Hawk Discrete Wire Termination Machine 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 Order No TM-011200949 Revision: D Release Date: 02-16-97 Revision Date: 03-03-11 UNCONTROLLED COPY Page 1 of 39 Hawk Discrete Wire Termination Machine WARNING NEVER USE THIS MACHINE WITHOUT THE GUARDS OR SAFETY DEVICES THAT ARE INTENDED TO PREVENT HANDS FROM REMAINING IN THE TERMINATION OR FEED AREAS. RUNNING THIS MACHINE WITHOUT GUARDS, UNDER ANY CIRCUMSTANCES, CAN CAUSE SERIOUS INJURY. NEVER LIFT THIS MACHINE WITHOUT THE AID OF MECHANICAL LIFTING DEVICES. SEVERE BACK OR OTHER INJURIES CAN RESULT. NEVER OPERATE, SERVICE, OR ADJUST THIS MACHINE, OR INSTALL TERMINATION TOOLING, WITHOUT PROPER INSTRUCTION AND WITHOUT FIRST 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. DISCONNECT 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 Order No TM-011200949 Revision: D Release Date: 02-16-97 Revision Date: 03-03-11 UNCONTROLLED COPY Page 2 of 39 Hawk Discrete Wire Termination Machine Table of Contents SECTION 1. General Description 2. Setting Up and Operation 3. Maintenance, Troubleshooting, and Fault Message Diagnostics 4. Parts Lists, Assembly Drawings, and Schematics 5. Glossary Appendix A Termination Information B Options Order No TM-011200949 Revision: D Release Date: 02-16-97 Revision Date: 03-03-11 UNCONTROLLED COPY Page 3 of 39 Hawk Discrete Wire Termination Machine 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 Order No TM-011200949 Revision: D Release Date: 02-16-97 Revision Date: 03-03-11 UNCONTROLLED COPY Page 4 of 39 Hawk Discrete Wire Termination Machine CONTROL BOX TERMINATION AREA REGULATOR CONNECTOR NEST CONNECTOR FEED NEST CLEARING TOOL FOOT SWITCH Figure 1-1 Order No TM-011200949 Revision: D Release Date: 02-16-97 Revision Date: 03-03-11 UNCONTROLLED COPY Page 5 of 39 Hawk Discrete Wire Termination Machine General Description 1.4 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 loads a cartridge containing preloaded connectors (70400 series) ranging from 2 to 25 circuits. As each connector assembly is completed, the machine automatically loads 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 terminates that wire and indexes to the next position. This machine is ideally suited for mid- volume, semi-automatic applications. 1.2 1.3 Delivery Check Features Automatic loading and indexing of termination nest Automatic insertion of terminals Automatic break-off of carrier strip 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: Consumption: Remove the top and sides of the crate. Then remove the screws that mount the machine to the skid. Check to see that following items are included in this package: Decription: Quantity 11-20-0949 (AM-60520E) Discrete Wire Termination Machine TM-011200949 Instruction Manual 63800-8394 Foot Switch Assembly 11-31-5302 Nest Cleaning Tool 11-31-1744 Carrier Tray 1.5 1 1 1 1 1 Tools The following tools are recommended for setup and adjustments to the this tool. 1.6 English Hex Wrench Set (inch) Large and small straight screwdriver Small Crescent Wrench Needle nose pliers Eye Loupe - 5X 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 should 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 5 BAR (80psig) minimum 14L/minimum (0.5 SCFM) Rate This machine terminates up to 1200 per hour, depending on operator skill and connector size. Order No TM-011200949 Revision: D Release Date: 02-16-97 Revision Date: 03-03-11 UNCONTROLLED COPY Page 6 of 39 Hawk Discrete Wire Termination Machine 1.7 WARNING: When servicing this machine, disconnect this power cord to insure complete safety to service person. Installation Foot Pedal Air Connection Connect the 5-pin DIN plug on the foot pedal to the 5-pin socket in the right side of the terminator control assembly. Note the locking action of the plug. 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 attach 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. Power Connection A power cord is supplied for standard 110VAC service. It is installed into the control box; plug the other end into a grounded outlet. The Hawk Discrete Wire Termination Machine will operate on 110VAC or 220VAC, 50 or 60 Hz. CYCLE COUNTER CIRCUIT SIZE ALARM INDICATOR POWER ON BUTTON RESET BUTTON Figure 1-2 Order No TM-011200949 Revision: D Release Date: 02-16-97 Revision Date: 03-03-11 PAWL RELEASE UNCONTROLLED COPY Page 7 of 39 Hawk Discrete Wire Termination Machine 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 Order No TM-011200949 Revision: D Release Date: 02-16-97 Revision Date: 03-03-11 UNCONTROLLED COPY Page 8 of 39 Hawk Discrete Wire Termination Machine Note: 2 circuit connectors are loaded in pairs stop is set for 4 circuits. Set Up 2.1 Air Pressure Connector Feed Stop 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. ADJUSTMENT KNOB 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. THUMB SCREW Figure 2-1 2.2 Connector Feed Adjustment Shuttle Stop SHIFT KNOB Figure 2-3 2.3 Shuttle Fine Adjustment FINE ADJUST THUMB SCREW Figure 2-2 The shuttle stop is adjustable from 3 to 25 circuits. 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. Order No TM-011200949 Revision: D Release Date: 02-16-97 Revision Date: 03-03-11 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 necessary 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. UNCONTROLLED COPY Page 9 of 39 Hawk Discrete Wire Termination Machine 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. SET SCREW AND 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. LOCK NUT CLEVIS JAM NUT Figure 2-4 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 counterclockwise. 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: Order No TM-011200949 Revision: D Release Date: 02-16-97 Revision Date: 03-03-11 Figure 2-5 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 circuit 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. UNCONTROLLED COPY Page 10 of 39 Hawk Discrete Wire Termination Machine 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 operator’s 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 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. 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. Order No TM-011200949 Revision: D Release Date: 02-16-97 Revision Date: 03-03-11 Figure 2-6 WIRE TERMINAL UNCONTROLLED COPY WIRE STOP Figure 2-7 Page 11 of 39 Hawk Discrete Wire Termination Machine Section 3 Maintenance 3.1. Cleaning 3.2. Lubrication 3.3. Perishable Parts 3.4. Spare Parts 3.5. Troubleshooting Order No TM-011200949 Revision: D Release Date: 02-16-97 Revision Date: 03-03-11 UNCONTROLLED COPY Page 12 of 39 Hawk Discrete Wire Termination Machine 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 Termination Machine should be cleaned daily with a soft bristle brush to remove any carrier strip debris and terminal plating dust from the tooling area. For continuous operation this may have to be done several times throughout the day. See Chart 3.1 for recommended Preventive Maintenance 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 dirt in the bowl indicates that the unit needs cleaning. 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 periodically 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 with Teflon or an equivalent. Molex ships its presses pregreased with Permatex multi-purpose synthetic grease with Teflon No. 82329. SAE 10 non-detergent oil or light spindle oil or 3-in-1 oil should be used on pivot points. WARNING: Never use penetrates such as WD40 for any lubrication on the Termination machine. Order No TM-011200949 Revision: D Release Date: 02-16-97 Revision Date: 03-03-11 UNCONTROLLED COPY Page 13 of 39 Hawk Discrete Wire Termination Machine 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 company’s standard chart, if applicable. Preventive Maintenance Chart Daily: Clean. See Section 3.1. Monthly: Check air filters and clean as necessary, See Section 3.1. Lubricate sliding parts, See Section 3.2. Check oil level in lubricator, See Section 3.2. CHECK SHEET Week MONTH _________YEAR _________ Monthly 1 2 3 4 Air Filters Lubricate Oil Level Cleaning Reapply greasing Reapply oil Inspect all tooling for wear Daily Clean MON TUE Days of the Week WED THU FRI SAT SUN Yes Yes Yes Solution SAE 10W motor oil SAE 10 non-detergent oil SAE 10W motor oil Yes Soft Brush Industrial Degreaser 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 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 kit in stock at all times. This will reduce the amount of production down time. These parts are identified in 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 out over time and will require replacement. Molex recommends that the customer keep some or all of them in stock to reduce production down time. These parts are identified in the parts list in Section 4. Order No TM-011200949 Revision: D Release Date: 02-16-97 Revision Date: 03-03-11 UNCONTROLLED COPY Page 14 of 39 Hawk Discrete Wire Termination Machine 3.5 Troubleshooting Symptom Switch does not turn on power No current Fuse blown Defective power switch Cause Improper shuttle fine adjustment Smashed terminals during termination Improper crimp and termination depth Damaged crimp or termination punches Nest Return cylinder rod end loose Carriers or other debris in lower slide area Damaged slide bearings Debris in anvil pockets Spring pressure on housing aligner bar too low Nest return cylinder pressure regulator set too low Improper adjustment of crimp and termination punch height Improper adjustment of termination punch depth Debris in anvil pockets Air pressure too low Termination cylinder flow control set improperly Carriers or other debris caught behind insertion slide mechanism Improper insertion depth Screws loose in insertion slide assembly (Terminals in Housing) Insertion cylinder loose or binding Debris caught under carrier bend slide Carriers not breaking off properly Bend cylinder loose or binding Improper coining on terminal carrier strip Loose carrier break-off cam block Shift nest not positioned properly Tube feed not working Shift cylinder binding Tube bowed excessively or burred at ends Air feeder malfunctioning Connector transfer Not working Improper clearance in connector feed guide or carrier guide I nest Debris in anvil pocket Debris behind shift nest slide Shuttle cylinder binding Shuttle cylinder flow controls improperly adjusted Improper alignment in transition areas Terminal carrier thickness out of spec Connector overshoots when transferred in Order No TM-011200949 Revision: D Shuttle cylinder flow control improperly set Spring pressure on housing aligner too loose Release Date: 02-16-97 Revision Date: 03-03-11 Solution Check power source. Replace. Replace. See Setting Up and Operation. Section 2.3. Repair or replace. Tighten. Remove and clean. See Maintenance Section 3,. Replace Remove and clean. See Maintenance Section 3,. Replace spring. Adjust regulator. See Setting Up and Operation Section 2.4. See Setting Up and Operation Section 2.4 Remove and clean. See Maintenance Section 3,. Check air supply and regulator. See Setting Up and Operation Section 2.1. Reset flow control. Carefully clean out area behind slide. Tighten all insertion slide screws. Tighten the rod connections or replace the cylinder if binding. Carefully clean area under bend slide. See Maintenance Section 3. If binding, replace the cylinder and tighten all rod fittings. Replace product. Tighten all screws. Adjust shift nest so connectors transition smoothly. Replace cylinder Replace tube Check air pressure and check for blockage of air passages. Contact Molex Application Tooling Group. Remove debris and clean area. Remove debris and clean area. Replace or repair cylinder. Readjust flows controls so cylinder extends and retracts but does not slam. Adjust alignments so that connector moves through smoothly. Replace product. Adjust flow control on front of cylinder to slow down cylinder extension. Replace spring. UNCONTROLLED COPY Page 15 of 39 Hawk Discrete Wire Termination Machine Symptom Cause Nest return cylinder pressure set too high Debris caught in ratchet mechanism Nest Step not stepping to next circuit position Nest step overshooting beyond next position Nest does not return Nest step cylinder loose or binding Nest step cylinder flow controls set too far closed Damaged pawls on ratchet mechanism Valve malfunctioning or control problem Air pressure too low Nest return cylinder pressure set too low Nest step cylinder flow controls too open Control problems Pawl release cylinder loose or binding Nest return cylinder pressure set too high Air pressure too low Order No TM-011200949 Revision: D Release Date: 02-16-97 Revision Date: 03-03-11 Solution Set separate regulator to a lower pressure, turn the knob counter clockwise. Carefully clean ratchet mechanism. See Section 3.1. Repair joints or replace cylinder. Open flow control slightly. Replace pawls. Contact Molex Application Tooling Group. See Section 2.1. Open separate regulator very slightly. Close down flow controls a little bit at a time until proper flow is achieved. Contact Molex Application Tooling Group. Repair or replace cylinder. Reduce pressure at separate regulator. Check pressure supply and pressure setting at main regulator. See Section 2.1. UNCONTROLLED COPY Page 16 of 39 Hawk Discrete Wire Termination Machine Section 4 4.1 Parts List and Assembly Drawings 4.2 Schematisc Drawings 4.3 Pneumatic Drawing Order No TM-011200949 Revision: D Release Date: 02-16-97 Revision Date: 03-03-11 UNCONTROLLED COPY Page 17 of 39 Hawk Discrete Wire Termination Machine 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 4 2 1 3 5 Figure 4- Order No TM-011200949 Revision: D Release Date: 02-16-97 Revision Date: 03-03-11 UNCONTROLLED COPY Page 18 of 39 Hawk Discrete Wire Termination Machine Frame Parts List Frame Assembly Figure 4-2 amd 4-3 Item Order No Engineering No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 11-31-0149 11-31-0156 11-31-0157 11-31-0173 11-31-1231 11-31-1730 11-31-1731 11-31-1754 11-31-1755 11-31-1756 11-31-1757 11-31-1759 11-31-1760 11-31-1784 11-31-1804 11-31-2017 11-31-3288 11-31-3289 11-31-3290 11-31-4538 11-31-4539 11-31-4571 11-31-5584 62500-2056 62500-2762 62500-2820 62500-2861 63600-2591 63700-1242 63700-1784 63700-2068 63700-2370 66694-1662 AM60510-5 AM60510-12 AM60510-13 AM60510-15 AM60520-14A AM60510-26 AM60510-27 AM60510-50 AM60510-51 AM60510-52 AM60510-53 AM60510-55 AM60510-56 AM60510-83 AM60510-115 AM60520-21A AM60520-15A AM60520-22A AM60520-23A AM60570-21 AM60570-22 AM60570-97 AM60510-70 62500-2056 62500-2762 62500-2820 62500-2861 63600-2591 63700-1242 63700-1784 63700-2068 63700-2370 66694-1662 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A Order No TM-011200949 Revision: D RSP / PP Parts Quantity and notes Cylinder RSP 1 Bracket, Clevis 1 Clevis, Rod 1 Bearing, Slide 2 Enclosure 1 Front Slide Guide 1 Rear Slide Guide 1 Left Frame Upright 1 Termination Head Top Plate 1 Right Termination Guide 1 Left Termination Guide 1 Termination Lever 1 Termination Pivot 1 Frame Upright Right 1 Spacer 2 Machine Base 1 Enclosure Cover 1 Machine Mount Plate 1 Standoff, Mount Plate 4 Slide, Nest 1 Slide Base 1 Front Guard 1 Clevis Pin 1 Air Lubricator, 2000 Series 1 Pipe Nipple 1/4" BSPT 1 1/2" Long 1 Filter/Regulator Combo With Gauge And Bracket 1 Regulator 0-30psi W/Gauge 1 25 by 25 End Cap 2 #10-32 T-Nut 2 Corner Bracket 1 #1/4-20 T-Nut 4 1.0 by 1.0 Extrusion by 8.0” Long 1 1.0 by 1.0 Extrusion by 10.0” Long 1 Hardware #5-40 by 3/8“ Long SHCS 32** #8-32 by 1/2“ Long BHCS 2** #8-32 by 5/8“ Long SHCS 6** #8-32 by 1.0“ Long SHCS 4** #8-32 by 3/16“ Long SSS 8** #10-32 by 1/4“ Long BHCS 2** #10-32 by 1/2“ Long SHCS 7** #10-32 by 3/4“ Long SHCS 14** #1/4-20 by 1/2“ Long BHCS 4** #1/4-20 by 3/4“ Long BHCS 2** #1/4-20 by 1/2“ Long SHCS 8** #1/4-20 by 3/4“ Long SHCS 4** #1/4-20 by 1.0“ Long SHCS 5** #1/4-20 by 2.0“ Long SHCS 1** #3/16 by 5/8” Long Dowel Pin 12** #1/8 by 3/8” Long Dowel Pin 2** #1/4 by 1.5” Long Dowel Pin 1** Release Date: 02-16-97 Revision Date: 03-03-11 Description UNCONTROLLED COPY Page 19 of 39 Hawk Discrete Wire Termination Machine Frame Assembly Figure 4-2 amd 4-3 Item 51 52 53 Order No Engineering No. N/A N/A N/A N/A N/A N/A Order No TM-011200949 Revision: D Description RSP / PP Parts Quantity and notes 1** 1** 1** #1/4-20 by .226“ Thick Hex Nut #1/4-28 by 3/4“ Long Set Screw (Cup Point) #5/16-18 Lock Nut 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). Release Date: 02-16-97 Revision Date: 03-03-11 UNCONTROLLED COPY Page 20 of 39 Hawk Discrete Wire Termination Machine Frame Assembly (Sheet 1) 52 41 (4) (6) 36 53 (6) 53 48 1 11 9 44 50 3 13 10 (4) 2 17 46 (4) 18 23 12 48 (4) 14 41 (6) 8 5 Figure 4-2 SEE SHEET 2 OF 2 44 47 40 (8) (2) (2) 29 33 26 28 (2) 43 39 (2) (4) 31 30 18 44 32 24 REF 42 (4) 25 (2) 16 39 (2) 45 46 Figure 4-2 SHEET 1 OF 2 Order No TM-011200949 Revision: D Release Date: 02-16-97 Revision Date: 03-03-11 19 (4) 27 (4) UNCONTROLLED COPY Page 21 of 39 Hawk Discrete Wire Termination Machine Frame Assembly (Sheet 2) (16) 34 4 (2) 20 (16) (4) 34 41 7 (8) 38 21 6 (3) 40 (2) 15 49 (2) 35 (2) 37 (4) 22 40 (4) (4) 48 Figure 4-3 SHEET 2 OF 2 14 8 Order No TM-011200949 Revision: D Release Date: 02-16-97 Revision Date: 03-03-11 UNCONTROLLED COPY Page 22 of 39 Hawk Discrete Wire Termination Machine Crimp Parts List Crimp Assembly Figure 4-4 Item Order No Engineering No. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 11-31-0147 11-31-0150 11-31-0151 11-31-0152 11-31-0154 11-31-0155 11-31-0418 11-31-0419 11-31-1219 11-31-1220 11-31-1221 11-31-1439 11-31-1728 11-31-1729 11-31-1735 11-31-1746 11-31-1748 11-31-1749 11-31-1750 11-31-1751 11-31-1752 11-31-1753 11-31-1758 11-31-1761 11-31-1783 11-31-1917 11-31-4548 11-31-4537 11-31-4540 11-31-4541 11-31-4542 11-31-4543 11-31-5302 11-31-7464 AM60510-3 AM60510-6 AM60510-7 AM60510-8 AM60510-10 AM60510-11 AM60510-57 AM60510-58 AM60520-1 AM60520-2 AM60520-3 AM60510-117 AM60510-24 AM60510-25 AM60510-31 AM60510-42 AM60510-44 AM60510-45 AM60510-46 AM60510-47 AM60510-48 AM60510-49 AM60510-54 AM60510-59 AM60510-82 R8432-40 AM60570-41 AM60570-20 AM60570-23 AM60570-30 AM60570-32 AM60570-33 AM60510-122 AM60510-28 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A Insertion Cylinder Nest Step Cylinder Pawl Release Cylinder Main Nest Return Cylinder Cylinder Bracket Cylinder Bracket Termination Punch Crimp Punch Insertion Bar Insertion Slide End Cover Pawl Release Guard Nest Spacer Insertion Guide Compression Spring Ratchet Pawl Stationary Pawl Guide Sliding Pawl Guide Pawl Slide Cover Pawl Slide Link Pawl Retract Ratchet Pawl Track Termination Slide Termination Head Cover Insertion Guard Exhaust Muffler (1/8 NPT) Ratchet Nest Nest Cover Housing Aligner Termination Anvil Carrier Guide Nest Clearing Tool Rod Aligner Hardware #4-40 by 3/16“ Long SSS #6-32 by 1/4“ Long BHCS #8-32 by 1/4“ Long SHCS #8-32 by 3/8“ Long SHCS #8-32 by 5/8“ Long SHCS #8-32 by 1-1/4“ Long SHCS #8-32 by 1/2“ Long SSS #10-32 by 1/2“ Long SHCS #10-32 by 3/4“ Long FHCS #10-32 by 3/4“ Long SHCS #10-32 by 1-1/4“ Long SHCS #10-32 by 2“ Long SHCS #1/4-20 by 1“ Long SHCS #5/16-18 by 1“ Long SHCS #3/8-18 by 1“ Long SHCS #1/8 by 3/8” Long Dowel Pin Order No TM-011200949 Revision: D Release Date: 02-16-97 Revision Date: 03-03-11 RSP / PP Parts Quantity and Notes RSP 1 RSP 1 RSP 1 RSP 1 1 2 PP 1 PP 1 1 1 1 1 2 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 PP 1 1 Not Shown 1 1 UNCONTROLLED COPY 1** 2** 4** 10** 8** 2** 1** 1** 2** 2** 2** 4** 4** 2** 1** 2** Page 23 of 39 Hawk Discrete Wire Termination Machine Crimp Assembly Figure 4-4 Item 51 52 53 Order No TM-011200949 Revision: D RSP / PP Parts Quantity and Notes N/A N/A #1/8 by 5/8” Long Dowel Pin 8** N/A N/A #1/8 by 1” Long Dowel Pin 2** 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). Order No Engineering No. Release Date: 02-16-97 Revision Date: 03-03-11 Description UNCONTROLLED COPY Page 24 of 39 Hawk Discrete Wire Termination Machine Crimp Assembly 51 (4) 38 11 47 36 (2) 25 28 29 (2) 15 (2) 31 32 30 14 52 (2) 38 47 9 51 1 10 49 (4) 44 37 (2) 13 (2) 53 (4) 26 4 (2) 11-31-4538 REF 46 50 24 39 (4) 11-31-1755 REF 27 (4) 23 45 34 40 12 48 (2) 51 43 (2) (2) 35 (2) 8 7 (2) 19 51 (2) 21 17 18 (2) 16 41 42 Figure 4-4 20 22 3 38 (2) (2) 37 5 39 (2) 11-31-4539 REF 2 6 Order No TM-011200949 Revision: D Release Date: 02-16-97 Revision Date: 03-03-11 39 (2) UNCONTROLLED COPY Page 25 of 39 Hawk Discrete Wire Termination Machine Feed Parts List Feed Assembly Figure 4-5 and 4-6 Item Order No Engineering No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 11-21-5835 11-31-0146 11-31-0153 11-31-0256 11-31-1222 11-31-1223 11-31-1224 11-31-1226 11-31-1229 11-31-1233 11-31-1743 11-31-1762 11-31-1763 11-31-1764 11-31-1765 11-31-1766 11-31-1767 11-31-1768 11-31-1769 11-31-1770 11-31-1771 11-31-1773 11-31-1774 11-31-1776 11-31-1777 11-31-1778 11-31-1779 11-31-1780 11-31-1782 11-31-1785 11-31-1786 11-31-1789 11-31-1797 11-31-1799 11-31-1800 11-31-1803 11-31-3116 11-31-3117 11-31-7475 11-31-7476 11-31-7722 62300-3101 62500-0816 66801-5187 AM8230-29 AM60510-2 AM60510-9 AM60510-16 AM60520-5 AM60520-6 AM60520-7 AM60520-8 AM60520-12 AM60520-4 AM60510-39 AM60510-61 AM60510-62 AM60510-63 AM60510-64 AM60510-65 AM60510-66 AM60510-67 AM60510-68 AM60510-69 AM60510-61 AM60510-73 AM60510-75 AM60510-76 AM60510-77 AM60510-78 AM60510-79 AM60510-81 AM60510-73 AM60510-84 AM60510-85 AM60510-88 AM60510-96 AM60510-98 AM60510-111 AM60510-114 AM60510-119 AM60510-120 AM60510-126 AM60510-127 AM60510-128 62300-3101 62500-0816 66801-5187 45 46 47 48 49 50 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A Order No TM-011200949 Revision: D RSP / PP Parts Quantity and notes Feeder Arm Bushing 1 Connector Shuttle Cylinder RSP 1 Mounting Bracket 2 Knob 1 Knob-Shift Rod 1 Guide Block, Shift Rod 1 Bearing, Shift Rod 1 Valve Bracket 1 Push Button 2-Way Valve 1 Shift Rod 1 Shuttle Adjustment Indicator 1 Shift Base 1 Left Spacer 1 Right Spacer 1 Shift Nest 1 Shift Guide 1 Shift Guide Rt. 1 Shift Nest Cover 1 Stop Cart. Feed 1 Shift Nest Bracket 1 Shift Stop 1 Shuttle Cylinder Stop 1 Adjustable Shuttle Stop 1 Cartridge Holder 1 Shuttle Blade 1 Shuttle Arm 1 Shuttle Guide 2 End Shuttle Guard 1 Front Shuttle Guard 1 Rear Shuttle Guard 1 Sensor Bracket 2 Sensor Flag 1 Terminal Feed Guide 1 Housing Shift Guard 1 Guard Mount 1 Shuttle Adjustment Scale 1 Shuttle Adjustment Base 1 Fine Adjustment Pad 1 Bushing 1 Washer 1 Shuttle Cylinder Stop Guide 1 GPS Tube Rest 1 Filter Reg