0623003100

Hawk Discrete Wire Termination Machine Hawk Discrete Wire Termination Machine Order No. 62300-3100 “CE” Certified For C-Grid SL IDT Connector, 70400 Series
Description
Operation
Maintenance Order No ATS-62300-3100 Revision: E Release Date: 09-16-99 Revision Date: 02-29-08 UNCONTROLLED COPY Page 1 of 38 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: ATS-6230031005 Release Date: 09-16-99 Revision: E Revision Date: 02-29-08 UNCONTROLLED COPY Page 2 of 38 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 C EC Declaration of Conformity Order No: ATS-6230031005 Release Date: 09-16-99 Revision: E Revision Date: 02-29-08 UNCONTROLLED COPY Page 3 of 38 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: ATS-6230031005 Release Date: 09-16-99 Revision: E Revision Date: 02-29-08 UNCONTROLLED COPY Page 4 of 38 Hawk Discrete Wire Termination Machine CONTROL ASSEMBLY OPERATION INTERFACE RESET BUTTON E-STOP BUTTON TERMINATION AREA FILTER REGULATOR LUBRICATOR General Description 1.1 Description The Molex Hawk Discrete Wire Termination Machine 62300-3100 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




FOOT PEDAL CONNECTION Figure 1-1 Features Automatic loading and indexing of termination nest Automatic insertion of terminals Automatic break-off of carrier strip A rugged, sealed operator interface with a 12 key tactile feedback keypad for data entry, and a 40 character, 2-line display for displaying circuit numbers, wire colors, fault messages, etc. Voids can be programmed Order No: ATS-6230031005 Release Date: 09-16-99 Revision: E Revision Date: 02-29-08



1.3 Wire colors can be programmed (up to 15different colors) Operator settable batch counter Totally enclosed for operator safety “CE” certified for sale in Europe Technical Specifications Dimensions Height Width Press with tooling 43.8cm (17.00”) 96.5cm (38.00”) 45.7cm (18.00”) Depth 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: 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. UNCONTROLLED COPY Page 5 of 38 Hawk Discrete Wire Termination Machine 1.4 Delivery Check 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: 1 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 1.7 POWER INLET POWER SWITCH Quantity 62300-3100 Termination Machine ATS-623003100 Instruction Manual 69002-5715 Foot Pedal Assembly 11-32-1659 Power Cord 11-31-5302 Nest Cleaning Tool 11-31-1744 Carrier Tray 1.5 into the socket on the left side of the control assembly, then plug the other end into a grounded outlet. 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 control assembly. Note the locking action of the plug. Power Connection A power cord is supplied for standard 10VAC service. To use in this manner plug the power cord Order No: ATS-6230031005 Release Date: 09-16-99 Revision: E Revision Date: 02-29-08 FUSE DRAWER FUSES VOLTAGE SELECTOR BLOCK Figure 1-2 The Hawk Discrete Wire Termination Machine will operate on 110VAC or 220VAC, 50 or 60 Hz. To change from one service to the other, do the following: (Refer to Figure 1.2) Locate the power inlet module on the left side of the control assembly. With a small screwdriver remove the fuse drawer. Remove the voltage selector block and rotate until the correct voltage will show in the window. Reinsert the voltage selector block. Change to the proper size fuse (see Electrical Schematics) and replace the fuse drawer. Install the proper power cord. 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. Thus 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. UNCONTROLLED COPY Page 6 of 38 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: ATS-6230031005 Release Date: 09-16-99 Revision: E Revision Date: 02-29-08 UNCONTROLLED COPY Page 7 of 38 Hawk Discrete Wire Termination Machine 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. 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. Figure 2-1 ADJUSTMENT KNOB Note: 2circuit connectors are loaded in pairs thus 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 2circuits.) 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 2.2 Connector Feed Adjustment Shuttle Stop FINE ADJUST THUMB SCREW SHIFT KNOB Figure 2-3 2.3 Shuttle Fine Adjustment Figure 2-2 The shuttle stop is adjustable from 3 to 25 circuits. To adjust the stop: 1. 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 Order No: ATS-6230031005 Release Date: 09-16-99 Revision: E Revision Date: 02-29-08 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: UNCONTROLLED COPY Page 8 of 38 Hawk Discrete Wire Termination Machine 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. 3. Then fine 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 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 LOCK NUT 1. To adjust, 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. Tighten the jam nut to clevis. CLEVIS JAM NUT Figure 2-5 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. Order No: ATS-6230031005 Release Date: 09-16-99 Revision: E Revision Date: 02-29-08 2.6 Programming The Controller 1. Turn the power switch located on the left side of the control box next to the power cord. (A greeting appears on the screen first, followed by the main menu.) 2. Press the green “POWER ON” button on the upper right corner of the control cabinet. The button should light up. See Figure 2.6. 3. Press F3 “SETUP” on the Operator Interface. Now you may edit the existing job or enter a new set of data. 4. If you elect to edit, press F6. If you elect to enter a new set of data, enter the number of circuits in the new connector. 5. To enter the number of circuits 6. Press “CLEAR”, then the number of circuits. 7. Press, “ENTER”. 8. Press the Right Arrow. Note: If the number of circuits doesn’t change, simply press the Right Arrow. 9. If colors and/or voids are required, press F5. Display line 1 will show the circuit number UNCONTROLLED COPY Page 9 of 38 Hawk Discrete Wire Termination Machine currently being addressed. Press the void key of the desired color key or key combination. Selected color (or void) will appear on the bottom line of the display for 2 seconds before moving to the next circuit. 10. Continue entering colors or void until all circuits have been addressed. See Table 2.1 Color chart. position, and then index the connector to the next position. If desired, the controller can be changed so that the termination head does not come down and crimp the terminal on a void, the connector is simply indexed to the next position. This is done by adding a jumper between wire #50 and PLC terminal 15. See Section 6 Electrical Schematic, sheet 2. WARNING: Inserting an uncrimped terminal into housing, may cause skiving or other damage to the plastic housing and may increase the force required to insert a mating connector. Table 2-1 Color Chart Color “F” Key(s) Void F2 Black F4 Brown F5 Red F6 Orange F7 Yellow F8 Green F9 Blue F10 Violet F11 White F12 Gray F1 & F4 Light Red F1 & F6 Light Green F1 & F9 Light Blue F1 & F10 11. If you elected to edit by pressing F6, pressing F3 will step you through the data currently in the machine. If at any time there appears to be a color or void that needs to be changed, simply press the correct key, then F3. 12. When all circuits have been addressed, the display will change to the mode select screen. Select “AUTO” or “MANUAL” and proceed. See Section 2.8, Operation. Setting Void Termination Function This section applies only to those machines that have a software revision sticker with a “C” or later revision. There is an option available on the controller that allows the operator to set whether or not the termination head comes down and crimps the terminal at a void position. This control comes from the factory set to crimp the terminal at a void Order No: ATS-6230031005 Release Date: 09-16-99 Revision: E Revision Date: 02-29-08 RESET BUTTON DISPLAY F-KEYS 2.7 Figure 2-6 KEYPAD 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. 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. UNCONTROLLED COPY Page 10 of 38 Hawk Discrete Wire Termination Machine 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. 2.8 Manual Mode In this mode each function can be individually toggled on and off. This is used mainly in trouble shooting. For example, pressing F7 will cause the Termination Punches to come down. Pressing F7 a second time returns the Termination Punches to the up position. Automatic Mode Operation After setup is completed, this machine can be operated in either of two modes, Manual or Automatic. Select a mode when screen says “SELECT MODE”, simply press F2 for Manual or F1 for Automatic. Figure 2-7 WIRE WIRE STOP F1 Auto Pressing F1 starts the Automatic cycle by loading the first connector into the termination position. The operator would then insert the proper wire into the locator slot. 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. The machine will terminate wire #1 and then index to termination position #2. When the last wire in a connector has been terminated, the nest will automatically return home, a new connector will be loaded and the insertion and break off will be performed on the loaded connector. F12 Cycle Stop If F1 is pressed any time during the automatic cycle, the machine will run as described above except that when the termination is completed another connector will not be loaded and insertion and break off will not occur. Note: Regardless of the condition of the current connector, a new connector will be loaded when you return to automatic. TERMINAL Figure 2-8 Order No: ATS-6230031005 Release Date: 09-16-99 Revision: E Revision Date: 02-29-08 UNCONTROLLED COPY Page 11 of 38 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 3.6. Fault Messages Diagnostics Order No: ATS-6230031005 Release Date: 09-16-99 Revision: E Revision Date: 02-29-08 UNCONTROLLED COPY Page 12 of 38 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. CAUTION: 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: ATS-6230031005 Release Date: 09-16-99 Revision: E Revision Date: 02-29-08 UNCONTROLLED COPY Page 13 of 38 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 1 2 3 4 Air Filters Lubricate Oil Level Cleaning Reapply greasing Reapply oil Inspect all tooling for wear MONTH _________YEAR _________ Monthly Daily Clean MON TUE Yes Yes Yes Days of the Week WED THU FRI SAT Solution SUN 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: ATS-6230031005 Release Date: 09-16-99 Revision: E Revision Date: 02-29-08 UNCONTROLLED COPY Page 14 of 38 Hawk Discrete Wire Termination Machine 3.5
Troubleshooting Symptom Switch does not turn on power

Cause
No current
Fuse blown
Defective power switch
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 Improper insertion depth (Terminals in Housing) slide mechanism
Screws loose in insertion slide assembly
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 hang-up
Shift cylinder binding
Tube bowed excessively or burred at ends
Air feeder malfunctioning
Improper clearance in connector feed guide Connector transfer hang up 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
Shuttle cylinder flow control improperly set
Spring pressure on housing aligner too loose Order No: ATS-6230031005 Release Date: 09-16-99 Revision: E Revision Date: 02-29-08 Solution Check power source. Replace. Replace. See Setting Up and Operation. Section 2.3. Repair or replace. Tighten. Remove and clean. See Section 3, Maintenance. Replace Remove and clean. See Section 3, Maintenance. Replace spring. Adjust regulator. See Setting Up and Operation Section 2.4. See Setting Up and Operation Section 2.4 Remove and clean. See Section 3, Maintenance. 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 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 38 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 3.6 Solution Set separate regulator to a lower pressure, turn the knob (CCW). 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. Fault Messages Diagnostics This machine has built in fault diagnostics. When some action fails to occur properly, a fault message will appear on the display. This message will indicate what did not happen and what sensor the controller expects to see on or off. For example the following message appears: "FAULT - SHUTTLE NOT FORWARD S2" This message tells us either: 1. The shuttle did not move at all; OR 2. The shuttle moved but jammed part way; OR 3. The shuttle moved all the way and the sensor is not seeing it; and it also tells us 4. The controller looking to see Sensor S2 on. Action: (Typical for all fault messages.) The Trouble Shooting Chart may help in finding and fixing these problems 1. 2. 3. 4. 5. Determine where shuttle is--is it all the way back, or part way forward or is it all the way forward? If the shuttle is all the way forward, jump to step 5. Check air pressure, See Section 2.1 for resetting instructions. Check for bent cylinder rod, loose mechanical joints, or debris. Clean, repair or replace cylinder as required. Locate the appropriate sensor and determine if it is functioning properly by placing a piece of steel in front of sensor. If the LED on the back goes on the sensor is OK. If LED does not go on, replace the sensor. CAUTION: Machine may be cycle and move when sensor is activated. 6. Make sure the shuttle flag is at least halfway in front of the sensor face and within 1mm of the face. 7. From the wiring schematic (See Section 4) it is determined that Sensor 2 is wired to input 011. Find input 011 LED on the controller on the door of the control cabinet. Check to see if this LED goes on when sensor LED goes on. If not, check wiring between sensor and controller. Order No: ATS-6230031005 Release Date: 09-16-99 Revision: E Revision Date: 02-29-08 UNCONTROLLED COPY Page 16 of 38 Hawk Discrete Wire Termination Machine Section 4 4.1 Parts List and Assembly Drawings 4.2 Schematisc Drawings 4.3 Pneumatic Drawing Order No: ATS-6230031005 Release Date: 09-16-99 Revision: E Revision Date: 02-29-08 UNCONTROLLED COPY Page 17 of 38 Hawk Discrete Wire Termination Machine 4.1 Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 42 43 44 45 46 47 48 49 50 51 52 62300-3100 Hawk Discrete Wire Termination Machine Sheets 1 thru 4 RSP / PP Parts Order No Description and notes 11-31-0145 Cylinder, Connector Shift RSP 11-31-0146 Cylinder, Connector Shuttle RSP 11-31-0147 Cylinder, Insertion RSP 11-31-0148 Cylinder, Carrier Bend RSP 11-31-0149 Cylinder, Crimp & Terminate RSP 11-31-0150 Cylinder, Nest Step RSP 11-31-0151 Cylinder, Pawl Release RSP 11-31-0152 Cylinder, Main Nest Return RSP 11-31-0153 Bracket, Cylinder 11-31-0154 Bracket, Cylinder 11-31-0155 Bracket, Cylinder 11-31-0156 Bracket, Clevis 11-31-0157 Clevis, Rod 11-31-0172 Assembly, 8-Valve 11-31-0173 Bearing, Slide 11-31-0256 Knob 11-31-0332 Regulator RSP 11-31-4537 Nest 11-31-4538 Slide, Nest 11-31-4539 Base, Slide 11-31-4540 Cover, Nest 11-31-1728 Spacer, Nest 11-31-1729 Guide, Insertion 11-31-1730 Guide, Front Slide 11-31-1731 Guide, Rear Slide 11-31- 7464 Aligner, Rod 11-31-6067 Plug, Orifice 11-31-4541 Aligner, Housing 11-31-1735 Spring 11-31-4542 Anvil, Termination 11-31-4543 Guide, Carrier 11-31-4544 Slide, Inner Insertion 11-31-4545 Slide, Outer Insertion 11-31-4546 Bar, Insertion 11-31-4547 Plate, Insertion Bar 11-31-1742 Cam, Break-off 11-31-1744 Tray, Carrier (Not Shown) 11-31-4548 Ratchet 11-31-1746 Pawl, Ratchet 11-31-1747 Spring 11-31-1748 Guide, Stationary Pawl 11-31-1749 Cover, Pawl Sliding 11-31-1750 Cover, Pawl Slide 11-31-1751 Link Pawl Slide 11-31-1752 Retract, Pawl 11-31-1753 Track, Ratchet pawl 11-31-1754 Upright, Left Frame 11-31-1755 Plate, Termination Head Top 11-31-1756 Guide, Right Termination Order No: ATS-6230031005 Release Date: 09-16-99 Revision: E Revision Date: 02-29-08 Quantity UNCONTROLLED COPY 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 Page 18 of 38 Hawk Discrete Wire Termination Machine Item 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 62300-3100 Hawk Discrete Wire Termination Machine Sheets 1 thru 4 RSP / PP Parts Order No Description and notes 11-31-1757 Guide, Left Termination 11-31-1758 Slide, Termination 11-31-1759 Lever, Termination 11-31-1760 Pivot, Termination 11-31-0418 Punch, Termination PP 11-31-0419 Punch, Crimp PP 11-31-1761 Cover, Termination Head 11-31-1762 Base, Shift 11-31-1763 Spacer, Left 11-31-1764 Spacer, Right 11-31-1765 Nest, Shift 11-31-1766 Guide, Left Shift 11-31-1767 Guide, Right Shift 11-31-1768 Cover, Shift Nest 11-31-1769 Stop, Cartridge Feed 11-31-1770 Bracket, Shift Nest 11-31-1771 Stop, Shift 11-31-5584 Assembly, Clevis Pin 11-31-1772 Nozzle, Cartridge Feed Air 11-31-1773 Stop, Shuttle Cylinder 11-31-1774 Stop, Adjustable Shuttle 11-31-1775 Arm, Support 11-31-1776 Holder, Cartridge 11-31-1777 Blade, Shuttle 11-31-1778 Arm, Shuttle 11-31-1779 Guide, Shuttle 11-31-1780 End, Shuttle Guard 11-31-1781 Base, Machine 11-31-1782 Guard, Shuttle Front 11-31-1783 Guard, Insertion 11-31-1784 Upright, Right Frame 11-31-1785 Guard, Shuttle Rear 11-31-1786 Bracket, Sensor 11-31-1787 Bracket, Dual Sensor 11-31-1789 Flag, Sensor 11-31-1790 Flag, Insertion Sensor 11-31-1791 Stand, Right Control 11-31-1792 Stand, Center Control 11-31-1793 Base, Control 11-31-1794 Cover, Front Valve 11-31-1795 Stand, Left Control 11-31-1796 Cover, Rear 11-31-1797 Guide, Terminal Feed 11-31-4571 Guard, Front 11-31-1799 Guard, Housing Shift 11-21-0008 FRL Assembly with Gauge RSP 11-31-0422 Filter, Coalescing RSP 69002-5715 Assembly, Foot Switch 11-32-1659 Cord, 3-Conductor Power 11-32-8840 Switch, 8MM Proximity RSP 11-39-0131 Assembly, Control See Control Drawing 11-41-0264 Logo, Molex Order No: ATS-6230031005 Release Date: 09-16-99 Revision: E Revision Date: 02-29-08 Quantity UNCONTROLLED COPY 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 5 1 1 Page 19 of 38 Hawk Discrete Wire Termination Machine 62300-3100 Hawk Discrete Wire Termination Machine Sheets 1 thru 4 RSP / PP Parts Item Order No Description Quantity and notes 106 11-32-6778 Overlay, Operator Interface 1 107 11-21-5835 Bushing, Feeder Arm 1 111 11-31-1800 Mount, Guard 1 114 11-31-1803 Scale, Shuttle Adjustment 1 115 11-31-1804 Spacer, Front Guard 2 116 11-31-1805 Chute, Carrier 1 117 11-31-1439 Guard, Pawl Release 1 119 11-31-3116 Base, Shuttle Adjustment 1 120 11-31-3117 Pad, Fine Adjustment 1 121 11-31-2187 Bracket, Filter 1 122 11-31-5302 Tool, Nest Cleaning (Not Shown) 1 126 11-31-7475 Bushing, Shift Cylinder Rod Align 1 127 11-31-7476 Washer, Shift Cylinder Rod Align 1 128 11-31-7722 Guide, Shuttle Cylinder Stop 1 11-31-0421 Valve, Replacement RSP Ref 11-31-5939 Strip, Bearing Replacement RSP Ref 129 62800-7317 Tag, “CE” Serial Number 1 130 11-32-3060 Cable, Right Angle Proximity 3 131 11-32-3061 Cable, Straight Proximity 2 132 11-31-0332 Regulator, Pressure (with gauge) 1 133 11-32-1177 Control, In-Line Flow 7 134 62300-3101 Tube rest, Global Standard Tube 1 66X 62300-3102 Cover, Shift Nest (Xerox Only) 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). Order No: ATS-6230031005 Release Date: 09-16-99 Revision: E Revision Date: 02-29-08 UNCONTROLLED COPY Page 20 of 38 Hawk Discrete Wire Termination Machine 4.1 Main Assembly Drawings Order No: ATS-6230031005 Release Date: 09-16-99 Revision: E Revision Date: 02-29-08 UNCONTROLLED COPY Page 21 of 38 Hawk Discrete Wire Termination Machine Order No: ATS-6230031005 Release Date: 09-16-99 Revision: E Revision Date: 02-29-08 UNCONTROLLED COPY Page 22 of 38 Hawk Discrete Wire Termination Machine Order No: ATS-6230031005 Release Date: 09-16-99 Revision: E Revision Date: 02-29-08 UNCONTROLLED COPY Page 23 of 38 Hawk Discrete Wire Termination Machine Order No: ATS-6230031005 Release Date: 09-16-99 Revision: E Revision Date: 02-29-08 UNCONTROLLED COPY Page 24 of 38 Hawk Discrete Wire Termination Machine 4.1 Controls Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 Item 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 Order No 11-31-1781 11-31-1791 11-31-1792 11-31-1793 11-31-1794 11-31-1795 11-31-1796 62300-4610 62300-4620 62300-4621 AM60510-103 AM60510-118 Order No 11-31-5111 11-32-1659 11-32-2733 11-32-4754 11-32-4831 11-32-5182 11-32-6551 11-32-6552 11-32-6562 11-41-0264 62300-4601 62500-0053 62500-0054 62500-0110 62500-0160 62500-0188 62500-0490 62500-0508 62500-0515 62500-0516 62500-0609 62500-0610 62500-0611 62500-0612 62500-0613 62500-0614 62500-0615 62500-0667 62500-0668 62500-0762 62500-1055 625001337 66687-8885 66801-5142 66801-5144 66801-5152 CE Hawk Controls Assembly 62300-4600 Description Base Machine Stand Control, Right Stand Control, Center Base Control Front Valve Cover Stand Control, Left Rear Cover CE Haw Control Box Assembly with Slow Start Hardware CE Hawk Control Box Misc. Parts (Old 60510) Molex Schematic Electrical CE Hawk Schematic Cylinder and Sensor Pneumatic Tubing Layout Quantity 1 1 1 1 1 1 1 1 1 1 1 1 CE Hawk Control Box Assembly 62300-4610 Description RSP / PP Parts Din Rail 1mm Long Power Cord Detachable 2-Pole Fuse Drawer Operator Interface Relay Spring Clip Power Entry Module 3 Pole 24V DC Relay Socket Relay Hawk Enclosure Molex Logo 3.0" Diameter (Red On White) Counter Bracket CE Hawk Omron End Plate Jumper 2AMP Slowblo Fuse, 5 by 20mm RSP 5mm Terminal Block, Single Deck Electrical Warning Label Slow Start Valve Spacer CPU Plc,18 inch 12 out, DC Powered Communications Adapter SWITCH Operator Push Button Legend Plate Legend Plate Green Led 24V DC Red Push Button Mushroom Head-Twist N.C. Cont Block For E-Stop EMI SHIELD BEAD CAPACITOR 24v Re-settable Counter Micro-Dc Series 4 Pin Female 22 AWG 24v 50watt Power Supply Cable Assembly Db25 DB9 Connector Back Shell DB9 Male Plug DB Male Pins Order No: ATS-6230031005 Release Date: 09-16-99 Revision: E Revision Date: 02-29-08 UNCONTROLLED COPY Quantity 1 1 1 1 1 1 1 1 1 1 1 1 9 2 15 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Page 25 of 38 Hawk Discrete Wire Termination Machine Item 37 38 Item 1 2 3 4 5 6 7 8 9 10 CE Hawk Control Box Assembly 62300-4610 Description RSP / PP Parts Quantity 6mm End Stop 4 Voltage Selector 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). Order No 66801-5293 69018-6221 Order No CE Hawk Control Misc. Parts 62300-4620 Description RSP / PP Parts 11-21-0008 Filter Regulator Lubricator with Gauge 11-31-0332 Pressure Regulator With Gauge 11-32-1071 Fitting Blank Plug, 3/8" 11-32-1084 Reducer Air Fitting 11-32-1177 Flow Control, 5/32" Tube, In-Line 62500-0251 Single Solenoid Valve, Vq2000 Series 62500-0765 Proximity Sensor 62500-0766 Prox Plug & Cord (90) 62500-1255 Manifold 8-Station With Connector 63700-1193 Exhaust Port Silencer Quantity 1 1 1 6 7 8 5 5 1 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). Order No: ATS-6230031005 Release Date: 09-16-99 Revision: E Revision Date: 02-29-08 UNCONTROLLED COPY Page 26 of 38 Hawk Discrete Wire Termination Machine 4.1 Control Assembly Drawings Order No: ATS-6230031005 Release Date: 09-16-99 Revision: E Revision Date: 02-29-08 UNCONTROLLED COPY Page 27 of 38 Hawk Discrete Wire Termination Machine 4.2 Electrical Drawings Order No: ATS-6230031005 Release Date: 09-16-99 Revision: E Revision Date: 02-29-08 UNCONTROLLED COPY Page 28 of 38 Hawk Discrete Wire Termination Machine 4.2 Electrical Drawings Order No: ATS-6230031005 Release Date: 09-16-99 Revision: E Revision Date: 02-29-08 UNCONTROLLED COPY Page 29 of 38 Hawk Discrete Wire Termination Machine 4.2 Electrical Drawings Order No: ATS-6230031005 Release Date: 09-16-99 Revision: E Revision Date: 02-29-08 UNCONTROLLED COPY Page 30 of 38 Hawk Discrete Wire Termination Machine 4.2 Electrical Drawings Order No: ATS-6230031005 Release Date: 09-16-99 Revision: E Revision Date: 02-29-08 UNCONTROLLED COPY Page 31 of 38 Hawk Discrete Wire Termination Machine 4.3 Pneumatic Drawing Order No: ATS-6230031005 Release Date: 09-16-99 Revision: E Revision Date: 02-29-08 UNCONTROLLED COPY Page 32 of 38 Hawk Discrete Wire Termination Machine 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. 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, 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. 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). Pushing terminals into the housing. Termination Head The part of the machine that holds the crimp and termination punches and terminates the wires. Discrete Wire A single cable or wire. Contrast it to ribbon cable, which consists of multiple cables or wires. Housing Insertion Order No: ATS-6230031005 Release Date: 09-16-99 Revision: E Revision Date: 02-29-08 UNCONTROLLED COPY Page 33 of 38 Hawk Discrete Wire Termination Machine Appendix A Termination Information NOTE: The following document is uncontrolled and may not 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. Order No: ATS-6230031005 Release Date: 09-16-99 Revision: E Revision Date: 02-29-08 UNCONTROLLED COPY Page 34 of 38 Hawk Discrete Wire Termination Machine SL IDT CONTACT INSPECTION (Applies to both male and female terminals .040” MIN. .100” MAX. FIRST INSULATION DISPLACEMENT SLOT WIRE MUST EXTEND PAST THE SECOND INSULATION DISPLACEMENT SLOT SECOND INSULATION DISPLACEMENT SLOT LOCKING TAB INSULATION CRIMP CONTACT AREA NOT DEFORMED 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 Order No: ATS-6230031005 Release Date: 09-16-99 Revision: E Revision Date: 02-29-08 UNCONTROLLED COPY Page 35 of 38 Hawk Discrete Wire Termination Machine LOCKING TAB INSPECTION Order No: ATS-6230031005 Release Date: 09-16-99 Revision: E Revision Date: 02-29-08 UNCONTROLLED COPY Page 36 of 38 Hawk Discrete Wire Termination Machine Appendix B Options Order No: ATS-6230031005 Release Date: 09-16-99 Revision: E Revision Date: 02-29-08 UNCONTROLLED COPY Page 37 of 38 Hawk Discrete Wire Termination Machine Appendix C EC Declaration of Comformity Americas Headquarters Lisle, Illinois 60532 U.S.A. 1-800-78MOLEX amerinfo@molex.com Far East North Headquarters Yamato, Kanagawa, Japan 81-462-65-2324 feninfo@molex.com Far East South Headquarters Jurong, Singapore 65-6-268-6868 fesinfo@molex.com European Headquarters Munich, Germany 49-89-413092-0 eurinfo@molex.com Corporate Headquarters 2222 Wellington Ct. Lisle, IL 60532 U.S.A. 630-969-4550 Fax: 630-969-1352 Visit our Web site at http://www.molex.com Order No: ATS-6230031005 Release Date: 09-16-99 Revision: E Revision Date: 02-29-08 UNCONTROLLED COPY Page 38 of 38