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pneumatic bench top wire stripping machine order no: tm-638019200 release date: 10-01-09 uncontrolled copy page 1 of 20 revision: b revision date: 04-07-11 ws-1000 pneumatic bench top wire stripping machine operation manual order no. 63801-9200 (awg wire) order no. 63801-9250 (metric wire) description operation maintenance
pneumatic bench top wire stripping machine order no: tm-638019200 release date: 10-01-09 uncontrolled copy page 2 of 20 revision: b revision date: 04-07-11 table of contents section 1 safety warnings 2 general description 3 setup and adjustments 4 maintenance 5 parts list, assembly drawings and troubleshooting
pneumatic bench top wire stripping machine order no: tm-638019200 release date: 10-01-09 uncontrolled copy page 3 of 20 revision: b revision date: 04-07-11 1. warning molex cannot be responsible for damage or injury re sulting from unsafe product use, lack of maintenance, or incorrect product and system application. all warnings must be carefully observed to help pre vent personal injury. never use this tool without guards or safety devices that are intended to prevent hands from remaining in the stripping space . never operate, service, install or adjust this tool witho ut proper instruction and without first reading and understanding the ins tructions in this manual and all applicable air powered crimping tool manuals. never install or service this machine while connected to the compressed air source. warning the pneumatic bench top wire stripping machine is not intended for the processing of materials other than those normally u sed in insulation and jacket materials for wires and electrical condu ctors. warning the pneumatic bench top wire stripping machine is also not intended for the processing of massive shields made of copper or harder materials, steel wire networks etc. warning molex specifications are valid only when used with molex terminals and tooling. work safely at all times for service, contact your local molex sales office molex application tooling group 2200 wellington court lisle, illinois 60532, usa tel: 630-969-4550 fax: 630-505-0049
pneumatic bench top wire stripping machine order no: tm-638019200 release date: 10-01-09 uncontrolled copy page 4 of 20 revision: b revision date: 04-07-11 section 2 general description 2.1 description 2.2 features 2.3 technical specifications 2.4 delivery check 2.5 tools
pneumatic bench top wire stripping machine order no: tm-638019200 release date: 10-01-09 uncontrolled copy page 5 of 20 revision: b revision date: 04-07-11 figure 2-1 safety cover filter regulator gauge hook up adjusting wheel for strip length blades adjusting wheel for cable cross section adjusting screw for strip length / partial wire / cable principal mechanical parts of the ws-1000 (63801-92 00 / 63801-9250)
pneumatic bench top wire stripping machine order no: tm-638019200 release date: 10-01-09 uncontrolled copy page 6 of 20 revision: b revision date: 04-07-11 general description 2.1 description (see figure 2-1) the ws-1000 pneumatic bench top wire stripping machine, order no. 63801-9200 for awg wire and 63801-9250 for metric wire, is a semi-automatic, pneumatic table instrument for the stripping of cables and wires with insulations of different natu ral and synthetic materials, such as; rubber, pur, teflon etc. the use of special blades, adapted to the cable to be processed, allows the processing of nearly all common round and flat cables. the pneumatic bench top wire stripping machine can handle extremely short wire leads, less than 9mm in length. it can adjust to change wire strip diameter settings, easily without tools, to process a full range of wire sizes. the v-shaped blades can be adjusted for the full range of wire sizes, quick ly in seconds, without tools, for quick production run changeouts. self-centering clamping jaws and release sensors ensure high quality strips, safely and efficiently. 2.2 features extremely short stranded wire ends can be processed (distance cover to stripping blades <= 9 mm) exact parallel guide of the blade heads processing with die-blades, prismatic blades and flat stripping blades blade change within seconds and without tools sensor release of the stripping process self-centering clamping jaws air blow-out guard cover for safety putting in the cable from above 2.3 technical specification dimensions width 95.0mm (3.74) depth 280.0mm (11.02) height 165.0mm (6.50) weight 4.3kg (9.5lbs) operating parameters cycle time 0.5 seconds operating air pressure 3 to 6 bar (43 to 87psi ) maximum 6 bar (87psi) air consumption per cycle 0.15l (0.005 cubic feet) sound level < 70 db(a) cable round cables up to 5.0mm (.196") o.d. cross section from 0.15 - 4mm2 (26 - 12 awg) flat cables up to 8mm wide (.315") partial stroke from 1.0 C 15.0mm (0.04 C 0.59") stripping length of 1.5-15.0mm (.06 - .59) (total stripping) removal length of 0 C 15.0mm (0 - .59) safety covers order no. standard . 63801-9228 4.0mm (.157) maximum insulation diameter cover with safety collar (optional) 63801-9229 8.0mm (.315) maximum insulation diameter 2.4 delivery check carefully remove wire stripping machine from its shipping container and determine that the following items are included in the package. description quantity 63801-92*0 pneumatic bench top wire stripping machine 1 63801-9243 hex wrench 5mm 1 63801-9271 pair of prismatic blades (installed at the factory) 1 63801-9230 pair of rubber pads for clamping jaws 1 63801-9201 air regulator & shut-off assy 1 tm-638019200 instruction manual 1 2.5 tools the following tools are recommended for setup and adjustments. metric standard hex wrench set adjustable wrench wire stripper / cutter
pneumatic bench top wire stripping machine order no: tm-638019200 release date: 10-01-09 uncontrolled copy page 7 of 20 revision: b revision date: 04-07-11 section 3 set-up and adjustments 3.1. setup 3.2. operation 3.3. adjustments 3.4. installing and replacing blades 3.5. adjustment of the brakes
pneumatic bench top wire stripping machine order no: tm-638019200 release date: 10-01-09 uncontrolled copy page 8 of 20 revision: b revision date: 04-07-11 3.1 set-up caution: always disconnect the air pressure until the system is ready to operate. note : detail nos. in parenthesis ( ) are shown on the a ssembly drawing in section 5. these are not order n os. air supply hook-up 1. read the following instructions before attempting t o operate the tool. 2. an air regulator assembly, order no. 63801-9201, is included with this tool. it includes a filter / regulator un it with air shut-off and supply hose. connect the assembly to the back panel of the machi ne, with the two included cap screws. see figure 3-1. 3. adjust the regulator to an operating pressure of 3 - 6 bar (43 C 87 psi). the maximum operating pressure is 6 bar ( 87 psi). operating the tool above the maximum pressure may c ause injury or damage to the tool. 4. before using the machine, make sure the clear pla stic safety cover is installed. safety devices the ws-1000 bench top wire stripping machine is equ ipped with all necessary safety devices. however, no system can be completely protected against misus e. all changes and amendments not made by the manufacturer, or other modifications that are not g ranted in writing by the manufacturer, will void al l guarantees and liability claims. when the safety cover is removed a safety switch wi ll prevent the machine from operating. the clear plastic safety cover supplied with the un it, order no. 63801-9228 (028.0071), is for cable o r wire insulation outer diameters up to 4.0mm. in addition to the standard safety cover, an option al safety cover, order no. 63801-9229 (028.0072), i s available for cable or wire insulation outer diamet ers over 4.0mm. the safety cover protects the operator from the haz ardous area of the wire stripping machine. please check regularly that the safety cover functions correctly by unscrewing the safety cover's two knurled scre ws, and sliding the cover forward (towards the operator) note: if the machine works correctly, the safety switch w ill interrupt the air supply and the machine will not function. if the safety device does not functio n properly, operation of the machine should be avoi ded until the safety switch is repaired. figure 3-1
pneumatic bench top wire stripping machine order no: tm-638019200 release date: 10-01-09 uncontrolled copy page 9 of 20 revision: b revision date: 04-07-11 3.2. operation the cable is put into the machine through the openi ng in the safety cover from above or from the front and is pu shed against the sensor. this sensor starts the working cycle, which functions as follows: 1. the starting position is where the clamp jaws (028.0010 and 028.0011) and blades are open and the blade head (028.0014) with sensor is in the front position. front position is when the blade head is placed directly behind the clamping jaws 2. the back position is when the blade head is placed at the end of its way towards the front plate (028.000 1). 3. insert the cable or wire into the slot of the safet y cover until the end touches the sensor (028.0035). see figure 3-2. 4. the clamp jaws will come together and then clamp and center the cable. 5. the blades move together and cut into the insulatio n of the cable or wire. 6. the complete slide, with blade head and blades, mov es backwards to the adjusted removal length. at the same time, the sensor moves backwards. 7. after the slide and the blade head have reached the ir final position, the clamp jaws open and then the blades. the slide moves backwards to the initial position. at t he same time, a small air jet blows the stripping debris in to the waste shaft (028.0028). 3.3. adjustments 1. cable / wire diameter (see figure 3-3) the adjusting wheel for the conductor diameter of t he wire to be stripped, is located in the front at the top of the machine. (028.0015 for metric or 028.0083 for awg) note: while using die blades, the adjusting wheel has to be put in the position marked ? . while using prismatic blades or flat stripping blades , the adjusting wheel has to be opened wide enough. adjust the necessary diameter step by step, until s atisfactory stripping results are obtained - otherw ise, there is risk that the blades will cut into the wires. the scale values on the adjusting wheel are related to the diameter of the conductor, when prismatic b lades are used. clamp jaws blades and blade holders wire sensor figure 3-2 figure 3-3 adjusting wheel
pneumatic bench top wire stripping machine order no: tm-638019200 release date: 10-01-09 uncontrolled copy page 10 of 20 revision: b revision date: 04-07-11 figure 3-5 63801-9271 prismatic blades 63801-9272 flat stripping blades 2. stripping length (see figure 3-4) the desired stripping length 1.5 C 15.0mm (.059 to .590) is adjusted with the adjusting wheel (028.0046) on the right si de of the machine in increments of 0.5mm. note: the middle scale line is valid when using the prismatic blade s. the front and rear scale lines are used when using the flat blades; the front line is used when the draft angle of the flat blade is facing out and the rear scale line is used when the draft angle of the flat blade is facing in (not visible) 3. removal length / partial stroke (see figure 2-1) the removal length also can be adjusted as required , (from 0 C 15.0mm). this is done by using a 5mm hex wrench to adjust the screw (028.0041), located through the hole on the l ower left side of the front plate. 3.4. installing and replacing blades this machine will accomadate 2 different interchang able blade sets. the 63801-9200 includes the standa rd prismatic blades, order no. 63801-9271. there are also optional flat stripping bades available, order no. 63801- 9272. follow the steps below to install and replac e them. 1. remove the safety cover. this is done by loosening (2) knurled screws on each side of the cover and then sliding the cover forward, up and off the mach ine. 2. push back the guide pin on the swing lever that is located behind each blade holder, (one side at a ti me) and pull out the blade from the side. see figure 3 .6. 3. make sure that the guide slots are clean and free o f debris. 4. to install new blades, push back the guide pin and slide in the blade until the blade clicks onto the guide pin. make sure that the guide pins catch in the cor responding holes of the blades. see figure 3-7. note: the prismatic blades must be installed so they ove rlap when closed. figure 3-4 adjusting wheel figure 3-7 push back guide pin push in the blade figure 3-6 guide pins
pneumatic bench top wire stripping machine order no: tm-638019200 release date: 10-01-09 uncontrolled copy page 11 of 20 revision: b revision date: 04-07-11 3.5 adjustment of the brakes the correct function of this machine is dependent o n two adjustable brakes. improper adjustment or we ar of the brakes can influence the function of the machin e and cause faulty stripping results. the following two malfunctions are possible, due to improperly adjusted brakes: 1. the blades move together before the clamp jaws clos e - this means that the cable is not sufficiently clamped and centered. correction: the brake, below the cylinder (028.6001), requires readjustment: 1. unscrew the button head screw (028.8033) on the sid e plate (028.0002). 2. turn the screw, located behind the side plate (028. 0002), with a 3mm hex wrench, approximately 1 to 3 turns clockwise (cw). 3. this tightens the brake and increases the brake pow er. 2. the slide blade head (028.0014) with blade holder a nd blade moves back before the blades have moved together C this means that the insulation is removed too late or not at all. caution: before re-adjusting the brake always disco nnect the compressed air from the machine. correction: the brake (028.0040) requires readjustment. 1. remove the compressed air supply from the machine. 2. unscrew the cover (028.5001). 3. turn the screw (009.8050) with a 3mm hex wrench app roximately 1 to 3 turns clockwise (cw). 4. check the correct brake adjustment by pushing back (machine should have no compressed air) the cylinder (028.6001) manually on the unscrewed carri er . the blades will first move together. then, the cone (028.0053) must move with its binding face against the adjusting screw (028.0036). finally, it pulls back the complete slide (blade he ad 028.0014) with blade holders and the blades. 5. in an opposite movement, the slide (blade head 028. 0014) is pulled towards the front plate (028.0001). the blades first have to open before t he slide (028.0014) moves.
pneumatic bench top wire stripping machine order no: tm-638019200 release date: 10-01-09 uncontrolled copy page 12 of 20 revision: b revision date: 04-07-11 section 4 maintenance 4.1 cleaning 4.2 lubrication 4.3 perishable parts 4.4 spare parts 4.5 storage
pneumatic bench top wire stripping machine order no: tm-638019200 release date: 10-01-09 uncontrolled copy page 13 of 20 revision: b revision date: 04-07-11 maintenance caution: always disconnect the compressed air suppl y before all maintenance in order to insure the best operating condition and machine safety, a regular inspection of all releva nt parts and functions should be done, appropriate to the fr equency of their use. 4.1 cleaning see chart for recommended preventive maintenance sc hedule. an example of a maintenance chart is shown below. copy and use this chart to track the maintenance of your machine or use this as a template to create yo u own schedule or use your companys standard chart , if applicable. the following applies to this machine with tooling installed. 1. for efficient operation, the tooling should be clea ned daily with a soft bristle brush to remove any d ebris from the tooling area. 2. all hose connections must be free of grit and grime . 3. machine interior: from time to time, the working area of the machine should be cleaned with a soft brush. an intermediat e cleaning is recommended in case of considerable dir t due to talcum and stripping scrap. make sure tha t there are no foreign parts or liquids getting into the case openings. 4. when it is necessary to change the tooling, care sh ould be taken to remove any debris from tapped hole s or mounting surfaces. debris can prevent tooling f rom being properly locked into position. 5. all rotating and other movable elements are equippe d with antifriction bearings or maintenance-free sl ide bearings. these parts are adequately lubricated an d do not require any further maintenance. caution: using compressed air to clean tooling is not recommended. chips can wedge in the tooling and/or fly at an operator. 4.2 lubrication pneumatics all control valves and cylinders have been adequate ly lubricated with pneumatic oil, and therefore, do not require any further maintenance. filter-regulator it will be necessary to check the filter bowl at le ast once a month, depending on how dirty the air su pply is, and empty as required. preventive maintenance chart daily: clean. see section 4.1.
pneumatic bench top wire stripping machine order no: tm-638019200 release date: 10-01-09 uncontrolled copy page 14 of 20 revision: b revision date: 04-07-11 check sheet month year _________ week daily use days of the week solution mon tue wed thu fri sat sun 1 2 3 4 bleeding air from the system after prolong use run the system thru several cycles. cleaning hose connections free of grit and dirt. use soft cloth schedule should be adjusted up or down depending on usage. molex recommends that a log of preventive maintenance be kept with the tool. 4.3 perishable parts customers are responsible for maintaining the pneum atic bench top wire stripping 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 parts in stock at all times. t his will reduce the amount of production down time. 4.4 spare parts customers are responsible for maintaining the the p neumatic bench top wire stripping machine. spare parts are available. moving and functioning parts can be damaged or wear out over time and will requi re replacement. molex recommends that the customer ke ep some or all of them in stock to reduce productio n down time. these parts are identified in the parts list. see section 5. 4.5 storage when storing the ws-1000 pneumatic bench top wire s tripping machine, disconnect the air supply and store in a dry location.
pneumatic bench top wire stripping machine order no: tm-638019200 release date: 10-01-09 uncontrolled copy page 15 of 20 revision: b revision date: 04-07-11 section 5 parts list, assembly drawings and troubleshooting 5.1. parts lists and assembly drawings 5.2. troubleshooting
pneumatic bench top wire stripping machine order no: tm-638019200 release date: 10-01-09 uncontrolled copy page 16 of 20 revision: b revision date: 04-07-11 5.1 main parts list ws-1000 pneumatic bench top wire stripping machine (63801-9200 or 36801-9250) order no detail no description rsp / pp parts and notes quantity 63801-9201 not shown filter regulator and shut-off valve assy pneumatic parts 1 63801-9202 003.6027 micro ram valve pneumatic parts 1 63801-9203 009.8050 screw 3 63801-9204 028.0001 front plate 1 63801-9205 028.0002 side plate (right) 1 63801-9206 028.0003 side plate (left) 1 63801-9207 028.0004 back plate 1 63801-9208 028.0005 bottom plate 1 63801-9209 028.0010 clamp jaw, right 1 63801-9210 028.0011 clamp jaw, left 1 63801-9211 028.0014 blade head 1 63801-9212 028.0015 adjusting wheel (metric wire sizes) on 638 01-9250 1 63801-9213 028.0017 sleeve 1 63801-9214 028.0025 sensor fork 1 63801-9215 028.0028 waste shaft 1 63801-9216 028.0034 pipe for sensor 1 63801-9217 028.0035 sensor 1 63801-9218 028.0036 adjusting screw 1 63801-9219 028.0037 rubber for ram 1 63801-9220 028.0038 swing pin 2 63801-9221 028.0040 brake 1 63801-9222 028.0041 screw 1 63801-9223 028.0046 adjusting wheel 1 63801-9224 028.0053 cone 1 63801-9225 028.0054 pedestal 2 63801-9226 028.0055 conus guide 1 63801-9271 028.0060 prismatic blades, pair pp 1 63801-9272 028.0063 flat stripping blades, pair pp optional part 0 63801-9227 028.0064 centering piece 1 63801-9228 028.0071 safety cover, standard rsp 1 63801-9229 028.0072 safety cover 8mm optional part 1 63801-9230 028.0075 pair of rubber pads for clamping jaws rsp accessories ref 1 63801-9231 028-0083 adjusting wheel (awg) on 63801-9200 1 63801-9232 028.5001 cover 1 63801-9233 028.6001 short stroke cylinder pneumatic parts 1 63801-9234 028.6002 5/2 sliding valve pneumatic parts 1 63801-9235 028.6034 throttle return stroke valve pneumatic par ts 1 63801-9236 028.8004 grooved ball bearing 2 63801-9237 028.8005 grooved ball bearing 2 63801-9238 028.8007 du-sleeves 4 63801-9239 028.8008 sleeve (sinter bronze) 1
pneumatic bench top wire stripping machine order no: tm-638019200 release date: 10-01-09 uncontrolled copy page 17 of 20 revision: b revision date: 04-07-11 ws-1000 pneumatic bench top wire stripping machine (63801-9200 or 36801-9250) order no detail no description rsp / pp parts and notes quantity 63801-9240 028.8012 guide pins 2 63801-9241 028.8013 swing levers 2 63801-9242 028.8023 sleeve (sinter bronze) 2 63801-9243 028.8025 hexagon socket wrench 5mm accessories ref 1 63801-9244 028.8033 button head screw 1 63901-9245 028.8034 high-grade steel strand 1 rsp - part is a molex r ecommended s pare p art. pp - part is a p erishable p art.
pneumatic bench top wire stripping machine order no: tm-638019200 release date: 10-01-09 uncontrolled copy page 18 of 20 revision: b revision date: 04-07-11 assembly drawing
pneumatic bench top wire stripping machine order no: tm-638019200 release date: 10-01-09 uncontrolled copy page 19 of 20 revision: b revision date: 04-07-11 5.2 troubleshooting symptom cause solution blades do not open. blade guide is dirty. clean blade head. insulation is cut improperly. dull blades. install new blades machine has excessive air leaking around the safety cover. safety switch is not pressed in far enough by the safety cover. push safety cover towards the front plate the cable is not sufficiently clamped and centered. worn or improperly adjusted brakes. see section 3.5 adjustment of the brakes the insulation is removed too late or not at all. worn or improperly adjusted brakes see section 3.5 adjustment of the brakes clamp jaws do not open. cable scrap between clamp jaws and safety cover. remove cable scrap. http://www.molex.com
pneumatic bench top wire stripping machine order no: tm-638019200 release date: 10-01-09 uncontrolled copy page 20 of 20 revision: b revision date: 04-07-11

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