Molex Taped Terminal Crimp Module
Doc. No: TM-640162000 Release Date: 12-03-08 UNCONTROLLED COPY Page 1 of 38
Revision: M Revision Date: 03-27-15
TAPED TERMINAL CRIMP MODULE
Operation Manual
Order No 64016-2000
Description
Operation
Maintenance
Molex Taped Terminal Crimp Module
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Revision: M Revision Date: 03-27-15
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
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.
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
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.
Always hand cycle the module in the equipment
to ensure the tooling is properly aligned.
Failure to observe these precautions may result in
injury or property damage.
Molex Taped Terminal Crimp Module
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Revision: M Revision Date: 03-27-15
WARNING
WARNING
Never use this 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.
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 equipment.
CAUTION
The Molex crimp module is designed to operate only in the Molex TM-3000 or TM-4000 presses.
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 Operation 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. Customer name
2. Customer address
3. Person to contact such as (name, title, e-mail, and telephone number
4. Applicator order number (Lease number also if applicable)
5. Serial number (Lease number also if applicable)
6. Molex Connector product order number
7. Urgency of request
8. Nature of problem
Molex Application Tooling Group
2200 Wellington Court
Lisle, IL 60532, USA
Tel: +1 (630) 969-4550
Visit our Web site at http://www.molex.com
Molex Taped Terminal Crimp Module
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Revision: M Revision Date: 03-27-15
Table of Contents
Contents
TAPED TERMINAL CRIMP MODULE ............................................................................................................................................ 1
Operation Manual ........................................................................................................................................................................... 1
Order No 64016-2000 ..................................................................................................................................................................... 1
Safety Warnings and Information ................................................................................................................................................... 2
Table of Contents ........................................................................................................................................................................... 4
Section 1 ......................................................................................................................................................................................... 5
General Description .................................................................................................................................................................... 5
Principal Mechanical Parts of the Taped Terminal Crimp Module .............................................................................................. 6
1.1 Description .................................................................................................................................................................... 7
1.2 Features ........................................................................................................................................................................ 7
1.3 Technical Specification ................................................................................................................................................. 7
1.4 Delivery Check .............................................................................................................................................................. 8
1.5 Tools ............................................................................................................................................................................. 8
1.6 Specification Sheets ...................................................................................................................................................... 8
Section 2 ......................................................................................................................................................................................... 9
Set-Up and Operation ................................................................................................................................................................ 9
2.1 Shut Height ................................................................................................................................................................. 10
2.2 Set-Up ......................................................................................................................................................................... 11
2.3. Crimp Height Adjustments .......................................................................................................................................... 12
2.4 Crimp Tooling Removal and Installation ...................................................................................................................... 13
2.5. Crimp Module Adjustments ......................................................................................................................................... 15
2.6 Operation .................................................................................................................................................................... 16
Section 3 ....................................................................................................................................................................................... 18
Maintenance ............................................................................................................................................................................. 18
3.1 Cleaning ...................................................................................................................................................................... 19
3.2 Lubrication................................................................................................................................................................... 19
3.3 Spare Parts ................................................................................................................................................................. 19
3.4 Perishable Parts .......................................................................................................................................................... 19
3.5 Spare Tooling Storage ................................................................................................................................................ 21
3.6 Module Storage ........................................................................................................................................................... 21
Section 4 ....................................................................................................................................................................................... 22
4.1 Parts Lists and Assemblies ......................................................................................................................................... 23
Assembly 64016-2000 (Figure 4-1) ..................................................................................................................................... 23
Parts List 64016-2100 (Figure 4-2) ...................................................................................................................................... 24
Assembly 64016-2100 (Figure 4-2) ..................................................................................................................................... 25
Parts List 64016-2200 (Figure 4-3) ...................................................................................................................................... 26
Assembly 64016-2200 (Figure 4-3) ..................................................................................................................................... 27
Parts List 64016-2300 (Figure 4-4) ...................................................................................................................................... 28
Assembly 64016-2300 (Figure 4-4) ..................................................................................................................................... 29
4.2 Troubleshooting .......................................................................................................................................................... 30
4.3 Guarding to be used on a TM-3000 and TM-4000 Press with the Tape Crimp Module Guard (64016-2000) ............. 30
Appendix A ................................................................................................................................................................................... 36
Pull Force Testing .................................................................................................................................................................... 37
A.1 Pull Force Procedure .............................................................................................................................................. 37
A.2 Pull Test Problems .................................................................................................................................................. 37
Molex Taped Terminal Crimp Module
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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 Taped Terminal Crimp Module
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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 PRESS YOKE
Figure 1-1
FEED
CYLINDER
Principal Mechanical Parts of the Taped Terminal Crimp Module
TERMINAL
FRONT GUIDE
Molex Taped Terminal Crimp Module
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General Description
1.1 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 (Order No. 19228-0030) and the Molex ATP-
201 Press (Order No. 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. Order No. 63801-7200
TM-3000 Universal Press 240V 50-60 Hz. Order No. 63801-7300
The TM-3000 should be used for 10-30 AWG terminals.
TM-4000 Universal Press 240V 50-60 Hz. Order No. 63801-7600
The TM-4000 should be used for 4-30 AWG terminals.
1.2 Features
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.
1.3 Technical Specification
Dimensions
Crimp Module Only
Width: 140mm (5.5")
Depth: 136mm (5.3")
Height: 175mm (6.9")
(ram down)
Weight 4.1kgf (9lbf)
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.
Molex Taped Terminal Crimp Module
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1.4 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.
1.5 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
1.6 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).
Molex Taped Terminal Crimp Module
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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
Molex Taped Terminal Crimp Module
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ADJUSTABLE
DIAL
LOOSEN M6 SOCKET
HEAD SCREW
Figure 2-2
LOOSEN M6 SOCKET
HEAD SCREW
SHUT HEIGHT GAUGE
PRESS QUICK CHANGE
MOUNTING PLATE
Figure 2-1
PRESS
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 severe tool damage.
Before installing the crimp module, the press shut height must be verified. The correct shut height is required for
proper crimping without causing tool damage.
The shut height of the TM-3000 and the TM-4000 presses are preset at the factory and labeled on the front of the press. Over
time, however, the press may wear causing 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 achieve the 135.80mm
(5.346") measurement. It is recommended that the shut height be checked monthly. A shut height gauge is available from
Molex, order number 63800-7900.
Always turn off and disconnect the power supply to the press.
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 instructions; the gauge reads “0” at the
correct shut height.
6. If shut height adjustment is necessary:
a. Loosen the four M6 socket head screws 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 socket head screws.
7. Repeat the above steps until the correct shut height is obtained.
8. Shut height gauges must be calibrated on a regular basis.
Molex Taped Terminal Crimp Module
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QUICK
CHANGE
PLATE
LOCATOR
CLAMPS
LOCKING
CLAMP
M5
SOCKET HEAD
SCREW
Figure 2-3
RAM
ADAPTER
BASE PLATE
PRESS YOKE
2.2 Set-Up
The principal mechanical parts of the crimp module are illustrated in the assembly drawings (Section 4-1).
Always turn off and disconnect the power supply to the press.
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, remove the locking set screw and loosen the set screw holding the press yoke. Pull the press
yoke straight down and remove it from the press. (Note: a storage 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 module in the press ram. Tighten the set screw securely and install the
locking screw.
5. Using a 4mm hex wrench, turn the M5 socket head screw clockwise until the locking clamp is fully opened.
6. Visually align the crimp module’s 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 side engage against the
stops, and at the same time, guide the ram adapter into the press yoke. See Figure 2-3.
8. To lock the crimp module, turn the M5 socket head screw 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 the 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 anvils 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 2-4.
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.
ANVIL
Figure 2-4
LOOSEN THE
#10 SOCKET HEAD SCREW
Molex Taped Terminal Crimp Module
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LOOSEN THE
#10 SOCKET HEAD SCREW
Figure 2-5
INSULATION CAM
PUNCHES
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 solder diameter is too large the crimped slug will have large extrusions, making it difficult to
measure the overall slug height.
2. With no terminals in the applicator, lay the solder across the anvils and cycle the press (under power).
3. Using a crimp micrometer or dial caliper, measure the solder slug height and compare to specification.
4. If adjustments are necessary, turn off the press and open the machine guard.
5. The conductor crimp height is based on the conductor 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 need 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 for shut height adjustment.
NOTE: Crimp height adjustments for closed-barrel industrial terminals are always based on solder slug 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 verify the mechanical integrity of the crimp. See Appendix A-Pull Force
Test.
Insulation Crimp Height
1. Place a stripped length of the appropriate wire into 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 socket head screw 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, and small diameter wires. The cam must be in one of the three positions; do not adjust it
between positions. See Figure 2-5.
6. While holding the punches up against the punch holder, securely tighten the #10 socket head screw.
7. Close the machine guards, restore power, and crimp a wire under power. Inspect the insulation crimp and make further
adjustments if needed.
Note: Due to the large variety of insulation wall thickness, materials, and durometers, Molex does not specify insulation
crimp height on closed –barrel terminals.
Molex Taped Terminal Crimp Module
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#10 SOCKET
HEAD SCREW
NOTE THE SIDE
PLATE POSITION
O-RING
Figure 2-7
ANVILS
ANVIL MOUNT
Figure 2-6
PUNCH HOLDER
PUNCHES
O-RING
#10 SOCKET
HEAD SCREW
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.
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 socket head screw holding the punches to the punch
holder. See Figure 2-6.
4. Remove the screw, punches, and O-ring together. Some tool kits may include a spacer plate (behind the conductor
punch).
5. To install, place the punches with the spacer (if used) and O-ring against the punch holder and securely tighten the #10
socket head screw. The conductor punch (“E2”) goes against the punch holder and the insulation punch (“I2”) is stacked
on the conductor punch. Make 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 punch and anvil. If
excessive resistance is felt, check for an incorrectly installed punch and/or anvil misalignment.
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 socket head screw holding the anvils to the anvil
mount. See Figure 2-7.
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 used) 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 “I1”on 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 socket head screw and reverse the side plate.
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Figure 2-9
FLAT FACE
OF THE ATP-201
PUNCH FACING
FORWARD
RAM
RAM
SET SCREW
VISIBLE IN
THE HOLE
RAM IN THE
FULL UP
POSITION
Figure 2-8
ATP-201
PUNCH
Figure 2-10
#10 SOCKET
HEAD SCREW
NOTE THE SIDE
PLATE POSITION
O-RING
ANVIL
ANVIL MOUNT
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
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 module’s front cover. See Figure 2-8.
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 2-9.
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
socket head screw holding the anvils to the anvil mount. See
Figure 2-10.
4. Remove the screw, anvil(s), and O-ring together.
5. To install, place the anvil(s) 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 “I1”on each anvil face
outward.
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KNOB
LOCKING
RING
Figure 2-11
FEED
CYLINDER
ADJUST
WIRE STOP
TERMINAL
M5 SOCKET
HEAD SCREW
Figure 2-13
ADJUST
Figure 2-12
ADJUST
M5 SOCKET
HEAD SCREW
M5 SOCKET
HEAD SCREW
WARNING: Use the mounting screws that are furnished with the ATP tool kit. Screws that are to 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 is not, loosen the M4 socket head screw 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 has no adjustable features.
Feed Speed Adjustments
Terminal feed speed is controlled by the flow control valve on the feed cylinder. Loosen the locking ring, then turn the
adjustment knob clockwise (CW) to reduce the feed speed or counterclockwise (CCW) to increase the feed speed. See
Figure 2-11.
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
socket head screw on the side of the stripper. Move the stripper toward
the punches, but not too close or it could interfere with the ram stroke.
See Figure 2-12. Tighten the M5 socket head screw when adjustment is
complete.
4. To adjust the stripper up and down, use a 4mm hex wrench to loosen the
M5 socket head screw 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 socket head screw when adjustment is complete.
NOTE: If the stripper is adjusted down too far it may interfere with the
terminal feed motion.
Molex Taped Terminal Crimp Module
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TRIM THE CORNER
OF THE TAPE
Figure 2-14
TRACK
COVER CLOSED
TRACK COVER
OPEN
HOLE
PULL KNOB OUT
LIFT KNOB UP
Figure 2-15
Figure 2-16
TERMINAL
ON ANVIL
TAPE SLOT
TERMINAL
Wire Stop Adjustment
The wire stop is used when the terminal being crimped does not have an internal wire stop tab. Some larger ring
terminals fall into this category.
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 wire stop, loosen the M5 socket head screw on the side of the stripper. Move the wire stop in or out
until it is near the end of the terminal barrel. See Figure 2-13. Tighten the M5 socket head screw when adjustment
is complete.
NOTE: Since they are mounted to the same block, adjustments to the wire stop will also influence the terminal stripper.
To achieve full adjustment of the wire stop, the stripping tool may need to be removed from the block.
2.6 Operation
Loading and Unloading Tape
1. Applicable terminals are listed on the Crimp Tooling Specification Sheet. Do not crimp terminals that are 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 2-14.
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 knob’s pin to
enter to hold the track cover open. See Figure 2-15.
5. Load the taped terminal strip from the front of the module, engaging the
slots in the tape with the teeth on the feed wheel. Make sure the terminal is
also centered above the crimp anvils. See Figure 2-16.
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.
Molex Taped Terminal Crimp Module
Doc. No: TM-640162000 Release Date: 12-03-08 UNCONTROLLED COPY Page 17 of 38
Revision: M Revision Date: 03-27-15
Figure 2-17
TAPE ENTERS
THRU GUARD
TAPE EXIT
TAPE REEL
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 the press guard below the bottom horizontal bar. If the tape is
threaded between the bars, a terminal may become snagged on the bar during feeding. See Figure 2-17.
While operating the crimp module, the tape entering the press should not become taut. The operator should
occasionally turn the terminal reel to maintain a slack 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 operator’s responsibility to
remove the crimped terminal from the tape.
If crimped wires are allowed to accumulate on the tape they will eventually cause a tape feed jam.
To prevent tape damage, the terminal should be pulled off the tape towards the operator’s right. This sideways action
makes it easier for the terminal to break free from the adhesive holding it to the tape.
Molex Taped Terminal Crimp Module
Doc. No: TM-640162000 Release Date: 12-03-08 UNCONTROLLED COPY Page 18 of 38
Revision: M Revision Date: 03-27-15
Section 3
Maintenance
3.1 Cleaning
3.2 Lubrication
3.3 Spare parts
3.4 Perishable Parts
3.5 Spare Tooling Storage
3.6 Module Storage
Molex Taped Terminal Crimp Module
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Revision: M Revision Date: 03-27-15
Figure 3-1
RAM LUBRICATION
GREASE RAM
(4 SIDES)
CAUTION: Always disconnect power before any maintenance activity
3.1 Cleaning
The crimp module should be cleaned daily. Use a soft bristle brush to remove debris from critical areas such as the
crimp tooling and tape track. For best results, remove the tooling from the module. Brush and then use a clean cloth to
wipe off the upper and lower tooling mounting areas. Tooling that crimps un-insulated terminals should be inspected for
possible plating build-up.
Before reinstalling tooling, wipe all sides of the punches and anvils with a clean cloth.
Do not use compressed air to clean the applicator. The forces created by compressed air can force debris into
the tool.
3.2 Lubrication
1. Grease the ram path. Lubricate with multipurpose synthetic lubricant with Teflon or an equivalent. Molex ships its
applicators pre-greased with Permatex multi-purpose synthetic grease with Teflon No. 82329.
2. The feed wheel is on a pre-lubricated bearing and should require no further lubrication.
WARNING: Never use penetrants such as WD-40 or Liquid Wrench for any lubrication on the crimp module.
3. Never lubricate the air cylinder. It is designed to run on dry air.
3.3 Spare Parts
Customers are responsible for maintaining the crimp module. 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 spare parts in stock to reduce production down time. These parts are identified in the Parts List. See Section 4.
3.4 Perishable Parts
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 Application Tooling
Specification Sheet available at Molex.com.
Molex Taped Terminal Crimp Module
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Revision: M Revision Date: 03-27-15
PRESS YOKE
ATP-301
PUNCH
HOLDER
WIRE STOP/
STRIPPER UNIT
STORE
WIRE STOP/ STRIPPER
WHEN NOT IN USE
STORE
PRESS YOKE
WHEN NOT IN USE
Figure 3-2
STORE
ATP-301 PUNCH
HOLDER
An example of a maintenance chart is shown below. Copy and use this chart to track the maintenance of the crimp
module or use this as a template to create your 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 _________
Week
Daily
Cycles
Daily
Clean
Days of the Week
Solution
MON
TUE
WED
THU
FRI
SAT
1
2
3
4
Cleaning Reapply grease
Reapply oil
25,000
Yes
Soft Brush Industrial
Degreaser
Inspect all tooling and
terminal feed for wear
25,000
Yes
Replace if signs
of wear.
Schedule should be adjusted up or down depending on usage. Molex recommends that a log of preventive
maintenance be kept with the press.
Molex Taped Terminal Crimp Module
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Revision: M Revision Date: 03-27-15
3.5 Spare Tooling Storage
To prevent unused tools from getting lost, the following on-module storage is available. See Figure 3-2.
The ATP301 punch holder can be mounted to the side of the frame.
The press yoke (or yoke from the TM-3000/TM-4000 Press) can be mounted to the side of the frame.
The wire stop/stripper unit can be mounted to the rear of the frame.
3.6 Module Storage
Prior to storage, the crimp module should be thoroughly cleaned and lubricated.
To prevent the bottoming of the ram which can cause damage to the crimp punches and anvils, leave a strip of
terminals in the applicator or place a piece of wood or rubber between the punches and the anvils.
Molex Taped Terminal Crimp Module
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Revision: M Revision Date: 03-27-15
Section 4
4.1 Parts Lists and Assembly Drawings
4.2 Troubleshooting
4.3 Press Guard Upgrade (For earlier TM-3000 presses)
Molex Taped Terminal Crimp Module
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Revision: M Revision Date: 03-27-15
1
2
3
Figure 4-1
4.1 Parts Lists and Assemblies
Molex Taped Terminal Crimp Module Figure 4-1
Item
Order No
Description
Quantity
Notes
1
64016-2100
Crimping Module Top Assembly
1
Figure 4-2
2
64016-2200
Crimping Module Track Assembly
1
Figure 4-3
3
64016-2300
Crimping Module Frame Assembly
1
Figure 4-4
Assembly 64016-2000 (Figure 4-1)
Molex Taped Terminal Crimp Module
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Revision: M Revision Date: 03-27-15
Parts List 64016-2100 (Figure 4-2)
Crimping Module Top Assembly 64016-2100
Item
Order No
Engineering No.
Description
RSP / PP Parts
Quantity
1
19228-0147
19228-0147
Cam-Insulation Crimp (ATP)
1
2
19228-0240
19228-0240
Back Plate-Upper Punch Hold
1
3
63700-4556
63700-4556
"E"-RING (5/32 Inch)
1
4
63600-3018
63600-3018
Shoulder Bolt
1
5
63600-3025
63600-3025
M5-Hard Washer
2
6
63801-6447
63801-6447
Ram Adapter
1
7
64016-2101
64016-2101
Ram
1
8
64016-2102
64016-2102
Yoke
1
9
64016-2103
64016-2103
301 Punch Holder
1
10
64016-2104
64016-2104
Mount, Wire Stop
1
11
64016-2105
64016-2105
Wire Stop
RSP
1
12
64016-2106
64016-2106
Stripper Arm
1
13
64016-2107
64016-2107
Stripper
1
Hardware
14
N/A
N/A
M2.5 by 6 Long SHCS
2**
15
N/A
N/A
M4 by 14 Long SHCS
2**
16
N/A
N/A
M5 by 14 Long SHCS
1**
17
N/A
N/A
M5 by 20 Long SHCS
1**
18
N/A
N/A
M8 by 25 Long FHCS
1**
19
N/A
N/A
M6 by 12 Long Set Screw
2**
20
N/A
N/A
3mm by 8 Long Dowel Pin
2**
RSP - Part is a Molex Recommended Spare Part.
PP - Part is a Perishable Part.
** Available from an industrial supply company such as MSC (1-800-645-7270).
Molex Taped Terminal Crimp Module
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Revision: M Revision Date: 03-27-15
8
19
9
14
13
3
1
7
(2)
18
6
5
20
11
2
10
4
Figure 4-2
(2)
16
12
15
17
(2)
(2)
Assembly 64016-2100 (Figure 4-2)
Molex Taped Terminal Crimp Module
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Revision: M Revision Date: 03-27-15
Parts List 64016-2200 (Figure 4-3)
Crimping Module Track Assembly 64016-2200
Item
Order No
Engineering No.
Description
RSP / PP Parts
Quantity
1
011321058
011321058
Male Elbow Air Fitting
1
2
62500-1584
62500-1584
Flow Control, Cylinder Mount
1
3
63600-3005
63600-3005
Air Cylinder
RSP
1
4
63600-3007
63600-3007
Spacer - Washer
1
5
63600-3008
63600-3008
Indexing Plunger
1
6
63600-3009
63600-3009
Spacer - Washer
1
7
63600-3010
63600-3010
Hinge Pin - Pivot
1
8
63600-3014
63600-3014
Washer
2
9
63600-3016
63600-3016
Ball Plunger
RSP
1
10
63600-3022
63600-3022
Key - 3mm by 3mm by 6mm Long
1
11
63600-3023
63600-3023
Key - 3mm by 3mm by 10mm Long
1
12
63600-3060
63600-3060
Extension Spring
1
13
63600-3093
63600-3093
Collar
1
14
64016-2201
64016-2201
Tape Track Bottom
1
15
64016-2202
64016-2202
Tape Track Top
1
16
64016-2203
64016-2203
Tape Drive Disk
1
17
64016-2204
64016-2204
Tape Index Wheel
RSP
1
18
64016-2205
64016-2205
Tape Drive Shaft
1
19
64016-2206
64016-2206
Ratchet Wheel
1
20
64016-2207
64016-2207
Cam Arm Retainer
1
21
64016-2208
64016-2208
Indexing Cam Arm
1
22
64016-2209
64016-2209
Index Clevis
1
23
64016-2213
64016-2213
Cylinder Mount
1
24
63700-5064
63700-5064
Nylon Tubing
2
Hardware
25
N/A
N/A
M3 Hex Nut
2**
26
N/A
N/A
M3 by 12 Long SHCS
2**
27
N/A
N/A
M5 by 14 Long SHCS
4**
28
N/A
N/A
M5 by 16 Long BHCS
1**
29
N/A
N/A
M5 by 20 Long SHCS
1**
30
N/A
N/A
M5 by 25 Long SHCS
2**
31
N/A
N/A
M5 by 35 Long SHCS
2**
32
N/A
N/A
M5 by 40 Long SHCS
2**
RSP - Part is a Molex Recommended Spare Part.
PP - Part is a Perishable Part.
** Available from an industrial supply company such as MSC (1-800-645-7270).
Molex Taped Terminal Crimp Module
Doc. No: TM-640162000 Release Date: 12-03-08 UNCONTROLLED COPY Page 27 of 38
Revision: M Revision Date: 03-27-15
19
13
23
30
21
6
22
(2)
26
29
1
8
3
26
31
7
2
11
20
Figure 4-3
(2)
(2)
(2)
17
18
16
10
8
26
28
14
4
9
12
24
25
27
5
15
64016-2301
REF
(2)
(2)
32
(2)
Assembly 64016-2200 (Figure 4-3)
Molex Taped Terminal Crimp Module
Doc. No: TM-640162000 Release Date: 12-03-08 UNCONTROLLED COPY Page 28 of 38
Revision: M Revision Date: 03-27-15
Parts List 64016-2300 (Figure 4-4)
Crimping Module Frame Assembly 64016-2300
Item
Order No
Engineering No.
Description
Quantity
1
63600-2003
Pipe Collar
2
2
63600-2004
Link
1
3
63600-2915
5mm Dowel Pin by 10 Long
2
4
63600-3011
Bushing
1
5
63600-3025
M5 Harder Washer
2
6
64016-2301
Frame
1
7
64016-2302
Side Plate
2
8
64016-2303
Anvil Mount
1
9
64016-2305
Adapter Plate
1
10
64016-2306
Front Cover
1
Hardware
11
N/A
N/A
M4 by 8 Long SHCS
1**
12
N/A
N/A
M4 by 12 Long SHCS
4**
13
N/A
N/A
M5 by 12 Long BHCS
6**
14
N/A
N/A
M5 by 16 Long SHCS
4**
15
N/A
N/A
M5 by 45 Long SHCS
2**
16
N/A
N/A
M6 by 12 Long Set Screw
2**
17
N/A
N/A
M6 by 14 Long SHCS
4**
18
N/A
N/A
M8 by 8 Long Set Screw
1**
** Available from an industrial supply company such as MSC (1-800-645-7270).
Molex Taped Terminal Crimp Module
Doc. No: TM-640162000 Release Date: 12-03-08 UNCONTROLLED COPY Page 29 of 38
Revision: M Revision Date: 03-27-15
8
9
14
13
3
1
7
(4)
18
6
5
11
2
10
4
Figure 4-4
(2)
16
12
15
17
(2)
(2)
(2)
(2)
13
(4)
(4)
(2)
(4)
Assembly 64016-2300 (Figure 4-4)
Molex Taped Terminal Crimp Module
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Revision: M Revision Date: 03-27-15
4.2 Troubleshooting
Symptom
Cause
Solution
Tape does
not feed
Reel jam or jam at track entry
Check tape entry into track
Tape jam in track
Reload tape
Feed cylinder flow too restricted
Adjust flow control open
Insufficient air pressure to feed cylinder
Adjust air pressure >80psi (0.5MPa)
Tape splice jammed in track
Clear jam
Tape overfeeds
Feed cylinder advancing too fast
Adjust flow control
Excessive flare (bell mouth)
(Un-insulated Product)
Conductor punch worn
Replace
Tooling backwards
Reverse mounting of Tooling
Conductor crimp
is too loose
Worn Tooling
Replace with new tooling
Wrong tooling
Replace with proper tooling
Wrong conductor crimp height
Reset conductor crimp height
Press shut height too high
Calibrate press shut height
Conductor crimp
Is too tight
Wrong tooling
Replace with proper tooling
Wrong crimp height
Reset crimp height
Punch installed backwards
Reverse mounting of punch
Press shut height too low
Calibrate press shut height
Terminal sticks
during crimping
Stripping blade too high
Lower stripping blade
Wrong tooling
Replace with proper tooling
Tooling worn or damaged
Replace tooling
Insulation crimp
is too tight
Wire insulation too big for terminal
Check product specification
Wrong insulation crimp height
Reset insulation crimp height
Wrong tooling
Replace with proper tooling
Press shut height too low
Calibrate press shut height
Low Pulls
Dies Backwards
Reverse mounting of Dies
Worn Tooling
Replace with new tooling
Crimp specification not achieved
Check solder slug height
Product location on tape incorrect
Replace with proper product
Wrong tooling
Replace with proper tooling
4.3 Guarding to be used on a TM-3000 and TM-4000 Press with the Tape Crimp Module Guard
(64016-2000)
The Molex TM-3000 and TM-4000 presses come standard with the 64016-2595 guard for industry standard
applicator use. However, when installing and using the Molex Tape Crimp Module (64016-2000) in the TM-
3000 or TM-4000 presses, the Tape Crimp Module Guard (64016-2800) must be installed to meet OSHA
safety regulations by the operator. The 64016-2800 Tape Crimp Module Guard comes with the purchase of
the 64016-2000 Crimp Tape Module. Below are instructions on how to install the Tape Crimp Module Guard
and the available “point of operation” guards for different wire sizes or replacement. The Tape Crimp Module
Guard will only fit into a Molex TM-3000 or TM-4000 crimp press and cannot be used in any other press
system.
FEATURES
An Exit Guide to assist in removing crimped wires and used Mylar tape from the press.
This feature allows the operator to leave crimped wires attached to the Mylar tape, and then after several
more machine cycles, the crimps can be easily removed from the tape, outside of the press guards.
A choice of easy to install “Point of Operation Guards”, designed to help get wires into the closed barrel
contacts for easier crimping. See Chart 1.
Molex Taped Terminal Crimp Module
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Revision: M Revision Date: 03-27-15
GUARDS
SHOWN REMOVED
Figure 4-6
Figure 4-7
INSTALL
64016-2308
EXIT GUIDE
INSTALL
(2) M5 BHCS
AND WASHERS
REMOVE
(4) M4 BHCS
TM-3000
or TM-4000
PRESS
REMOVE
(4) M4 BHCS
Figure 4-5
64016-2541
64016-2537
Chart 1
3 possible configurations for the Tape Module Guard Upgrade Kit.
All Shown with the Exit Guide and Right Guard for reference only
64016-3360
64016-3365
64016-3370
Point of Operation Guard Assembly
for 16 AWG to 8 AWG Wire Sizes
Point of Operation Guard Assembly
for 18 AWG and Smaller Wirer Sizes
Point of Operation Guard Assembly
for 6 AWG to 2AWG Wire Sizes
Preparing the Press for the Tape Crimp Module Guarding
Always turn off and disconnect the power supply to the press when changing over any guarding.
Do Not Use the TM-3000 or TM-4000 Crimp Press without all the correct Guarding installed.
1. If the TM-3000 or TM-4000 press was previously set up for use
with a standard metal strip applicator, the guard assembly
(64016-2590) will need to be changed to the 64016-2595 Safety
Guard Upgrade Kit.
2. Remove the (4) M4 BHCS from the Front Guard (Order number
64001-2537) and the (4) M4 BHCS from Right Guard (Order
number 64016-2541). See Figure 4-5.
3. Remove the Front and Right Guard and set aside.
See Figure 4-6.
Molex Taped Terminal Crimp Module
Doc. No: TM-640162000 Release Date: 12-03-08 UNCONTROLLED COPY Page 32 of 38
Revision: M Revision Date: 03-27-15
INSTALL 64016-3360
POINT OF OPERATION GUARD
INSTALL
(4) M4 BHCS
Figure 4-9
INSTALL
(4) M4 BHCS
INSTALL 64016-2547
GUIDE EXTENSION
Figure 4-8
INSTALL 64016-2309
RIGHTGUARD
Figure 4-10
INSTALL THE 64016-3365
POINT OF OPERATION
GUARD ASSEMBLY
REMOVE THE
TERMINAL STRIPPER
INSTALL
(4) M4 BHCS
(2) 64016-2523
MOUNTING
BRACKETS
(2) 64016-2523
MOUNTING
BRACKETS
For all wire sizes install the guard assembly in the following steps:
1. Install the Exit Guide (Order number 64016-2307).
2. Install the (2) M5 BHCS with the hardened washers into the Exit
Guide. See Figure 4-7.
3. Install the Right Guard (Order number 64016-2309) using the
threaded holes in the top mounted brackets with (2) M4 BHCS.
See Figure 4-8.
4. Install the Guide Extension (Order number 64016-2547) using the
threaded holes in the bottom mounted brackets with (2) M4
BHCS. See Figure 4-8.
Note: The Right Guard, Exit Guide, and the Guide Extension are used with all three Tape Module Point of
Operation Guard Assemblies. They do not need to be removed when changing Tape Module Point of
Operation Guard Assemblies for different wire sizes.
Installing the 64016-3360 Point of Operation Guard Assembly
(For 16 AWG to 8 AWG wire crimping)
1. Install the Point of Operation Guard assembly (Order number 64016-
3360) into the threaded holes in the (4) mounting brackets (64016-
2523) with (4) M4 BHCS. See Figure 4-9.
Installing the 64016-3365 Point of Operation Guard Assembly
(For 18 to and smaller AWG wire crimping)
Note: If using the optional wire stop, (that is stored on the tape module)
the terminal stripper may need to be removed before installing the 64016-3365 Point of Operation Guard
Assembly.
1. The 64016-3365 Point of Operation Guard Assembly is designed to allow the operator to get closer to the
crimping area, when using 18 AWG and smaller wire.
2. Remove the (4) M4 BHCS and any Point Of
Operation Guard.
3. Place the 64016-3365 Point of Operation
Guard Assembly on the far side of the (4)
mounting brackets (64016-2523).
4. Install the (4) M4 BHCS into the clearance
holes (not the tap holes). See Figure 4-10.
Note: That the 64016-3365 Point of Operation
Guard Assembly is recessed inward, for easy
access to the crimping area.
Molex Taped Terminal Crimp Module
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Revision: M Revision Date: 03-27-15
Figure 4-12
EXISTING (2) M5 BHCS
INSTALL THE
64016-3600
WIRE GUIDE
ASSEMBLY
Figure 4-11
SWING THE FRONT DOOR
GUARD ASSEMBLY
HANDLE
OPEN
Figure 4-14
FRONT DOOR
GUARD OPEN
64016-3330
INSTALL
(4) M4 BHCS
INSTALL THE 64016-3370
POINT OF OPERATION GUARD
Figure 4-13
FRONT DOOR
GUARD
Installing the 64016-3370 Point of Operation Guard Assembly
(For 6 AWG to 2 AWG insulation wire crimping)
Always turn off and disconnect the power supply to the press when changing over any guarding.
1. Open the front door guard assembly by using the handle mounted on the door. Swing the door
approximately 90° so there will be access to backside of the guard door in order to mount the Point of
Operation Guard Assembly. See Figure 4-11.
2. Install the Wire Guide Assembly (Order Number 64016-3600) using the (2) M5 BHCS on the front of the
64016-2000 tape module. Adjust the height of the Wire Guide Assembly to best suit the application. See
Figure 4-12.
3. Place the Point of Operation (Order Number 64016-3370) 6 AWG to 2 AWG Guard Assembly on the outside
of the Front Door Guard. See Figure 4-13.
4. From inside of the Front Door Guard, locate the clearance holes of the (4) mounting brackets (64016--2523).
5. Install the Point of Operation (Order Number 64016-3370) 6 AWG to 2 AWG Guard Assembly using (4) M4
BHCS through the mounting brackets and into the (4) square posts. See Figure 4-14.
6. Close the Front Door Guard assembly making sure the magnetic latch secures it shut.
Molex Taped Terminal Crimp Module
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Revision: M Revision Date: 03-27-15
Figure 4-15
1
5
4
2
TAPE CRIMP MODULE
REFERENCE
3
7
6
Parts List
Tape Crimp Module Guard 64016-2800. See Figure 4-15
Item No.
Order No.
Eng. No.
Description
Qty.
1
64016-2308
64016-2308
Exit Guide
1
2
64016-2309
64016-2309
Right Guard
1
3
64016-2547
64016-2547
Guide Extension
1
4
64016-3360
64016-3360
Point of Operation Guard Assembly Tape Module 16 AWG to 8 AWG
1
5
64016-3365
64016-3365
Point of Operation Guard Assembly Tape Module 18 AWG or Smaller
1
6
64016-3370
64016-3370
Point of Operation Guard Assembly Tape Module 6 AWG to 2 AWG
1
7
64016-3600
64016-3600
Wire Guide Assembly
1
Assembly
Molex Taped Terminal Crimp Module
Doc. No: TM-640162000 Release Date: 12-03-08 UNCONTROLLED COPY Page 35 of 38
Revision: M Revision Date: 03-27-15
For more information use the Industrial Crimp Quality Handbook
There is no charge for this book, which can be found on the Molex website (www.molex.com) or contact your local
Molex sales engineer
Molex Taped Terminal Crimp Module
Doc. No: TM-640162000 Release Date: 12-03-08 UNCONTROLLED COPY Page 36 of 38
Revision: M Revision Date: 03-27-15
Appendix A
A.1 Pull Force Procedure
A.2 Pull Force Problems
Molex Taped Terminal Crimp Module
Doc. No: TM-640162000 Release Date: 12-03-08 UNCONTROLLED COPY Page 37 of 38
Revision: M Revision Date: 03-27-15
Pull Force Testing
A.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. 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 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.
7. Regardless of pull tester type, both wire and terminated end must be securely clamped. (Note: The clamp terminal
contact interface, do not clamp the conductor crimp. Insulated terminals should have their insulation trimmed back so
the contact can be clamped.)
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.2 Pull Test Problems
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.
PULL FORCE TESTING
Molex Taped Terminal Crimp Module
Doc. No: TM-640162000 Release Date: 12-03-08 UNCONTROLLED COPY Page 38 of 38
Revision: M Revision Date: 03-27-15
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.
Solution: 1) Evaluate a new terminal.
2) Or 3) Contact terminal manufacturer.
Stripping Evaluation
Cause: Wrong strip length.
Solution: Adjust strip length.
Tensile Test Value (LB)
Wire Size (AWG)
*Military
**UL- 486A
***UL – 486C
*****UL-310
26
7
3
N/A
N/A
24
10
5
N/A
N/A
22
15
8
8
8
20
19
13
10
13
18
38
20
10
20
16
50
30
15
30
14
70
50
25
50
12
110
70
35
70
10
150
80
40
80
8
225
90
45
N/A
6
300
100
50
N/A
4
400
140
N/A
N/A
2
550
180
N/A
N/A
1
650
200
N/A
N/A
1/0
700
250
N/A
N/A
2/0
750
300
N/A
N/A
3/0
825
350
N/A
N/A
4/0
875
450
N/A
N/A
*Military – Military Approved Terminals
**UL-486A – Terminals (Copper conductors only)
***UL-486C – Butt Splices, Parallel Splices, Closed End Connectors, and Wire Nuts
****UL-310 – Quick Disconnects, Flags and Couplers
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