pulling out the spring - loaded knob and lifting the cover up. a hole is provided in the module frame for the knobs pin to enter to hold the track cover open. see figure 2-1 4. 5. load the taped terminal strip from the front of the module, engaging the slots in the tape with the tee th on the feed wheel. make sure the terminal is also centered above the crimp anvils. see figure 2-15. 6. pull out the spring-loaded knob and lower the track cover, allowing the pin to engage the lower hole. 7. unloading the tape is the reverse process. tape de-reeling information the tape reel should be mounted on the reel arm of the press, with the printed side of the reel facing the operator. the tape de-reels counterclockwise (ccw). to prevent tape feed jams, the tape should enter th e press guard below the bottom horizontal bar. if th e tape is threaded between the bars, a terminal may become snagged on the bar during feeding. see figure 2-16. trim the corner of the tape figure 2-13
tm-3000 and tm-4000 universal press order no: tm-638017299 release date: 06-06-05 uncontrolled copy page 47 of 47 revision: d revision date: 12-0-02-09 figure 2-16 tape enters below guard tape exit tape reel while operating the crimp module, the tape entering the press should not become taut. the operator sh ould occasionally turn the terminal reel to maintain a s lack loop. the scrap tape exits below the press guard. removal of crimped terminals from tape after being crimped, the tape feed will advance the terminal one position to the right. it is the ope rators responsibility to remove the crimped terminal from the tape. if crimped wires are allowed to accumulate on the t ape they will eventually cause a tape feed jam. to prevent tape damage, the terminal should be pull ed off the tape towards the operators right. this sideways action makes it easier for the terminal to break fr ee from the adhesive holding it to the tape.

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