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Hawk Discrete Wire Termination Machine
3.5
Troubleshooting
Symptom
Switch does not
turn on power
Smashed terminals
during termination
Improper crimp and
termination depth
Improper insertion depth
(Terminals in Housing)
Carriers not breaking
Cause
No current
Fuse blown
Defective power switch
Improper shuttle fine adjustment
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
Screws loose in insertion slide assembly
Insertion cylinder loose or binding
Debris caught under carrier bend slide
Bend cylinder loose or binding
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
off properly
Improper coining on terminal carrier strip
Loose carrier break-off cam block
Shift nest not positioned properly
and tighten all rod fittings.
Replace product.
Tighten all screws.
Adjust shift nest so connectors transition
smoothly.
Tube feed not working
Connector transfer
Not working
Connector overshoots
when transferred in
Shift cylinder binding
Tube bowed excessively or burred at ends
Air feeder malfunctioning
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
Shuttle cylinder flow control improperly set
Spring pressure on housing aligner too loose
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.
Order No TM-011200949
Revision: D
Release Date: 02-16-97
Revision Date: 03-03-11
UNCONTROLLED COPY
Page 15 of 39
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