MOLEX TERMINATOR - Use in TM40, TM42, and Base Unit Adapter

MOLEX TERMINATOR - Use in TM40, TM42, and Base Unit Adapter

  • Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 1 of 42 Revision: D Revision Date: 05-28-08 MOLEX TERMINATOR Use in TM40, TM42, and Base Unit Adapter Instruction Manual
  • Description
  • Operation
  • Maintenance

MOLEX TERMINATOR - Use in TM40, TM42, and Base Unit Adapter

Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 2 of 42 Revision: D Revision Date: 05-28-08 WARNING NEVER USE THIS TERMINATOR IN A PRESS WITHOUT GUARDS OR SAFETY DEVICES THAT ARE INTENDED TO PREVENT INJURY. THE TERMINATOR IS SUPPLIED WITHOUT GUARDS.

PLEASE USE GUARDS SUPPLIED WITH THE PRESS. RUNNING THE PRESS WITHOUT GUARDS UNDER ANY CIRCUMSTANCES CAN CAUSE SERIOUS INJURY. NEVER OPERATE, SERVICE, INSTALL OR ADJUST THIS TERMINATOR WITHOUT PROPER INSTRUCTION AND WITHOUT FIRST READING AND UNDERSTANDING THE INSTRUCTIONS IN THIS MANUAL AND THE TM42 PRESS, TM40 PRESS, OR 3BF WITH BASE UNIT ADAPTER MANUALS.

NEVER INSTALL, REMOVE, OR SERVICE TERMINATOR TOOLING WHILE THE FLYWHEEL IS IN MOTION OR WHILE CONNECTED TO ANY ELECTRICAL POWER SOURCE. DISCONNECT POWER BY UNPLUGGING THE PRESS FROM ITS POWER SOURCE. NEVER INSTALL, REMOVE, OR SERVICE THE TERMINATOR TOOLING WITHOUT MANUALLY CYCLING THE PRESS TO VERIFY THAT THE CLUTCH CONTROL IS IN THE LOCKED POSITION PAST TOP DEAD CENTER. BLOCK THE RAM IN THE UP POSITION IF A DEFECTIVE CLUTCH IS SUSPECTED. CAUTION THE PRESS SHOULD ALWAYS BE HAND CYCLED WITH THE TERMINATOR INSTALLED PRIOR TO RUNNING PRODUCTION THIS PROCEDURE WILL PREVENT DAMAGE OR REDUCE TOOL WEAR.

CAUTION MOLEX CRIMP SPECIFICATIONS ARE VALID ONLY WHEN USED WITH MOLEX TERMINALS, TERMINATORS 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

MOLEX TERMINATOR - Use in TM40, TM42, and Base Unit Adapter

Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 3 of 42 Revision: D Revision Date: 05-28-08 Table of Contents SECTION 1 General Description 2 Installation - Setup - Operation 3 Maintenance 4 Parts List, Assembly Drawings, Troubleshooting and Base Unit Adapter APPENDIX A Crimp Termination B Statistical Process Control

MOLEX TERMINATOR - Use in TM40, TM42, and Base Unit Adapter

Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 4 of 42 Revision: D Revision Date: 05-28-08 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

MOLEX TERMINATOR - Use in TM40, TM42, and Base Unit Adapter
  • Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 5 of 42 Revision: D Revision Date: 05-28-08 Molex Presses and Adapters For “T” or “T2” Style Terminators TM42 Press
  • ISO Metric
  • Flexible external light
  • Resettable counter
  • 1.5” Stroke TM40 Press (Not Shown)
  • Internal Light
  • Non resettable counter
  • 1.125’ Stroke Base Unit Adapter
  • Allows 3BF press to run
  • Terminator style tooling General Descrition 1.1. Description The Molex Terminator is designed to provide an effective method of applying a wide range of side feed terminals to a pre-stripped discrete wire. It is an easy to use tool for the termination of a variety of Molex crimp terminals. Production flexibility is obtained using simple interchangeable tooling. The tooling is inexpensive, and unlike a modular applicator, all crimp height and terminal feed adjustments are located in the press. The terminator die is ideally suited for midvolume bench operation.
  • The Molex T2 terminator is the newer version tool that allows for track adjustment. The Molex T2 terminator will be replacing the Molex Terminator where possible. Most 14 AWG and smaller (16, 18, and 20) will eventually be designed into the T2 Terminator Die. Molex offers the following crimp tools/machines for operating the Molex Terminator: TM40 Terminating Press TM42 Termination Press 69002-5099 Base Unit Adaptor 11-19-3001 1.2. Features
  • Track Adjustment capabilities in the T2 terminators for improved control of the bellmouth size and cutoff tab length.
  • T2 terminator has standardized tooling with Molex FineAdjust Applicator which will reduce your inventory requirements.
  • Quick release punches that will reduce set-up time and increase productivity.
  • T2 Terminator available for most Molex brand terminals.
  • Flexible and inexpensive tooling will reduce overall cost.
MOLEX TERMINATOR - Use in TM40, TM42, and Base Unit Adapter

Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 6 of 42 Revision: D Revision Date: 05-28-08 1.3. Technical Specification Dimensions Width: 127.00mm (5.0") Depth: 44.00mm (1.8") Height: 25.00mm (1.0") Weight 1.4kg (3 lbs) Guards Caution: DO NOT use the Terminator without guards The Terminator is supplied with no guards and is intended to be used with the guards supplied with the TM40 and TM42 Press or Base Unit. 1.4. Delivery Check Carefully remove the Terminator from its shipping container and determine that the following items are included in the package.

  • Description Qty. Terminator 1 (Tooled for desired terminal) Setup and Specification Sheets 1 ATS-638500090 Instruction Manual 1 Sample Crimped Terminals 5 1.5. Tools The following tools are recommended for setup and adjustments to the Terminator in this press
  • Metric standard hex wrench set
  • English Allen Set (for older terminator tools)
  • Adjustable wrench
  • Wire stripper / cutter
  • Scissors
  • Large and small screwdriver
  • Pliers (needle nose)
  • Crimp Micrometer
  • Eye Loop (10x) 1.6. Specification Sheets Molex ships specification sheets with every Terminator. The specification sheet contains the following:
  • 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 The specification sheet should be filed. These are available on the Molex website (www.molex.com).
MOLEX TERMINATOR - Use in TM40, TM42, and Base Unit Adapter

Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 7 of 42 Revision: D Revision Date: 05-28-08 Section 2 Set-Up and Operation 2.1. Setup 2.2. Adjustments 2.3. Final Check and Operation

MOLEX TERMINATOR - Use in TM40, TM42, and Base Unit Adapter

Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 8 of 42 Revision: D Revision Date: 05-28-08 PUNCH PLATE #10-32 BHCS FRONT STRIKER CONDUCTOR PUNCH LEFT LOCATING PLATE BOLSTER PLATE INSULATION PUNCH PUNCH RELEASE PIN RAM RIGHT LOCATING PLATE M5 BHCS T2 TERMINATOR BASE Figure 2-2 SETTING 1 is Maximum Height SETTING 6 is Minimum Height INSULATION ADJ.

INDICATOR CONDUCTOR ADJ. INDICATOR INSULATION ADJ. CAM CONDUCTOR ADJ. LOCK CONDUCTOR ADJ. SCREW PUNCH RELEASE PIN PUNCH PLATE Figure 2-1 Read the following instructions before attempting to operate the Terminator.

2.1. Set-Up The principal mechanical parts of the Terminator are illustrated in Section 4- Assembly Drawings. Terminator Die Removal CAUTION - Always power down the press when installing or removing Molex tooling by pressing the emergency stop button located on the front panel. 1. Always turn off and disconnect the power supply to the press. Remove the press guards. Refer to the Press or Base Unit manual order no. 11-05-0026. 2. Set both the conductor and insulation indicators to a reference setting of “1”. See Figure 2-1. 3. Loosen the M5 BHCS and remove the right locating plate.

Lift the feed finger clear and slide the terminator die out of the press. 5. Remove the punches, nose hold-down, rear striker, and center carrier cutoff tooling. 6. The terminator die is best stored in its original container. Terminator Die Installation Before any die is installed make sure the cover alignment procedure and the track adjustment procedure, (when applicable) have been completed. See the appropriate terminator die instruction manual for these procedures. 1. Power down the press and remove the guards. Refer to the Press or Base Unit manual order no. 11-05-0026.

2. Not all terminator dies have nose hold down, rear strikers, or center carrier cutoff tooling. If present on the terminator die, attachment points are located behind the punches either in the front of or on the bottom of the ram. Refer to the Specification sheet supplied with each individual terminator die for parts supplied with that terminator. 3. Fit the (2) punches in the opening on the underside of the ram. The conductor punch should be positioned in the rear. See Figure 2-2. A click will be heard when the punch retaining/release pin engages.

MOLEX TERMINATOR - Use in TM40, TM42, and Base Unit Adapter

Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 9 of 42 Revision: D Revision Date: 05-28-08 DRAG CAM DRAG FRAME 1ST TERMINAL CENTERED ABOVE ANVILS TERMINAL STRIP LIFT THE FEED FINGER UP ROTATE Figure 2-3 “T2” Style DRAG FINGER 1ST TERMINAL CENTERED ABOVE ANVILS TERMINAL STRIP LIFT THE FEED FINGER UP Figure 2-4 “T” Style ANTI-BACK UP FINGER DRAG AND ANTI-BACK UP PINS 4.

Set both the conductor and insulation indicators to a reference setting of “1”. See Figure 2-1. 5. The front striker slides in front of the punches and is attached with a #10-32 BHCS through the hole in the punch plate.

6. Clean the bolster plate of scrap or chips that may interfere with the Terminator installation. 7. Remove the right locating plate from the bolster plate by removing the M5 BHCS. 8. Lift the feed finger clear and slide the terminator die onto the left locating plate. 9. Attach the right locating plate and tighten the M5 BHCS. Fitting Terminal Strip 1. The specified terminals are printed on the specification sheet for the Terminator. Only use the Molex terminals on the setup sheet which is supplied with the Terminator.

2. Always disconnect the power supply from the press. Remove the machine guards if necessary.

3. Install the terminal reel on the press reel holder. CAUTION: Terminals and terminal carrier strips may have sharp edges that can scratch or cut. Use caution while handling terminals. “T2” STYLE 1. If using a T2 Terminator, rotate the drag cam 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. 2. Push the terminal strip until the first terminal comes to rest centered above the anvil.

3. If severe resistance is encountered or the terminal strip does not fit, you may need to make a cover plate adjustment. See Section 2.2. 4. Rotate the drag cam to engage the terminal drag frame. 5. 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. 6. When unloading the terminal strip, make sure the power is turned off and disconnected from the press. Remove the machine guards if necessary. 7. Rotate the drag cam until the drag frame is in the upright position.

8. 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. 9. Replace the machine guards before operating the press. “T” STYLE 1. If using a “T” style Terminator, push both the drag and anti backup pins located on the front of the terminator die. This will allow the terminals to slide freely through the terminator die track. See Figure 2-4.

2. Push the terminal strip until the first terminal comes to rest centered above the anvils.

MOLEX TERMINATOR - Use in TM40, TM42, and Base Unit Adapter

Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 10 of 42 Revision: D Revision Date: 05-28-08 Figure 2-6 “T” STYLE #10-32 SHCS M4 SHCS (2) Figure 2-5 “T2” STYLE 3.

If severe resistance is encountered or the terminal strip does not fit, you may need to make a cover plate adjustment. See Section 2.2. 4. Release the terminal drag and anti-backup pins to engage the terminal drag frame on the track. 5. Check that all other parts slide and engage without any interference. It is recommended to go through this procedure several times.

6. When removing the terminal strip, make sure the power is turned off and disconnected from the press. Remove the machine guards if necessary. 7. Raise terminal drag finger and anti-backup finger from the carrier strip. 8. Lift the feed finger and pull terminal strip back until disengaged from terminator track. If preferred, cut the terminal carrier strip and pull it through the terminator with needle nose pliers. 9. Replace the machine guards before operating the press. Punch and Anvil Alignments Note: Always clean mounting surfaces of crimp tooling and tooling holders prior to alignment.

1. Always disconnect the power supply from the press. Remove the machine guards if necessary. 2. With a terminal in position over the anvils, slightly release anvil mounting screw. See Figures 2-5 and 2-6.

3. Place the hand cycling wrench through the hole in the center of the rear cover. 4. Gently lower the press ram until it is in the fully down position, with a terminal sitting on the the anvils the punch will align the bottom tooling. 5. With the ram in the fully down position tighten the anvil mounting screws in this position to ensure perfect alignment of punches and anvils. Tighten center carrier cut-off tooling if necessary. 6. Bring the ram back to top dead center insuring that the clutch collar is engaged by the actuator. 7. Hand cycle the press ram to the highest position. 8. Replace the machine guards before operating the press.

Manually Cycling the Press Manually cycling is necessary to confirm correct tool alignment, terminal feed adjustment and to give the setup person the ability to step through the press cycle manually. 1. Always power down the press by pressing the emergency stop button on the front control panel. 2. Release the clutch by inserting a screwdriver through the access hole to trip the locked actuator. See Figure 2-7. Figure 2-7 MANUAL CYCLE CLUTCH RELEASE

Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 11 of 42 Revision: D Revision Date: 05-28-08 Figure 2-9 “T2” STYLE TERMINAL REAR COVER M4 X 12 LG BHCS (2) REAR COVER #8-32 BHCS (2) TERMINAL Figure 2-10 “T” STYLE ANTI-BACK UP FINGER Figure 2-8 MANUAL CYCLING 3.

Insert the 10 mm hex wrench supplied with the press through the hole in the center of the rear cover and engage it in the socket in the press flywheel. See Figure 2-8. WARNING: Never insert anything through this hole while the press is under power.

4. Rotate the press flywheel to move the ram as desired. CAUTION: By disengaging the actuator the ram will be free to move. See manual of the Press and Base Unit. The weight of the ram can result in downward motion. Use caution to ensure that the area under the ram is clear of fingers and hand tools. The machine guard should be in place. 2.2 Adjustments Cover Plate Adjustments 1. Always disconnect the power supply from the press. Remove the machine guards if necessary. 2. Remove the terminator from the press. Refer to Terminator Die Installation and Removal. 3. For the “T2”style only, rotate the drag cam until the drag frame is in the upright position.

4. The rear cover plate should be adjusted so that the terminal strip will slide smoothly through the track with no resistance. 5. Loosen the two M4 BHCS for the “T2” or the two #8-32 BHCS for the “T” style, to adjust the position of the rear cover. See Figures 2-9 and 2-10. 6. Slide terminal strip through the track to ensure accurate cover positioning. 7. After the correct position is achieved, tighten the two M4 BHCS. 8. Re-install the terminator to the press. Refer to Terminator Die Installation and Removal. Feed Finger Adjustments 1. Power down the press and remove the guards. 2. Make sure the press ram is in the full up right position and the clutch collar is engaged by the actuator.

Refer to the Press or Base Unit manual. 3. Slide the terminal carrier strip all the way forward until it is centered over the anvils.

4. See the feed finger location Figure 2-12 for feed finger position. 5. Loosen the terminal feed finger shaft M4 locking screw and slide the feed finger shaft in or out. See Figure 2-11.

Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 12 of 42 Revision: D Revision Date: 05-28-08 FEED FINGER LOCATION END CARRIER NOSE CARRIER CENTER CARRIER CENTER CARRIER DUAL CARRIER FEED FINGER LOCATION FEED FINGER LOCATION FEED FINGER LOCATION FEED FINGER LOCATION Figure 2-12 Figure 2-11 MAKE SURE LOCKING SCREW IS LOOSENED BEFORE TURNING SHAFT TO LOCKING SCREW (M4) FEED LEVER FEED FINGER SHAFT FEED ARM FEED FINGER TORSION SPRING INCREASE (CW) CLOCKWISE DECREASE (CCW) COUNTER CLOCKWISE BACK FEED ADJ.

SCREW Figure 2-13 M6 JAM NUT FEED FINGER M6 FORWARD FEED ADJ. LOCK SCREW M4 LOCKING SET SCREW FORWARD FEED ADJ. INDICATOR FORWARD FEED ADJ. WHEEL 6. Position the feed finger to pick up the best feeding position. This may differ from terminal to terminal. Typically, terminals are fed via carrier strip holes or by the tab between the insulation terminal section and the carrier strip. See Figure 2-12 for locations. 7. With a small screwdriver, rotate the feed finger shaft CW to increase or CCW to decrease spring tension on the feed finger. Tighten the feed finger shaft locking screw while maintaining the spring pressure on the feed finger.

This will lock the feed finger in position. See Figure 2-11.

8. Cycle the press by hand; See Manually Cycling the Press, to be certain that the feed finger transfers the next terminal to be aligned over the anvil. 9. Check that all other parts slide and engage without any interference. 10. Repeat this procedure several times if necessary. 11. If a manual cycle cannot be completed, or the terminal is not positioned over the anvil, refer to the Back Stoke and Forward Feed Adjustments. Back Stroke Feed Adjustment 1. The feed finger requires over-travel on the backstroke to pick up the next position on the loaded terminal strip.

2. Manually cycle the press 180 degrees to the bottom dead center position.

3. With the press in the down position, loosen the M6 hex jam nut. See Figure 2-13. 4. Adjust the M6 back feed adjustment screw to change the backstroke position of the feed finger.

Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 13 of 42 Revision: D Revision Date: 05-28-08 Figure 2-14 CONDUCTOR ADJ. INDICATOR CONDUCTOR ADJ. LOCK SCREW CONDUCTOR ADJ. SCREW PUNCH RELEASE PIN SETTING 1 IS MAXIMUM HEIGHT SETTING 6 IS MINIMUM HEIGHT 5. After the stroke is adjusted, tighten the M6 hex jam nut. 6. Verify the forward stroke position and readjust if necessary. Forward Feed Adjustment A forward or back feed adjustment may be necessary if the terminal is not centered over the anvil during the manual cycle.

1. Power down the press and remove the guards.

2. To check the forward feed position, the terminal being crimped should be positioned exactly over the anvil and the ram in the up position. 3. Loosen the M6 forward feed adjustment lock screw located on the top of the punch plate. See Figure 2-13. 4. Rotate the forward feed adjustment wheel to center the terminal over the anvil. 5. After adjusting the forward feed position of the terminal, tighten the M6 forward feed adjustment lock screw. Conductor Crimp Punch Adjustment It is recommended to adjust the conductor adjustment wheel all the way to (1) on the conductor adjustment indicator, to avoid punch crash prior to beginning this process.

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 Measurement. 3. If adjustments are necessary, turn off and disconnect the power supply from the press. Remove the machine guards. 4. Loosen the M6 conductor adjustment lock screw located on the front of the punch plate. See Figure 2-14. 5. With a screwdriver, turn the conductor adjusting screw located on the right side of the punch plate. Rotating the adjusting screw clockwise one full turn will lower the crimp height approximately .03mm (.001").

Each increment in the reference window represents approximately .13mm (.005") for a total adjustment of .65mm (.026"). The "1” setting, on the conductor adjustment indicator, equates to the loosest crimp height and the “6” setting is the tightest.

6. Tighten the M6 locking screw. 7. Replace the machine guards. 8. Repeat the above steps until the correct crimp height is achieved. Insulation Crimp Punch Adjustment 1. Place a stripped length of wire into the terminal and terminate under power. 2. Examine the quality of the initial insulation crimp. See Appendix A, Crimp Terminations. 3. Power down the press and remove the guards. 4. Rotate the insulation adjusting screw to obtain the required insulation crimp height. Each increment in the reference window represents approximately .2mm (.0078") for a total adjustment of 1.60mm (.063"). The "1" setting, on the insulation adjustment indicator, equates to the loosest crimp height and the "8" setting is the tightest.

See Figure 2-15.

5. Repeat the above steps until the desired insulation crimp height is obtained. NOTE: Due to the large variety of insulation wall thickness, material, and durometers, Molex does not specify insulation crimp height. The insulation crimp height should be inspected, measured, and documented as a quality indicator for all wire types and sizes.

Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 14 of 42 Revision: D Revision Date: 05-28-08 Figure 2-15 INSULATION ADJ. INDICATOR INSULATION ADJ. CAM PUNCH RELEASE PIN Figure 2-16 WIRE STOP PRESTRIPPED WIRE Wire Stop Adjustment 1.

Check the specification sheet to obtain the correct strip length. 2. Place the correct wire into the terminal and crimp the wire under power. 3. Observe quality of crimp and the wire brush length position. See Appendix A.1, Conductor Brush and Terminal Position.

4. If adjustments are necessary, turn off and disconnect the power supply from the press. Remove the machine guards. 5. Adjust the position of the wire stop by loosening the screw on top of the wire stop . Adjusting the wire stop towards the operator decreases the brush length and away from the operator increases the brush length. 6. Hand cycle the press to ensure the Terminator is functioning properly. Then Crimp a terminal under power and observe the quality of the termination. See Appendix A. 2.3 Operation 1. Check that all setup procedures were followed and that the terminations are meeting specification.

2. Verify the machine was manually cycled before operating under power.

3. With guards in place, turn on the press by pressing the run button on the front of the press control assembly. The motor starts and the run light comes on. Pressing the Emergency Stop button disconnects power to the motor and the clutch. The run light goes off. NOTE: To fully remove power to the press, unplug the power cord from the press control assembly. 4. Place the pre-stripped wire through the slot in the guard above the terminal and touch the wire stop. See Figure 2-16. 5. Press the foot pedal down once and release. The press will cycle once. Keep the foot raised or remove it from the foot pedal to prevent unwanted crimp cycles.

CAUTION: Call maintenance immediately if the press cycles more than once. Do not operate the press. (See Section 4.5 Clutch Unit.) 6. The press is set up to have a terminal over the anvil before beginning the crimp cycle. During the crimp cycle, but after the wire is terminated, the operator should make a slight rightward motion of the crimped wire/terminal. This rightward motion should take place during the upward cycle of the press. This will prevent the next indexing terminal from being tangled during the upward cycle of the press. 7. Be sure to remove the crimped terminal out of the slot in the guard before the next termination.

8. Periodically check the terminations for crimp height and visual attributes described in Appendix A: Crimp Terminations, and Appendix B: Statistical Process Control.

Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 15 of 42 Revision: D Revision Date: 05-28-08 Section 3 Maintenance 3.1 Cleaning 3.2 Spare parts 3.3 Perishable Parts

Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 16 of 42 Revision: D Revision Date: 05-28-08 3.1. Cleaning CAUTION: Always disconnect power supply before all maintenance Terminator maintenance will increase tool life and produce a consistent, reliable quality crimp. The following procedure should be followed at the end of each operation.

1. Always disconnect the power supply from the press and remove the press guard. 2. For efficient operation, the Terminator should be cleaned daily. Use a soft bristle brush to remove debris from critical areas such as the crimp tooling.

3. 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. 4. The Terminator should be free of all carrier strip tabs and plating that may have accumulated during production. An example of a maintenance chart is shown below. Copy and use this chart to track the maintenance of your Terminator or use this as a template to create you own schedule or use your company’s standard chart, if applicable.

Preventive Maintenance Chart Daily: Clean. See Section 3.1. As Required: Lubricate.

See Section 3.2. CHECK SHEET MONTH YEAR _ _ Days of the Week Week Daily Cycles Daily Clean MON TUE WED THU FRI SAT SUN Solution 1 2 3 4 Cleaning Reapply grease Reapply oil Yes Soft Brush Industrial Degreaser Inspect all tooling, feed fingers etc. for wear 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.

Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 17 of 42 Revision: D Revision Date: 05-28-08 3.2. Spare Parts Customers are responsible for maintaining the Terminator. 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. These parts are identified in the Parts List. See Section 5. 3.3. Perishable Parts Customers are responsible for maintaining the Terminator. 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 Terminator.

Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 18 of 42 Revision: D Revision Date: 05-28-08 Section 4 4.1. Terminator Types 4.2. Troubleshooting 4.3. Base Unit Adapter

Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 19 of 42 Revision: D Revision Date: 05-28-08 M5 X 10LG SHCS TERMINAL TRACK TRACK ADJUSTMENT FRONT T2 TERMINAL BASE TRACK ADJUSTMENT BACK Figure 4-1 4.1. Terminator Types Molex supplies different types of Terminators depending on the vintage. The following illustrations are a generic guide to the Tool that you may have.

Description Terminator Style Figure Track Adjustment T2 Figure 4-1 End carrier T2 Figure 4-2 Dual carrier T2 Figure 4-3 Center carrier T Figure 4-4 Micro terminal T Figure 4-5 T2 Terminator Assembly T2 Figure 4-6 Rear Striker Installation T and T2 Figure 4-7 Track Adjustment T2 Series (Figure 4-1) The T2 Terminator allows for adjustment of both the bell mouth and cut-off tab by loosening the M5 SHCS on the bottom of the terminal base. Adjust the terminator track to the front or to the back to achieve desired crimping condition.

Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 20 of 42 Revision: D Revision Date: 05-28-08 REAR COVER WIRE STOP INSULATION ANVIL SCRAPE CHUTE TRACK CUT-OFF PLUNGER FEED GUIDE CONDUCTOR ANVIL CUT-OFF PLUNGER SPRING FRONT PLUNGER RETAINER FINE SPACER KEY FRONT PLUNGER STRIKER CONDUCTOR PUNCH INSULATION PUNCH Figure 4-2 M4 X 6LG SHCS M4 X 50LG SHCS (2) M4 X 14LG SHCS (2) M3 X 6LG SHCS (2) M4 X 12LG BHCS (2) #10-32 X 3/8”LG BHCS M3 X 6LG FHCS HEIGHT SPACER WIRE STOP M5 X 12LG SHCS M4 X 6LG SHCS WIRE STOP L-BRACKET COARSE SPACER FINE SPACER TERMINATOR BASE T2 End Carrier (Figure 4-2)

Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 21 of 42 Revision: D Revision Date: 05-28-08 REAR COVER WIRE STOP INSULATION ANVIL CUT-OFF DIE BLADE TERMINATOR BASE TRACK FRONT CUT-OFF PLUNGER FEED COVER CONDUCTOR ANVIL FRONT PLUNGER RETAINER SPACER COARSE SPACER KEY REAR CUT-OFF PLUNGER CUT-OFF PLUNGER SPRING (2) REAR PLUNGER RETAINER FRONT PLUNGER STRIKER WIRE STOP L-BRACKET SCRAP CHUTE REAR STRIKER CONDUCTOR PUNCH INSULATION PUNCH Figure 4-3 M3 X 6LG FHCS M4 X 50LG SHCS (2) M4 X 14LG SHCS (2) M3 X 6LG SHCS (2) M4 X 12LG BHCS (2) M5 X 10LG SHCS #10-32 X 3/8”LG BHCS M4 X 6LG SHCS FINE SPACER HEIGHT SPACER WIRE STOP M4 X 6LG SHCS M5 X 12LG SHCS T2 Dual Carrier (Figure 4-3)

Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 22 of 42 Revision: D Revision Date: 05-28-08 TERMINAL HOLD DOWN PIN COVER PLATE COMBINATION ANVIL TERMINAL GUIDE RAIL CUT-OFF BLADE CUT-OFF PUNCH WIRE STOP AND STRIPPER 1/16” X 1/4” LG ROLL PIN (2) TERMINAL BASE AND TRACK DIE BLADE AND ANVIL SPACER PIVOT PIN STOP FINGER CONDUCTOR PUNCH INSULATION PUNCH Figure 4-4 #8-32 X 3/8”LG BHCS (2) #6-32 X 1/4”LG BHCS #8-32 X 3/8” LG SHCS TERMINAL DRAG SPRING STOP FINGER TORSION SPRING 1/8” X 1/8” LG TUBULAR RIVET TERMINAL HOLD DOWN SPRING #8-32 X 1/2”LG SHCS (2) #10-32 X 1” LG SHCS #8-32 X 1/4”LG BHCS “T” Center Carrier (Figure 4-4)

Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 23 of 42 Revision: D Revision Date: 05-28-08 “T” Micro Terminal (Figure 4-5) REAR COVER WIRE STOP SPRING PLATE ADAPTOR PLATE TRACK CUT-OFF PLUNGER FRONT COVER COMBINATION ANVIL CUT-OFF PLUNGER SPRING PLUNGER RETAINER ANVIL MOUNTING BLOCK 2MM X 10LG ROLL PIN FRONT PLUNGER STRIKER CONDUCTOR PUNCH INSULATION PUNCH Figure 4-5 M2 X 5LG FHCS (2) M3 X 25LG SHCS (2) M3 X 20LG SHCS M3 X 6LG SHCS (2) M4 X 12LG BHCS (2) #10-32 X 3/8”LG BHCS ADJUSTING SCREW WIRE STOP BRACKET ADJUSTOR BAR M4 X 8LG LOW HEAD SHCS (2) M3 X 6LG SHCS (2) M5 X 10LG SHCS

Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 24 of 42 Revision: D Revision Date: 05-28-08 T2 Terminator Assembly (Figure 4-6) Item Order No. Description Qty 63800-0108 Terminal Track 1 63800-0115 Spacer Tube 1 63800-0312 Drag Frame 1 63800-0313 Drag Cam 1 63800-0316 Guide Pin - Drag Frame 2 63800-8501 T2 Terminator Base 1 69028-0660 Drag Springs 2 N/A M4 by 12 Long BHCS 1** N/A M5 by 10 Long SHCS 1** The components indicated with **are available from an Industrial supply company such as MSC (1-800-645-7270). (2) Figure 4-6 (2)

Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 25 of 42 Revision: D Revision Date: 05-28-08 RAM HOLD DOWN PLUNGER SET SCREW HOLD DOWN SPRING HOLD DOWN PLUNGER TERMINAL HOLD DOWN #5-32 SHCS M5 SHCS MOUNTING SCREW REAR STRIKER Figure 4-7 Rear Striker and Hold Down Installation (Figure 4-7)

  • Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 26 of 42 Revision: D Revision Date: 05-28-08 4.2. Troubleshooting Symptom
  • Cause Solution
  • Verify terminals are not bent or damaged Replace terminals
  • Feed finger worn or not properly adjusted Check proper finger setting
  • Drag plate holding terminal strip back Check compression springs
  • Terminal jammed under cover plate Clear and reinsert terminals Terminals do not index
  • Backstroke feed needs adjustment Adjust
  • Conductor punch worn Replace Excessive flare
  • Track out of position Adjust base and track for proper alignment with the punches and anvil away from the operator
  • Cut-off plunger adjusted to tight against anvil Readjust
  • Cut-off plunger spring damaged or broken Replace spring Cut-off plunger does not return to original position
  • Cut edges worn, plunger sides or plunger retainer scored Remove scoring marks. If problem not solved, replace with new cut-off parts.
  • Wrong tooling Replace with proper tooling
  • Tooling worn or damaged Replace tooling Conductor crimp is too loose
  • Wrong cam setting Adjust the conductor cam tighter
  • Wrong tooling Replace with proper tooling Conductor crimp is too tight
  • Cam out of adjustment Readjust conductor cam (Loosen)
  • Cam out of adjustment Readjust insulation cam (Loosen) Insulation crimp is too tight
  • Wrong tooling Replace with proper tooling
  • Wrong tooling Replace with proper tooling Terminal sticks during crimping
  • Tooling worn or damaged Replace tooling

Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 27 of 42 Revision: D Revision Date: 05-28-08 For more information use the Quality Crimping Handbook There is no charge for this book. It can be found on the Molex Website (www.molex.com) or contact you local Molex sales engineer.

  • Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 28 of 42 Revision: D Revision Date: 05-28-08 4.3. Base Unit Adapter
  • General Description
  • Die Stop Replacement General Description The Base Unit Adapter, figure 4-8, is an assembly which allows customers with 3BF Crimping Presses to run T and T2 Style Terminators. The Base Unit Adapter accepts the T and T2 Style Terminators. This combination is mounted in the 3BF Press. The 3BF Press is an older generation flywheel style crimping press no longer built, but still supported by Molex.

Die Stop Replacement Due to continual improvement to our application tooling, Molex has developed a universal 2-Piece Wire Stop used on most of our Applicator and T2 Terminator tooling. For the 2-Piece Wire Stop to fit the Base Unit Adapter, a new Hex Style Die Stop, 63800-9503, was developed. Shown in figure 4-9 this Hex Style Die Stop will permanently replace the existing Die Stop and 1/2 inch cap screw. 3BF PRESS T2 TERMINATOR Figure 4-8 Figure 4-8

Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 29 of 42 Revision: D Revision Date: 05-28-08 Figure 4-9 GUIDE PINS T2 TERMINATOR 1/2” CAP SCREW DIE STOP (EXISTING) Figure 4-10 T2 TERMINATOR HEX STYLE DIE STOP 63800-9503 2- PIECE WIRE STOP Replacement requires lifting the Ram off the two Guide Pins and loosening the 1/2 inch socket head cap screw with a 3/8” Hex Wrench.

Remove the 1/2 inch cap screw and the Die Stop. Screw in the new Hex Style Die Stop where the 1/2 inch cap screw was removed using a 5/8 inch wrench. The Hex Style Die Stop provides clearance for the universal 2-Piece Wire Stop. Reinstall the Ram.

Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 30 of 42 Revision: D Revision Date: 05-28-08 APPENDIX A Crimp Terminations B Statistical Process Control

Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 31 of 42 Revision: D Revision Date: 05-28-08 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

Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 32 of 42 Revision: D Revision Date: 05-28-08 INSULATION CRIMP BRUSH STRIP LENGTH BELL MOUTH CRIMP HEIGHT BEND DOWN BEND UP ROLLING 18 DUCTOR TWISTING CUT-OFF TAB SEAM Figure A-1 Figure A-3 Figure A-4 Figure A-2 TERMINAL ATTRIBUTES A.1 Conductor Brush and Terminal Position 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. A-2 Insulation Under Conductor Crimp, Good Conductor Brush Length Cause: Strip length too short. Solution: Verify strip length specification and adjust as necessary.

A-3 Insulation Under Conductor Crimp, Long Conductor Brush Length Cause: Wire stop position incorrect. Solution: Adjust wire stop to center the insulation in the transition area. A-4 Insulation Under Conductor Crimp, Short or No Conductor Brush Length Cause: 1) Strip length too short and 2) Wire stop position incorrect. Solution: 1) Verify strip length specification and adjust as necessary. 2) Adjust wire stop to center the insulation in the transition area.

Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 33 of 42 Revision: D Revision Date: 05-28-08 Figure A-8 Figure A-5 Figure A-7 Figure A-6 A-5 Insulation Edge Centered in the Transition Area, Conductor Brush Too Long Cause: 1) Strip length too long.

2) Irregular wire cut-off or wire strands pulled from insulation bundle. Solution: 1) Verify strip length specification and adjust as necessary. Readjust wire stop for bench applications. 2) Check for worn stripping blades. A-6 Insulation Edge in the Center of Transition Area, Conductor Brush Too Short Cause: Strip length too short. Solution: Verify strip length specification and adjust as necessary. Readjust wire stop for bench applications.

A-7 Insulation Edge Under Insulation Crimp Form, Good or Long 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 Form, Short or No Conductor Brush Length Cause: 1) Wire stop position incorrect. 2) Verify operator’s placement ability, or crimp rate. Solution: 1) Adjust the wire stop to center the insulation in the transition area. 2) Operator training, reduce crimping rate. A.2 Conductor Bell Mouth and Terminal Cutoff Tab A-2.1 Optimum Crimp Setup Tooling was set up to produce conductor bell mouth to nominal specification, and/or approximately 1x to 2x terminal material thickness.

The cutoff tab is approximately 1x terminal material thickness. A-2.2 Excessive Bell mouth, Cutoff Tab Flush With Insulation Crimp Cause: 1) Terminal tooling position. 2) Camber in the terminal strip. Solution: 1) Adjust terminal track into the Terminator. 2) Verify pull force.

Figure A-2.1 Figure A-2.2

Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 34 of 42 Revision: D Revision Date: 05-28-08 A-2.3 No or Small Bell mouth, Long Cutoff Tab Cause: 1) Terminal to tooling position. 2) Camber in the terminal strip. Solution: 1) Adjust terminal track towards operator. 2) Verify pull force. A-2.4 Excessive Bell mouth, Good Cutoff Tab Cause: 1) Check for worn conductor punch tooling. 2) Check for correct conductor punch tooling. Solution: Replace tooling if necessary A-2.5 Excessive Cutoff Tab, Good Conductor Bell mouth Cause: 1) Check for worn cutoff tooling.

2) Check for correct cutoff tooling. Solution: Replace tooling if necessary. A.3 Crimp Height Measurement NOTE: Conductor height should be measured with a blade type micrometer or a caliper. CAUTION: Care must be taken not to measure the extrusions A.3.1 Crimp height off target Cause: 1) Changed wire type, stranding or vendor. 2) Changed insulation color or durometer. 3) Changed crimp tooling.

4) Changed crimping press. (Shut-height) 5) Changed press type. (Manufacturer) 6) Changed terminal reel. (Lot code) 7) Changed tooling set-up. 8) Damaged or worn tooling. Solution: Adjust tooling back to target (Refer to Section 2.8 & 2.9) A.3.2 Crimp height variability too high Cause: 1) Wire variability. 2) Terminal variability. 3) Damaged, loose, or worn tooling. 4) Measurement error *. 5) Terminal spring back too great **. 6) Cut or missing wire strands. Solution: 1 or 2) Inspect incoming product for variability.

3) Tooling replacement or tightening. 4) Gauge capability analysis.

5) Tooling crimp height adjustment. 6) Stripping process adjustment. Figure A-2.3 Figure A-2.4 Figure A-2.5 CALIPER Figure A-3.1 CRIMP HEIGHT MEASUREMENT EXTRUSION POINTS MICROMETER

Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 35 of 42 Revision: D Revision Date: 05-28-08 * Most common cause of crimp height variability A.4 INSULATION CRIMP A.4.1 Preferred Insulation Crimp It is preferred that the insulation crimp surrounds the outside diameter of the insulation completely. 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 Acceptable Insulation Crimp A terminal is normally specified to cover a wide range of insulation wall thickness over a range of wire sizes. Within this specified range, an insulation crimp may not completely surround the wire, or fully hold the full diameter of the wire. This condition will still give an acceptable insulation crimp for most applications.

a) A large insulation crimp should firmly grip at least 88% of the wire.

b) A smaller insulation crimp should firmly grip at least 50% of the wire and firmly hold the top of the wire. A.4.3 Marginal Insulation Crimp An insulation diameter near the maximum and minimum specification of a terminal may cover less than what is normally considered acceptable. These strain reliefs should only be used on applications that have low vibration or movement. a) An insulation crimp that covers less than 88% of a large insulation diameter.

Cause: Not enough terminal grip length. Solution: 1) Evaluate if the same terminal is available in a different wire range. 2) Try crimping the wire one setting tighter. This will embed the terminal more into the insulation. The insulation wall thickness is normally enough; therefore cutting strands is not a worry. Terminal insulation grips kicking back away from the terminal or slight insulation bulging may be noticed. Evaluate the terminal loaded into a housing for acceptability ** It is normal for a termination to spring back to a final crimp position after crimping. It is possible to achieve the same final crimp height with two different tool height setups.

This is due to the inherent spring back characteristics of a terminal and wire combination. The tighter the crimp, the more it may spring back. You may adjust the crimp tool 0.05mm (.002") tighter and measure a crimp height change of only 0.03mm (.001"). Figure A-4.1 Preferred Insulation Crimp Figure A-4.2 Acceptable Insulation Crimp Figure A-4.3 Marginal Insulation Crimp

Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 36 of 42 Revision: D Revision Date: 05-28-08 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 Marginal Insulation diameters are crimps that are small, thin-walled insulated wire. A loose crimp ensures no strand damage and offers insulation containment. Insulation crimps that pierce through the insulation will offer more strain relief.

In some cases insulation terminal grips will push the strands to the side. Yet, there is 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. A.5 PULL FORCE TESTING A.5.1 Pull Force Procedure Wire connectors and soldering lugs for use with copper conductors. (Per UL486A October 8, 1991) UL Section 12 Pullout Test. 12.1 The connectors subjected to the static heating test or secureness test shall be subjected to a direct pull of the value specified for one minute. Only those conductors that have been subjected to the secureness test are to be subjected to the pullout test. The connector is acceptable if it does not become separated from the conductor or conductors after completion of the test.

12.2 For an insulated connector in which the insulation is assembled to the connector during installation, the test should be conducted with the insulation in place if it is always supplied with the connector by the manufacturer. Otherwise, the test should be conducted without the insulation assembled to the connector. Breaking or tearing of the insulation of an insulated connector is acceptable in the pullout test. The pull is to be exerted by means of a tension testing machine or equivalent, so that there will be no sudden application of force or jerking during the test.

The following is the procedure Molex uses for the qualification of pull force: 1.

Cut wire length approximately 150mm (6.0”) long. 2. Strip one end to 13mm (.50”), or long enough so no wire insulation is under the insulation grip. 3. Terminate the appropriate terminal to the wire to the nominal crimp height. 4. Visually inspect the termination for bell mouth, wire brush and cut strands. 5. Set pull tester to 25.4mm (1.0”.) per minute. For most applications, a higher rate will not have a significant impact on the data. Verify higher pull rates with data taken at 25.4mm (1.0”.) per minute. 6. Knot the non-terminated end of the wire.

Figure A-4.4 Marginal Insulation Crimp

Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 37 of 42 Revision: D Revision Date: 05-28-08 7. Regardless of pull tester type, both wire and terminated end must be securely clamped. (Note: If Clamp terminal contact interface, do not clamp conductor crimp.) 8. Activate pull test. 9. Record a minimum of 25 readings of maximum pull force. After the application has been qualified, a minimum of 5 pull force measurements should be done to confirm each setup. 10. Compare lowest reading to minimum pull force specification.

A.5.2 Pull Test Problems A.5.2.1 Wire breaks before conductor grip pull force low Material Evaluation Cause: Wire material properties, and/or coatings. Solution: Test non-terminated wire for breaking strength. Stripping Evaluation Cause: Cut or nicked strands from stripping operation. 1) Wire being manually stripped.

2) Poor automatic stripping cutoff. 3) Worn strip tooling. Solution: 1) Switch to semiautomatic or automatic wire stripping machine. 2) Correct stripping machine setup. A.5.2.2 Wire pulls out of conductor grip, crimp height good Material Evaluation Cause: 1) Terminal material thickness too small. 2) Terminal serration depth/form. 3) Terminal plating thickness. 4) Gold plating application. Solution: 1) Evaluate a new terminal. 2) Or 3) Contact terminal manufacturer. 4) Evaluate selective Gold application. Stripping Evaluation Cause: Wrong strip length, poor conductor brush. Solution: Adjust strip length.

Test Values For Pullout Test UL486A Conductor Size Pullout Force AWG mm2 N LB 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 Figure A-5.0 Pull Force Testing

Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 38 of 42 Revision: D Revision Date: 05-28-08 APPENDIX B Statistical Process Control (Summary) 1 Crimp Process Control 2 Process Capability 3 Production

Molex Terminator Doc No: ATS-638500090 Release Date: 01-07-99 UNCONTROLLED COPY Page 39 of 42 Revision: D Revision Date: 05-28-08 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 remanufacturing.

The key to quality is to target nominal specifications while continuously reducing variability. Achieving target is determined by the adjustability of the tooling. The Terminator 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 one N (.25 lbs). 2 Process Capability Molex qualifies each Terminator design for pull force and crimp height.

This qualification is performed on a common wire stranding, and is targeted at two 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. CpK +/- Sigma % Yield PPM 0.67 2 95.45 45,500 1 3 99.73 2,699 1.33 4 99.99 63 1.67 5 99.99+ 0.57 2 6 99.99++ 0 PPM - Parts per million potential defects. 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 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

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