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
UNCONTROLLED COPY
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
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
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
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
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.
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.
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 2 of 50
FineAdjust Applicator
WARNING
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.
WARNING
Do not use
compressed air to clean
this equipment.
The forces created by compressed
air can force debris into the tool.
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
UNCONTROLLED COPY
Page 3 of 50
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
Doc. No: TM-638004900
Revision: G
Release Date: 09-04-03
Revision Date: 01-15-13
UNCONTROLLED COPY
Page 4 of 50
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
UNCONTROLLED COPY
Page 5 of 50
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