View 11-31-1786_4150709.PDF datasheet online --- IC-ON-LINE

Datasheet File OCR Text:

hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 1 of 39 revision: d revision date: 03-03-11 hawk discrete wire termination machine operation manual order no. 11-20-0949 engineering no. am-60520e for c-grid sl idt connector, 70400 series description operation maintenance
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 2 of 39 revision: d revision date: 03-03-11 warning never use this machine without the guards or safety devic es that are intended to prevent hands from remaining in the te rmination or feed areas. running this machine without guards, under any circumstances, can cause serious injury. never lift this machine without the aid of mechanical lif ting devices. severe back or other injuries can result. never operate, service, or adjust this machine, or instal l termination tooling, without proper instruction and without fir st reading and understanding the instructions in this manual. never install termination tooling or service this machine while it is connected to any electrical power source. disconne ct power by unplugging the machine from its power source. 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
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 3 of 39 revision: d revision date: 03-03-11 table of contents section 1. general description 2. setting up and operation 3. maintenance, troubleshooting, and fault message dia gnostics 4. parts lists, assembly drawings, and schematics 5. glossary appendix a termination information b options
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 4 of 39 revision: d revision date: 03-03-11 section 1 general description 1.1. description 1.2. features 1.3. technical specifications 1.4. delivery check 1.5. tools 1.6. lifting 1.7. installation
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 5 of 39 revision: d revision date: 03-03-11 figure 1-1 connector nest foot switch control box termination area regulator connector feed nest clearing tool
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 6 of 39 revision: d revision date: 03-03-11 general description 1.1 description the molex am-60520e hawk discrete wire termination machine was developed to assemble .100 s.l. idt series (.100 in. centers insulation displacement technology) discrete wire harnesses. an operator l oads a cartridge containing preloaded connectors (70400 series) ranging from 2 to 25 circuits. as each con nector assembly is completed, the machine automatically lo ads a new connector into the terminating nest, pushing the previously loaded connector into the next station. then it inserts the terminals and breaks off the carrier strip. the operator then removes the completed harness, loads a wire (in its proper assembly order), then depresses the foot pedal. the machine then termina tes that wire and indexes to the next position. this m achine is ideally suited for mid- volume, semi-automatic applications. 1.2 features automatic loading and indexing of termination nest automatic insertion of terminals automatic break-off of carrier strip 1.3 technical specifications dimensions press with tooling height 34.3cm (13.50) width 99.1cm (39.00) depth 50.8cm (20.00) unpacked weight 48.1kg (103.00 lbs.) power requirements voltage: 110v ac or 220v ac 50/60 hz current: 2a @ 110v 1a @ 220v pneumatics pressure: 5 bar (80psig) minimum consumption: 14l/minimum (0.5 scfm) rate this machine terminates up to 1200 per hour, depending on operator skill and connector size. 1.4 delivery check remove the top and sides of the crate. then remove the screws that mount the machine to the skid. che ck to see that following items are included in this package: decription: quantity 11-20-0949 (am-60520e) 1 discrete wire termination machine tm-011200949 instruction manual 1 63800-8394 foot switch assembly 1 11-31-5302 nest cleaning tool 1 11-31-1744 carrier tray 1 1.5 tools the following tools are recommended for setup and adjustments to the this tool. english hex wrench set (inch) large and small straight screwdriver small crescent wrench needle nose pliers eye loupe - 5x 1.6 lifting warning : the molex hawk terminator weights 48kg (103 lbs.). it is not intended to be lifted by a single individual. the guarding or housing load assemblies are not attached to provide support for lifting purposes. mechanical lifting devices shoul d be used from below the unit. a person lifting this machine could sustain severe back or other injuries. care should be taken at all times. an electrical, hydraulic, or mechanical lift should be used to lift this termination machine
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 7 of 39 revision: d revision date: 03-03-11 figure 1-2 circuit size cycle counter alarm indicator power on button reset button pawl release 1.7 installation foot pedal connect the 5-pin din plug on the foot pedal to the 5-pin socket in the right side of the terminator co ntrol assembly. note the locking action of the plug. power connection a power cord is supplied for standard 110vac service. it is installed into the control box; plu g the other end into a grounded outlet. the hawk discrete wire termination machine will operate on 110vac or 220vac, 50 or 60 hz. warning : when servicing this machine, disconnect this power cord to insure complete safety to service person. air connection because there are so many variations in air connections, molex does not supply any type of fitting for air installation. the user must supply a fitting of his choice to att ach air of the correct pressure and volume to the 1/4 npt port on the f-r-l unit. use 1/4 inch line minimum. once attached, adjust the regulator on the f-r-l to 80-85psig. air will not flow into the machine proper until power is on and the " reset " button is pressed.
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 8 of 39 revision: d revision date: 03-03-11 section 2 setting up and operation 2.1. air pressure 2.2. connector feed adjustment 2.3. shuttle position fine adjustment 2.4. termination depth adjustment 2.5. termination punch up adjustment 2.6. programming the controller 2.7. safety precautions 2.8. operation
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 9 of 39 revision: d revision date: 03-03-11 thumb screw shift knob figure 2-3 figure 2-1 adjustment knob thumb screw fine adjust figure 2-2 set up 2.1 air pressure set the air pressure regulator on the air inlet to 5 - 6 bar (80 - 90 psi). this is done by pulling out the adjustment knob and setting to the proper pressure, then pushing in the knob. see figure 2-1. 2.2 connector feed adjustment shuttle stop the shuttle stop is adjustable from 3 to 25 circuit s. 1. to adjust the stop, loosen the thumb screw on top of the cartridge holder. this holds and locates the cylinder stop on the bottom side. starting from 3 circuit to the left, each notch represents 1 circuit position on the shuttle. the left side of the connector must always go to the left end of the termination anvil when fed in. 2. move the stop to the correct circuit size. 3. tighten the thumb screw. note : 2 circuit connectors are loaded in pairs stop is set for 4 circuits. connector feed stop this stop is also adjustable from 3 to 25 circuits. to adjust the stop: 1. remove the nest guard. 2. loosen the thumb screw on the connector feed stop located in front of the shift nest. 3. starting from 3 circuits to the right, stop locates on every circuit position to 25 circuits. adjust so that only 1 connector (except 2-2 circuits.) at a time can enter the shift nest from the cartridge feed. 4. when adjustment is set, tighten thumb screw. 5. replace guard. see figure 2-3. 2.3 shuttle fine adjustment with a connector in the nest and the shuttle full forward against the stop, the first terminal should be centered on the terminal punch. due to tolerance variations in connector lengths, it may be necessar y to occasionally make a fine adjustment to the shuttle. to adjust the shuttle: 1. load a connector into the termination head in manual mode. 2. with the shuttle blade in the forward position, loosen the cap screws at the rear of the shuttle adjustment base.
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 10 of 39 revision: d revision date: 03-03-11 set screw and lock nut figure 2-4 clevis jam nut figure 2-5 3. then adjust the location shuttle adjustment base by turning the set screw on the edge of the stop block located to the right. hold the connector against the shuttle blade while making this adjustment. turning the set screw in moves the connector to the right and out moves it to the left. see figure 2-4. 4. tighten the cap screws. 2.4 termination depth adjustment termination depth is set by: 1. loosening the lock nut located on top of the termination head. 2. to raise the punch depth, turn the screw clockwise. to lower, turn the screw counter- clockwise. the punch depth should be adjusted so that a terminated wire is touching the lower surface of the terminal, but is not crushed and the crimp tongs are securely gripping the wire without cutting into the insulation. see appendix a for termination specifications. 3. terminate a wire and check the settings. 4. repeat steps 2 and 3 until the termination depth is correct. 5. then tighten the lockout. 2.5 punch up adjustment termination punches should be adjusted so that the bottom of the punch is about .015 - .020 inch above the top of the terminals. to adjust the punch: 1. loosen the jam nut on the clevis attached to the crimp and termination cylinder rod end. 2. turning the rod end clockwise lowers the punches and counterclockwise raises them. the rod end can be turned with the jam nut by turning the jam nut down snug against the end of the threads on the rod. then turn off the air supply and turn the jam nut to adjust. see figure 2-5. 3. turn the air back on to check punch height 4. retighten the jam nut to clevis. 2.6 programming the controller on the front of the base there is a pair of thumb wheels. these set the counter to the correct circu it size for the connector. example: a 3-circuit connector would be set at .03 . 2.7 safety precautions the following safety precautions should be taken before operating the terminator. 1. check that the work area is well lighted. adjust work light for best visibility. 2. check that the area is clean and free of debris. check that no tools have been left in the machine or work area. never operate in areas of excess moisture.
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 11 of 39 revision: d revision date: 03-03-11 figure 2-6 te rminal wire wire stop figure 2 - 7 3. be sure all guards are in place. both the operator and bystanders must wear approved safety glasses when terminator is in operation. never operate this terminator without guards in place. 4. make sure the unit is plugged into a grounded outlet. check the connection at both ends of the power cord. also check that the power cord is not damaged or in danger of being damaged. 5. check that the terminator position is suitable for the operators size. the foot pedal should be positioned for ease of use. a stool or chair with adjustable height and backrest should be provided for maximum comfort and back support to the operator. the machine should be located parallel and approximately 150mm (6 in) from the edge of the table. a chair or stool, with adjustable height and back rest, should be provided for maximum comfort and back support for the operator. 6. be sure all setup procedures were followed and that terminations are within specifications. see appendix a for termination specifications. 2.8 operation 1. set housing and shuttle stops and circuit counter as described in sections 2.2 and 2.6. 2. turn air "on" and push reset button to reset nest to the #1 position. 3. load a tube of connectors with the terminals up and forward. 4. to start cycle, pull connector shift nest knob forward. 5. when the connector is in the shift nest, push the shift nest knob all the way "in". this will load the connector into the nest, ready for termination. if a connector is already in the nest it will automatically cycle through the insertion cycle and be ready for removal. 6. to load wires, insert appropriate wire under termination punches until it stops. the wire must be perpendicular to the face of the tooling and not angled up or down. see figure 2-7 and 2-8 for correct position. when the wire is in the correct position, press the foot switch 7. repeat operation until connector is complete. machine will automatically reset and loaded connector is ready for removal. 8. repeat steps 4 and 5 then remove connector by pulling the wires briskly to the left. 9. repeat steps 6 through 8 until tube is empty or the run is complete. note : the machine should be kept clean and free of carrier strips and other debris.
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 12 of 39 revision: d revision date: 03-03-11 section 3 maintenance 3.1. cleaning 3.2. lubrication 3.3. perishable parts 3.4. spare parts 3.5. troubleshooting
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 13 of 39 revision: d revision date: 03-03-11 3.1 cleaning warning : disconnect the compressed air line and the power cord from the power source during all maintenance operations. for efficient operation, the hawk discrete wire ter mination machine should be cleaned daily with a sof t bristle brush to remove any carrier strip debris an d terminal plating dust from the tooling area. for continuous operation this may have to be done several times th roughout the day. see chart 3.1 for recommended preventive maintenanc e schedule. when it is necessary to change tooling, care should be taken to remove any debris from tapped holes or mounting surfaces. debris can prevent tooling from being properly locked into position. keep the air filter clean. a visible coating of di rt in the bowl indicates that the unit needs cleani ng. to clean, remove the bowl with the filter unit and wipe with denatured alcohol. note : using compressed air to clean tooling is not recommended. chips can wedge in the tooling and/or fly at an operator. 3.2 lubrication 1. check the oil level in the lubricator bowl periodic ally and fill as needed with sae 10w motor oil. 2. sparingly lubricate the sliding parts approximately every month with sae 10w motor oil or equivalent. 3. lubricate with multipurpose synthetic lubricant wit h teflon or an equivalent. molex ships its presses pre- greased with permatex multi-purpose synthetic greas e with teflon no. 82329. sae 10 non-detergent oil or light spindle oil or 3-in-1 oil should be used o n pivot points. warning : never use penetrates such as wd40 for any lubrica tion on the termination machine.
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 14 of 39 revision: d revision date: 03-03-11 an example of a maintenance chart is shown below. copy and use this chart to track the maintenance of your press or use this as a template to create your own schedule or use your companys standard chart, if a pplicable. preventive maintenance chart daily : clean. see section 3.1. monthly : check air filters and clean as necessary, see se ction 3.1. lubricate sliding parts, see section 3.2. check oil level in lubricator, see section 3.2. check sheet month _________year _________ week monthly daily clean days of the week solution mon tue wed thu fri sat sun 1 2 3 4 air filters yes sae 10w motor oil lubricate yes sae 10 non-detergent oil oil level yes sae 10w motor oil cleaning reapply greasing reapply oil yes soft brush industrial degreaser inspect all tooling 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. 3.3 perishable parts customers are responsible for maintaining the hawk discrete wire termination machine. perishable part s are those parts that come in contact with the product a nd will wear out over time. molex recommends that all customers keep at least one set of the perishable t ool kit in stock at all times. this will reduce th e amount of production down time. these parts are identified i n the parts list in section 4. 3.4. spare parts customers are responsible for maintaining the hawk discrete wire termination machine. spare parts are moving and functioning parts that can be damaged or wear o ut over time and will require replacement. molex recommends that the customer keep some or all of th em in stock to reduce production down time. these parts are identified in the parts list in section 4.
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 15 of 39 revision: d revision date: 03-03-11 3.5 troubleshooting symptom cause solution switch does not turn on power no current check power source. fuse blown replace. defective power switch replace. smashed terminals during termination improper shuttle fine adjustment see setting up and operation. section 2.3. damaged crimp or termination punches repair or repl ace. nest return cylinder rod end loose tighten. carriers or other debris in lower slide area remove and clean. see maintenance section 3,. damaged slide bearings replace debris in anvil pockets remove and clean. see maintenance section 3,. spring pressure on housing aligner bar too low repl ace spring. nest return cylinder pressure regulator set too low adjust regulator. improper adjustment of crimp and termination punch height see setting up and operation section 2.4. improper crimp and termination depth improper adjustment of termination punch depth see setting up and operation section 2.4 debris in anvil pockets remove and clean. see maintenance section 3,. air pressure too low check air supply and regulator. see setting up and operation section 2.1. termination cylinder flow control set improperly re set flow control. improper insertion depth (terminals in housing) carriers or other debris caught behind insertion slide mechanism carefully clean out area behind slide. screws loose in insertion slide assembly tighten al l insertion slide screws. insertion cylinder loose or binding tighten the rod connections or replace the cylinder if binding. carriers not breaking off properly debris caught under carrier bend slide carefully cl ean area under bend slide. see maintenance section 3. bend cylinder loose or binding if binding, replace the cylinder and tighten all rod fittings. improper coining on terminal carrier strip replace product. loose carrier break-off cam block tighten all screw s. tube feed not working shift nest not positioned properly adjust shift nest so connectors transition smoothly. shift cylinder binding replace cylinder tube bowed excessively or burred at ends replace tu be air feeder malfunctioning check air pressure and check for blockage of air passages. connector transfer not working improper clearance in connector feed guide or carrier guide i nest contact molex application tooling group. debris in anvil pocket remove debris and clean area . debris behind shift nest slide remove debris and cl ean area. shuttle cylinder binding replace or repair cylinder . shuttle cylinder flow controls improperly adjusted readjust flows controls so cylinder extends and retracts but does not slam. improper alignment in transition areas adjust alignments so that connector moves through smoothly. terminal carrier thickness out of spec replace prod uct. connector overshoots when transferred in shuttle cylinder flow control improperly set adjust flow control on front of cylinder to slow down cylinder extension. spring pressure on housing aligner too loose repla ce spring.
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 16 of 39 revision: d revision date: 03-03-11 symptom cause solution nest step not stepping to next circuit position nest return cylinder pressure set too high set separate regulator to a lower pressure, turn the knob counter clockwise. debris caught in ratchet mechanism carefully clean ratchet mechanism. see section 3.1. nest step cylinder loose or binding repair joints o r replace cylinder. nest step cylinder flow controls set too far closed open flow control slightly. damaged pawls on ratchet mechanism replace pawls. valve malfunctioning or control problem contact mol ex application tooling group. air pressure too low see section 2.1. nest step overshooting beyond next position nest return cylinder pressure set too low open sepa rate regulator very slightly. nest step cylinder flow controls too open close down flow controls a little bit at a time until proper flow is achieved. nest does not return control problems contact molex application tooling group. pawl release cylinder loose or binding repair or re place cylinder. nest return cylinder pressure set too high reduce p ressure at separate regulator. air pressure too low check pressure supply and pressure setting at main regulator. see section 2.1.
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 17 of 39 revision: d revision date: 03-03-11 section 4 4.1 parts list and assembly drawings 4.2 schematisc drawings 4.3 pneumatic drawing
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 18 of 39 revision: d revision date: 03-03-11 2 4 3 1 figure 4 - 5 4.1 main parts list and assembly 11-20-0949 am60520e hawk discrete wire termination machine item order no engineering no. description quantity figure ref 11-20-0949 am60520e main assembly 1 4-1 1 n/a n/a frame assembly 1 4-2 and 4-3 2 n/a n/a crimp assembly 1 4-4 3 n/a n/a feed assembly 1 4-5 and 4-6 4 62300-6510 62300-6510 control assembly 1 4-7 5 62300-6520 62300-6520 miscellaneous electrical 1 4-8
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 19 of 39 revision: d revision date: 03-03-11 frame parts list frame assembly figure 4-2 amd 4-3 item order no engineering no. description rsp / pp parts and notes quantity 1 11-31-0149 am60510-5 cylinder rsp 1 2 11-31-0156 am60510-12 bracket, clevis 1 3 11-31-0157 am60510-13 clevis, rod 1 4 11-31-0173 am60510-15 bearing, slide 2 5 11-31-1231 am60520-14a enclosure 1 6 11-31-1730 am60510-26 front slide guide 1 7 11-31-1731 am60510-27 rear slide guide 1 8 11-31-1754 am60510-50 left frame upright 1 9 11-31-1755 am60510-51 termination head top plate 1 10 11-31-1756 am60510-52 right termination guide 1 11 11-31-1757 am60510-53 left termination guide 1 12 11-31-1759 am60510-55 termination lever 1 13 11-31-1760 am60510-56 termination pivot 1 14 11-31-1784 am60510-83 frame upright right 1 15 11-31-1804 am60510-115 spacer 2 16 11-31-2017 am60520-21a machine base 1 17 11-31-3288 am60520-15a enclosure cover 1 18 11-31-3289 am60520-22a machine mount plate 1 19 11-31-3290 am60520-23a standoff, mount plate 4 20 11-31-4538 am60570-21 slide, nest 1 21 11-31-4539 am60570-22 slide base 1 22 11-31-4571 am60570-97 front guard 1 23 11-31-5584 am60510-70 clevis pin 1 24 62500-2056 62500-2056 air lubricator, 2000 series 1 25 62500-2762 62500-2762 pipe nipple 1/4" bspt 1 1/2" long 1 26 62500-2820 62500-2820 filter/regulator combo with gauge and br acket 1 27 62500-2861 62500-2861 regulator 0-30psi w/gauge 1 28 63600-2591 63600-2591 25 by 25 end cap 2 29 63700-1242 63700-1242 #10-32 t-nut 2 30 63700-1784 63700-1784 corner bracket 1 31 63700-2068 63700-2068 #1/4-20 t-nut 4 32 63700-2370 63700-2370 1.0 by 1.0 extrusion by 8.0 long 1 33 66694-1662 66694-1662 1.0 by 1.0 extrusion by 10.0 long 1 hardware 34 n/a n/a #5-40 by 3/8 long shcs 32** 35 n/a n/a #8-32 by 1/2 long bhcs 2** 36 n/a n/a #8-32 by 5/8 long shcs 6** 37 n/a n/a #8-32 by 1.0 long shcs 4** 38 n/a n/a #8-32 by 3/16 long sss 8** 39 n/a n/a #10-32 by 1/4 long bhcs 2** 40 n/a n/a #10-32 by 1/2 long shcs 7** 41 n/a n/a #10-32 by 3/4 long shcs 14** 42 n/a n/a #1/4-20 by 1/2 long bhcs 4** 43 n/a n/a #1/4-20 by 3/4 long bhcs 2** 44 n/a n/a #1/4-20 by 1/2 long shcs 8** 45 n/a n/a #1/4-20 by 3/4 long shcs 4** 46 n/a n/a #1/4-20 by 1.0 long shcs 5** 47 n/a n/a #1/4-20 by 2.0 long shcs 1** 48 n/a n/a #3/16 by 5/8 long dowel pin 12** 49 n/a n/a #1/8 by 3/8 long dowel pin 2** 50 n/a n/a #1/4 by 1.5 long dowel pin 1**
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 20 of 39 revision: d revision date: 03-03-11 frame assembly figure 4-2 amd 4-3 item order no engineering no. description rsp / pp parts and notes quantity 51 n/a n/a #1/4-20 by .226 thick hex nut 1** 52 n/a n/a #1/4-28 by 3/4 long set screw (cup point) 1** 53 n/a n/a #5/16-18 lock nut 1** 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).
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 21 of 39 revision: d revision date: 03-03-11 13 1 14 10 11 8 19 18 17 3 16 (6) 12 9 5 2 figure 4-2 sheet 1 of 2 23 31 (4) 47 (2) (4) 40 (6) 52 (4) 50 (4) (4) 44 39 5 3 (6 ) (4) 48 27 46 figure 4-2 see sheet 2 of 2 36 (8) 18 ref 33 28 (2) (4) 53 41 41 48 45 26 (2) 24 25 43 39 (2) (2) 29 30 46 42 (4) 44 (2) 32 44 frame assembly (sheet 1)
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 22 of 39 revision: d revision date: 03-03-11 41 15 7 35 14 22 8 (2) 21 6 (2) 20 4 (4) figure 4-3 sheet 2 of 2 (2) (16) 40 37 (4) (3) 34 (16) 34 (4) 40 38 (8) 49 (2) 48 (4) frame assembly (sheet 2)
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 23 of 39 revision: d revision date: 03-03-11 crimp parts list crimp assembly figure 4-4 item order no engineering no. description rsp / pp parts and notes quantity 1 11-31-0147 am60510-3 insertion cylinder rsp 1 2 11-31-0150 am60510-6 nest step cylinder rsp 1 3 11-31-0151 am60510-7 pawl release cylinder rsp 1 4 11-31-0152 am60510-8 main nest return cylinder rsp 1 5 11-31-0154 am60510-10 cylinder bracket 1 6 11-31-0155 am60510-11 cylinder bracket 2 7 11-31-0418 am60510-57 termination punch pp 1 8 11-31-0419 am60510-58 crimp punch pp 1 9 11-31-1219 am60520-1 insertion bar 1 10 11-31-1220 am60520-2 insertion slide 1 11 11-31-1221 am60520-3 end cover 1 12 11-31-1439 am60510-117 pawl release guard 1 13 11-31-1728 am60510-24 nest spacer 2 14 11-31-1729 am60510-25 insertion guide 2 15 11-31-1735 am60510-31 compression spring 2 16 11-31-1746 am60510-42 ratchet pawl 2 17 11-31-1748 am60510-44 stationary pawl guide 1 18 11-31-1749 am60510-45 sliding pawl guide 1 19 11-31-1750 am60510-46 pawl slide cover 1 20 11-31-1751 am60510-47 pawl slide link 1 21 11-31-1752 am60510-48 pawl retract 1 22 11-31-1753 am60510-49 ratchet pawl track 1 23 11-31-1758 am60510-54 termination slide 1 24 11-31-1761 am60510-59 termination head cover 1 25 11-31-1783 am60510-82 insertion guard 1 26 11-31-1917 r8432-40 exhaust muffler (1/8 npt) 1 27 11-31-4548 am60570-41 ratchet 1 28 11-31-4537 am60570-20 nest 1 29 11-31-4540 am60570-23 nest cover 1 30 11-31-4541 am60570-30 housing aligner 1 31 11-31-4542 am60570-32 termination anvil pp 1 32 11-31-4543 am60570-33 carrier guide 1 33 11-31-5302 am60510-122 nest clearing tool not shown 1 34 11-31-7464 am60510-28 rod aligner 1 hardware 35 n/a n/a #4-40 by 3/16 long sss 1** 36 n/a n/a #6-32 by 1/4 long bhcs 2** 37 n/a n/a #8-32 by 1/4 long shcs 4** 38 n/a n/a #8-32 by 3/8 long shcs 10** 39 n/a n/a #8-32 by 5/8 long shcs 8** 40 n/a n/a #8-32 by 1-1/4 long shcs 2** 41 n/a n/a #8-32 by 1/2 long sss 1** 42 n/a n/a #10-32 by 1/2 long shcs 1** 43 n/a n/a #10-32 by 3/4 long fhcs 2** 44 n/a n/a #10-32 by 3/4 long shcs 2** 45 n/a n/a #10-32 by 1-1/4 long shcs 2** 46 n/a n/a #10-32 by 2 long shcs 4** 47 n/a n/a #1/4-20 by 1 long shcs 4** 48 n/a n/a #5/16-18 by 1 long shcs 2** 49 n/a n/a #3/8-18 by 1 long shcs 1** 50 n/a n/a #1/8 by 3/8 long dowel pin 2**
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 24 of 39 revision: d revision date: 03-03-11 crimp assembly figure 4-4 item order no engineering no. description rsp / pp parts and notes quantity 51 n/a n/a #1/8 by 5/8 long dowel pin 8** 52 n/a n/a #1/8 by 1 long dowel pin 2** 53 n/a n/a #1/8 by 1-1/2 long dowel pin 4** 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).
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 25 of 39 revision: d revision date: 03-03-11 figure 4-4 20 18 38 27 11 4 7 3 2 21 12 9 23 22 25 10 11-31-1755 ref (2) (2) (2) (4) 1 (2) 11-31-4539 ref 16 14 13 19 17 15 8 5 26 (2) (2) 42 43 (4) (2) 38 (2) 36 (2) 39 (4) 28 37 39 (2) 11-31-4538 ref 35 34 (2) 6 30 40 (2) (2) 32 38 (2) 31 (2) 29 (4) 24 37 39 41 44 45 53 47 47 48 49 50 (2) 51 52 51 (2) 51 51 (2) 46 (4) crimp assembly
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 26 of 39 revision: d revision date: 03-03-11 feed parts list feed assembly figure 4-5 and 4-6 item order no engineering no. description rsp / pp parts and notes quantity 1 11-21-5835 am8230-29 feeder arm bushing 1 2 11-31-0146 am60510-2 connector shuttle cylinder rsp 1 3 11-31-0153 am60510-9 mounting bracket 2 4 11-31-0256 am60510-16 knob 1 5 11-31-1222 am60520-5 knob-shift rod 1 6 11-31-1223 am60520-6 guide block, shift rod 1 7 11-31-1224 am60520-7 bearing, shift rod 1 8 11-31-1226 am60520-8 valve bracket 1 9 11-31-1229 am60520-12 push button 2-way valve 1 10 11-31-1233 am60520-4 shift rod 1 11 11-31-1743 am60510-39 shuttle adjustment indicator 1 12 11-31-1762 am60510-61 shift base 1 13 11-31-1763 am60510-62 left spacer 1 14 11-31-1764 am60510-63 right spacer 1 15 11-31-1765 am60510-64 shift nest 1 16 11-31-1766 am60510-65 shift guide 1 17 11-31-1767 am60510-66 shift guide rt. 1 18 11-31-1768 am60510-67 shift nest cover 1 19 11-31-1769 am60510-68 stop cart. feed 1 20 11-31-1770 am60510-69 shift nest bracket 1 21 11-31-1771 am60510-61 shift stop 1 22 11-31-1773 am60510-73 shuttle cylinder stop 1 23 11-31-1774 am60510-75 adjustable shuttle stop 1 24 11-31-1776 am60510-76 cartridge holder 1 25 11-31-1777 am60510-77 shuttle blade 1 26 11-31-1778 am60510-78 shuttle arm 1 27 11-31-1779 am60510-79 shuttle guide 2 28 11-31-1780 am60510-81 end shuttle guard 1 29 11-31-1782 am60510-73 front shuttle guard 1 30 11-31-1785 am60510-84 rear shuttle guard 1 31 11-31-1786 am60510-85 sensor bracket 2 32 11-31-1789 am60510-88 sensor flag 1 33 11-31-1797 am60510-96 terminal feed guide 1 34 11-31-1799 am60510-98 housing shift guard 1 35 11-31-1800 am60510-111 guard mount 1 36 11-31-1803 am60510-114 shuttle adjustment scale 1 37 11-31-3116 am60510-119 shuttle adjustment base 1 38 11-31-3117 am60510-120 fine adjustment pad 1 39 11-31-7475 am60510-126 bushing 1 40 11-31-7476 am60510-127 washer 1 41 11-31-7722 am60510-128 shuttle cylinder stop guide 1 42 62300-3101 62300-3101 gps tube rest 1 43 62500-0816 62500-0816 filter regulator 1 44 66801-5187 66801-5187 8mm proximity switch, 10-30vdc npn, 1.5m m sensing range 3 hardware 45 n/a n/a #6-32 by 3/8 long shcs 9** 46 n/a n/a #6-32 by 3/8 long sss 1** 47 n/a n/a #8-32 by 1/4 long bhcs 2** 48 n/a n/a #8-32 by 1/2 long bhcs 2** 49 n/a n/a #8-32 by 3/8 long fhcs 2** 50 n/a n/a #8-32 by 1/2 long shcs 6*
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 27 of 39 revision: d revision date: 03-03-11 feed assembly figure 4-5 and 4-6 item order no engineering no. description rsp / pp parts and notes quantity 51 n/a n/a #8-32 by 5/8 long shcs 8** 52 n/a n/a #8-32 by 1.0 long shcs 2** 53 n/a n/a #8-32 thumb screw 1** 54 n/a n/a #10-32 by 1/4 long bhcs 4** 55 n/a n/a #10-32 by 3/8 long bhcs 2** 56 n/a n/a #10-32 by 1/2 long bhcs 4** 57 n/a n/a #10-32 by 3/8 long shcs 2** 58 n/a n/a #10-32 by 1/2 long shcs 1** 59 n/a n/a #10-32 by 5/8 long shcs 2** 60 n/a n/a #10-32 by 3/4 long shcs 7** 61 n/a n/a #10-32 by 1/2 long sss 3** 62 n/a n/a #10-32 by 1/8 thk hex jam nut 3** 63 n/a n/a #10-32 by 11/16 thk lock nut 2** 64 n/a n/a #10-32 flat washer 1** 65 n/a n/a #1/4-20 by 3/4 long bhcs 2** 66 n/a n/a #3/32 by 1.0 long dowel pin 1** 67 n/a n/a #1/8 by 1/4 long dowel pin 11** 68 n/a n/a #1/8 by 3/4 long dowel pin 8** 69 n/a n/a #1/8 by 1.0 long dowel pin 4** 70 n/a n/a #3/16 by 3/8 long dowel pin 1** 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).
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 28 of 39 revision: d revision date: 03-03-11 60 18 62 44 16 12 (2) 60 figure 4-5 sheet 1 of 2 5 59 19 45 13 21 45 68 6 7 61 34 56 68 35 9 10 45 11-31-4539 ref (2) (2) (2) (2) (2) (2) (2) (2) (6) (2) (4) 8 53 33 52 14 69 39 40 51 20 15 66 31 32 50 61 44 31 50 feed assembly (sheet 1 of 2)
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 29 of 39 revision: d revision date: 03-03-11 476 38 63 48 37 69 36 (4) 43 42 49 50 58 54 24 22 61 11 23 (2) (2) (2) (2) (2) (2) (4) (2) figure 4-6 sheet 2 of 2 64 4 48 29 56 30 (4) 67 60 46 54 28 67 55 26 25 57 3 2 70 27 68 17 65 62 41 60 (2) (2) (2) (2) (2) ref (10) (2) (2) (2) (2) ref (2) 1 (2) 12 14 44 51 feed assembly (sheet 2 of 2)
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 30 of 39 revision: d revision date: 03-03-11 4.1 control box parts list 62300-6510 control box assembly figure 4-7 item order no engineering no. description quantity 1 11-31-8646 am60585-e204 led red 28 vdc 3/8 od, cyli ndrical cap 1 2 11-41-0264 km241 molex 3" diameter logo (red on whi te) 1 3 62500-0667 62500-0667 ring ferrite 1 4 62500-0694 62500-0694 terminal block, dbl pos. jumperable 10 5 62500-0721 62500-0721 jumper for 4mm wago term block 4 6 62500-0762 62500-0762 resettable, or non-resettable, 8 digits counter 1 7 62500-1023 62500-1023 din rail 6 inches 1 8 62500-1055 62500-1055 micro-dc series 4 pin female,22awg w/12" leads receptacle 1 9 62500-1330 62500-1330 cord grip 0.20-0.47 by 1/2npt plastic 1 10 62500-1331 62500-1331 cord grip 0.35-0.71 by 3/4npt plastic 1 11 62500-1382 62500-1382 homerun straight conn x 2m long black co nn/cable 1 12 62500-1519 62500-1519 terminal ground block, top wire, 3 condu ctor, 24-12 awg 1 13 62500-1620 62500-1620 plate separator for 279 terminal blocks, orange oversized 3 14 62500-2324 62500-2324 cord plug, 15 amp 1 15 62500-2361 62500-2361 cable w/con m8 straight single ended x 4 m long 3 16 62500-2362 62500-2362 cable w/con m8 rt. angle single ended by 4m long black cable 1 17 62500-2366 62500-2366 breaker 4 amp single pole 1 18 62500-2523 62500-2523 10"h by 8"w by 6" deep hinge cover box r la7035 enclosure 1 19 62500-2527 62500-2527 subpanel for jb100806hc enclosure 1 20 62500-2812 62500-2812 e-stop, illuminated (1) n.o. (2) n.c. sw itch 1 21 62500-2813 62500-2813 m22-k10 block n.0. contact block for m22 series pb's 1 22 62500-2816 62500-2816 illuminated pb green flush type, 24vdc l ed (1) n.o switch 1 23 62500-2819 62500-2819 24vdc,30watt supply 1 24 62500-2823 62500-2823 1.5mfd @400vdc capacitor 1 25 62500-2826 62500-2826 non-illum. flush black mom. (1) n.o. swi tch 1 26 62500-2832 62500-2832 relay dpdt 24vdc, (2) form "c", 8amp con tacts 1 27 62500-2964 62500-2964 overlay for am60520 hawk control 1 28 62500-2965 62500-2965 12 dc in 8 trans out, 24vdc input supply , 13watts 1 29 63800-8394 63800-8394 foot switch assembly 1 30 66801-5293 66801-5293 6mm end stop 2 31 66801-5318 66801-5318 omron tw switch 2 32 66801-5319 66801-5319 omron tw end plate switch 1
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 31 of 39 revision: d revision date: 03-03-11 29 figure 4-7 18 4 31 7 (10) (2) (2) 19 (2) 13 (3) 5 (4) (3) control box assembly 25 17 15 10 8 26 28 23 32 21 12 30 27 2 22 9 20 1 6 14 16 3 24
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 32 of 39 revision: d revision date: 03-03-11 figure 4-8 7 8 4 9 13 11 (4) 10 3 11-31-1231 ref 11-31-2017 ref 6 (5) 62300-6520 miscellaneous electrical control box ass embly figure 4-8 item order no engineering no. description quantity 1 11-31-1229 am60520-12 valve 2-way see figure 4-5 2 62500-0816 62500-0816 micromist seperator,1/4", .01 micron fil tration see figure 4-6 3 62500-2025 62500-2025 j-box 8 port picofast, 3-pin snap lock, no leds 1 4 62500-2045 62500-2045 blank plate for sy5000 series valves on bar stock manifold 1 5 62500-2056 62500-2056 smc al20-02b-2 lubricator 2000 series se e figure 4-2 6 62500-2124 62500-2124 spacer individual supply, for ss5y manif olds 2 7 62500-2192 62500-2192 manifold bar stock, 6 station for sy5100 valves 1 8 62500-2607 62500-2607 valve single solenoid w/integrated m8 pi co connector 5 9 62500-2610 62500-2610 valve single solenoid w/integrated m8 pi co connector 1 10 62500-2699 62500-2699 cable m8 pico right angle, for smc sv va lves .5m long 5 11 62500-2762 62500-2762 1/4" bspt by 1 1/2" long pipe nipple, br ass (1 )see also figure 4-2 12 62500-2820 62500-2820 filter/regulator 2000 series combo with built in gauge see figure 4-2 13 62500-2861 62500-2861 regulator 0-30ps1, 1/8 npt ports, self r elieving see figure 4-2 14 66801-5187 66801-5187 8mm proximity switch, 10-30vdc npn, 1.5m m sensing range see figure 4-5 and 4-6
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 33 of 39 revision: d revision date: 03-03-11 4.2 electrical schematic
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 34 of 39 revision: d revision date: 03-03-11 4.3 pneumatic drawing
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 35 of 39 revision: d revision date: 03-03-11 section 5 glossary of terms carrier a metal strip that temporarily holds the terminals together on a reel. it must be removed upon completion of an assembly. circuit size the number of terminals/pins in the assembly which represents the number of electrical circuits the connector can transmit/carry crimp a controlled-dynamic process and method of mechanical bonding, i.e., a connector-to-conductor termination where one end of the connector (containing the conductor or wire positioned in a crimp barrel) is highly compressed and deformed (connector + conductor together) in order to create an interface that "bonds" the two dissimilar metals (usually different materials for the connector and conductor, respectively) intimately together. on crimped terminal, a second crimp is often added to the insulation area for added strain relief. discrete wire a single cable or wire. contrast it to ribbon cable, which consists of multiple cables or wires. housing a device, usually plastic, used to contain and insulate electrical contacts. also used for mating or locking with a specified mating connector. housings are also called shells. insertion pushing terminals into the housing. idt it means insulation displacement technology. a termination method in which insulated wire is forced into a slot smaller in width than the diameter of the conductor. the sharp edges of the slot displace the insulation and make a permanent electrical interface between the wire conductor and the walls of the slot. nest part of a crimping die set that provides the location and support for the terminal barrel as it is being deformed into the desired crimp configuration by the indentor. pawl a spring loaded device which moves and holds the nest during termination. punch the tooling piece that crimps or terminates wires to terminals. sensor an electrical non-contact switch that detects the presence of metal moving into its field and signals the machine control. terminal a device designed to terminate a conductor that is to be affixed to a post, stud, chassis, or other conductor, to establish an electrical connection. it is a synonym for contact. termination the process of attaching a wire(s) to a terminal(s). termination head the part of the machine that holds the crimp and termination punches and terminates the wires.
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 36 of 39 revision: d revision date: 03-03-11 appendix a termination information note : the following document is uncontrolled and may no t be the latest revision. for the latest product specifications and product drawings (sdes-70400), contact molex or visit our web site at http://www.molex.com.
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 37 of 39 revision: d revision date: 03-03-11 insulation crimp first insulation displacement slot second insulation displacement slot locking tab wire must extend past the second insulation displacement slot .040 min. .100 max. contact area not deformed sl idt contact inspection (applies to both male and female terminals sl idt inspection bad terminations wire not seated in second insulation displacement slot wire too short one or both insulation crimp tabs are not folded around the wire insulation wire too long
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 38 of 39 revision: d revision date: 03-03-11 locking tab inspection
hawk discrete wire termination machine order no tm-011200949 release date: 02-16-97 uncontrolled copy page 39 of 39 revision: d revision date: 03-03-11 appendix b options http://www.molex.com

▲Up To Search▲

Price & Availability of 11-31-1786

	To Download 11-31-1786 Datasheet File
If you can't view the Datasheet, Please click here to try to view without PDF Reader .