Customer Manual
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All Rights Reserved.
*Trademark
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PRODUCT INFORMATION 1-800-522-6752
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.te.com.
AMP 3K/40* CE Terminating Machines
PN 2161400-[ ] and AMP 5K/40* CE
Terminating Machines PN 2161500-[ ]
ORIGINAL INSTRUCTIONS
409-10204
16 SEP 16 Rev G
SAFETY PRECAUTIONS — AVOID INJURY — READ THIS FIRST! ...................................... 2
1. INTRODUCTION .................................................................................................................. 3
2. DESCRIPTION ..................................................................................................................... 5
2.1.Functional Description .................................................................................................... 5
2.2.Electrical Description ...................................................................................................... 8
2.3.Machine Guard ............................................................................................................... 8
3. RECEIVING INSPECTION AND INSTALLATION ............................................................... 8
3.1.Receiving Inspection ...................................................................................................... 8
3.2.Installation ...................................................................................................................... 9
3.3.Considerations Affecting Placement of Bench Machines (Figure 8) ............................ 10
4. OPERATION ...................................................................................................................... 11
4.1.Control Panel Operation ............................................................................................... 11
4.2.Applicator Installation ................................................................................................... 11
4.3.Setup ............................................................................................................................ 13
4.4.Mode Selection and Operation ..................................................................................... 13
4.5.Adjusting the Motor Speed ........................................................................................... 14
4.6.Crimp Height Adjustment ............................................................................................. 14
4.7.End-Feed/Side-Feed Applicator Conversion ................................................................ 14
5. PREVENTIVE MAINTENANCE ......................................................................................... 14
5.1.Cleaning ....................................................................................................................... 14
5.2.Lubrication .................................................................................................................... 15
6. ADJUSTMENTS ................................................................................................................. 15
6.1.Measuring the Shut Height ........................................................................................... 16
6.2.Shut-Height Adjustment ............................................................................................... 16
6.3.Crimp Height Adjustment Using Precision Adjustment Mechanism ............................. 17
6.4.Guard Insert Adjustment .............................................................................................. 18
7. MACHINE OPTIONS AND INSTALLATION OF THE AIR FEED VALVE
ASSEMBLY ........................................................................................................................ 19
8. TROUBLESHOOTING ....................................................................................................... 21
8.1.Error Codes .................................................................................................................. 21
8.2.Diagnostics ................................................................................................................... 22
9. SOTWARE VERSION IDENTIFICATION .......................................................................... 22
10. DISPOSAL ......................................................................................................................... 22
11. REPLACEMENT AND REPAIR ......................................................................................... 23
12. RoHS INFORMATION ........................................................................................................ 23
13. REVISION SUMMARY ....................................................................................................... 23
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SAFETY PRECAUTIONS — AVOID INJURY — READ THIS FIRST!
Safeguards are designed into this application equipment to protect operators and maintenance personnel from
most hazards during equipment operation. However, certain safety precautions must be taken by the operator
and repair personnel to avoid personal injury, as well as damage to the equipment. For best results, application
equipment must be operated in a dry, dust-free environment. Do not operate equipment in a gaseous or
hazardous environment.
Carefully observe the following safety precautions before and during operation of the equipment:
Always wear approved eye protection while operating
equipment.
Always wear appropriate ear protection while using
equipment.
Moving parts can crush and cut. Always keep guard(s)
in place during normal operation.
Electrical shock hazard.
Always turn off the main power switch and disconnect
the electrical cord from the power source when
performing repair or maintenance on the equipment.
Never insert hands into installed equipment.
Never wear loose clothing or jewelry that may catch in
moving parts of the equipment.
Never alter, modify, or misuse the equipment.
SUPPORT CENTER
CALL TOLL FREE 1-800-522-6752 (CONTINENTAL UNITED STATES AND PUERTO RICO ONLY)
The Support Center offers a means of providing technical assistance when required. In addition, Field Service
Specialists are available to provide assistance in the adjustment or repair of the application equipment when
problems arise which your maintenance personnel are unable to correct.
INFORMATION REQUIRED WHEN CONTACTING THE SUPPORT CENTER
When calling the Support Center regarding service to equipment, it is suggested that a person familiar with the
device be present with a copy of the manual (and drawings) to receive instructions. Many difficulties can be
avoided in this manner.
When calling the Support Center, be ready with the following information:
1. Customer name
2. Customer address
3. Person to contact (name, title, telephone number, and extension)
4. Person calling
5. Equipment number (and serial number if applicable)
6. Product part number (and serial number if applicable)
7. Urgency of request
8. Nature of problem
9. Description of inoperative component(s)
10. Additional information/comments that may be helpful
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Figure 1
1. INTRODUCTION
This manual contains information on operation, preventive maintenance, and adjustments of the AMP 3K/40 and
AMP 5K/40 CE Terminating Machines PN 2161400-[ ] and PN 2161500-[ ] respectively. See Figure 1.
Descriptions in this manual pertain to the controls and adjustments on the AMP 3K/40 and AMP 5K/40 machines
only.
The various applicators that can be used in the machines are covered in applicator instruction sheets packaged
with each applicator. Applicator instruction sheets provide information on applicator installation, care, and
adjustment.
The specifications and requirements for the AMP 3K/40 and AMP 5K/40 CE Terminating Machines are as listed
below:
—
Deflection: 0.13 mm [.0046 in.] Maximum per 4,448 Newtons [1,000 lb] Crimp Force
—
Noise: Less than 82 dBa Typical at operator position with standard mechanical feed applicator
—
Weight: 77.3 Kilograms [170.4 lb]
—
Height: 585 mm [23 in.] without reel supports
—
Electrical: 100-240 Vac, 50/60 Hz, Single-Phase Current. Operating current is 3 amp.
—
Air: 620-760 kPa [90-100 psi], 2.83 liters/sec (6 scfm) When required for use with air-feed applicators
—
Physical Environment: Temperature: 4.45-40° C [40.5-104° F]
Relative Humidity: Less than 95% (non-condensing)
Transportation and Storage: Store in a clean, dry environment after coating
all
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surfaces lightly with a rust preventing oil
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When reading this manual, pay particular attention to DANGER, CAUTION, NOTE statements.
Always wear approved eye protection while operating the equipment.
Always wear approved hearing protection while operating the equipment.
Use caution working with this equipment.
Main electric ON/OFF switch.
Do NOT operate the equipment if the guard is removed.
Lift point for the equipment.
Read and understand the entire manual before using the equipment.
Moving parts can crush and cut. Do not operate the equipment without guards in place.
DANGER
Denotes an imminent hazard which may result in moderate or severe injury.
CAUTION
Denotes a condition which may result in product or equipment damage.
NOTE
Highlights special or important information.
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ORIGINAL APPLICATOR
FEED TYPE
CHANGEOVER CAMS (PN) FOR THE MACHINES
41.25 mm [1 5/8-in.]
Stroke Machines
30 mm [1 1/8-in.]
Stroke Machines
1 1/8-in. Stroke Applicator for Model “K"
Terminating Machine
Pre-Feed
690602-6
---
Post Feed
690501-4
---
1 5/8-in. Stroke Applicator for Model “T"
and Model “G" Terminating Machines
Pre-Feed
---
690602-5
Post Feed
---
690501-3
Heavy-Duty Industrial (HD-I) Applicator
Pre-Feed/Post Feed
Refer to the HD-I Applicator customer drawing for part numbers.
Hex Key Location
for Manual Cycling
Power Cord
Receptacle
2. DESCRIPTION
The AMP 3K/40 and AMP 5K/40 CE terminating Machines were designed to be used as stand-alone semiautomatic bench units. They are assembled with metric hardware.
NOTE
Measurements are in metric units [followed by U.S. customary units in brackets] unless otherwise indicated. Some commercial
items may contain non-metric hardware.
These machines accepts a wide variety of miniature (mini) quick-change applicators, with minor adjustments,
thus providing a great selection of terminals for many applications. Figure 2 lists changeover cams required to
run 1 1/8-in. stroke cams (for AMP-O-LECTRIC* Model “K" terminating machines) and 1 5/8-in. stroke cams
(for Model “T" and Model “G" Terminating machines) in the machines.
Figure 2
2.1. Functional Description
These machines provide the force required to crimp terminals in the applicator. A terminal is attached to the
wire by placing the wire in the crimp area and pressing the foot switch. The machine consists of four functional
areas:
1. The motor group includes a dc motor which drives a crankshaft. See Figure 3 and Figure 4. The
motor is activated each cycle and rotates the crankshaft one full revolution. A hex key is located on
the end of the motor, which allows the motor to be cycled manually. The hex key is accessed by
unplugging the power cord from the rear of the motor.
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Figure 3
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Motor Gearbox
Assembly
Electrical Control
Box Assembly
Terminal Strip Guide
Mounting Surface for
End-Feed Applicators
Figure 4
2. The crankshaft-ram group conveys the motor rotational force to the up-and-down action of the ram
for driving the applicator during the crimping cycle.
3. The base plate provides the mounting surface on which the applicator is installed. The quick-release
latching feature permits fast, easy installation and removal of the applicator. See Figure 5.
4. The crimp height adjustment group uses an eccentric located in the ram linkage, along with
detented stops in the mechanism to adjust the crimp height. Indexing the mechanism in either
direction will change the crimp height in increments of approximately 0.013 mm [.0005 in.] per step.
Refer to Figure 5 for the Precision Crimp Height Adjustment Mechanism.
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Figure 5
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Membrane Keypad
Button(s)
Display
ON/OFF Switch
2.2. Electrical Description
The PN 2161400-[ ] and PN 2161500-[ ] machine electrical components consist of the operator control panel,
the motor, and the CPU/motor controller and safety circuit package. The machine operates on 100/240 Vac,
50/60 Hz, single-phase current with ground. The machine will automatically detect the supply voltage and
adjust the controller accordingly.
The operator control panel (Figure 6) is mounted on the left side of the machine frame. The control panel
consists of five button membrane key pad and a two line by eight column display. The membrane key pad has
icons representing the function of each button.
Figure 6
A main power switch/circuit breaker (Figure 6) is located on the front of the control panel. The main power
switch/circuit breaker connects ac power to the control system. The CPU/motor controller and safety circuit are
located in the electrical control box.
2.3. Machine Guard
A guard is installed to provide protection for the operator while maintaining proper visibility of the work area.
The guard swings open to allow easy access for applicator installation and setup. A safety switch on the guard
prevents machine operation if the guard door is open.
3. RECEIVING INSPECTION AND INSTALLATION
3.1. Receiving Inspection
These machines are thoroughly inspected during and after assembly. A final series of inspections is made to
insure the proper machine functioning before packaging and shipping.
To protect against damage that may have occurred during shipment, remove the machine from the crate
(paragraph 3.2.) and carefully inspect the machine for damage. If damage is evident, file a claim against the
carrier and notify TE immediately.
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Lift point for the equipment.
Base Plate Assembly
Hole for Customer
Supplied Lift Ring
Tongue Operated
Safety Switch
3.2. Installation
Remove all mounting bolts securing the machine to the shipping pallet. Install lift ring (see Figure 7) on top of
the machine.
NOTE
Lift ring (M1220 eye bolt) is customer supplied.
CAUTION
Install the lift ring carefully. A 19.05-mm [.75-in.] thread length engagement is required for the lift ring to support the machine.
Attach a suitable hoist to the lift ring, lift the machine, and place it in the selected operating location.
Insert the reel support post into the appropriate hole on top of the machine until the roll pin engages a groove in
the machine frame.
Attach the terminal strip guide included with the machine with the two thumbscrews supplied. Mount the guide
on the left guard for side-feed applicators. Mount the guide on the right guard for end-feed applicators.
Connect the power cord to a suitable electrical supply.
NOTE
The machine will automatically detect the supply voltage and adjust the controller accordingly.
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Figure 7
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3.3. Considerations Affecting Placement of Bench Machines (Figure 8)
The location of the machine in relation to the operator's position is extremely important in terms of both safety
and maximum efficiency. Studies have repeatedly shown that operator fatigue will be reduced, and greater
efficiency achieved, if:
the bench is of appropriate height, preferably with sound-deadening rubber mounts;
the machine is properly located on the bench with ample work areas on both sides to facilitate work flow;
the operator uses a swivel chair with padded seat and back rest which are independently adjustable; and
the foot switch, on machines so equipped, is placed on a rubber mat to maintain its movability, while
preventing it from sliding unintentionally.
Figure 8 illustrates proper machine location, operator position, and recommended foot switch position.
Figure 8
Bench
The bench to be used should be of sturdy construction, preferably with rubber mounts to minimize noise.
A height of 762 to 812.8 mm [30 to 32 in.] is the most suitable for operator comfort and convenience. This
height allows the operator to rest both feet on the floor, thereby providing for the shifting of weight and leg
position.
Machine Mounting and Location on Bench
The machine should be located near the front of the bench with the “target area" (tooling area where the
product is applied) not more than 152.4 to 203.2 mm [6 to 8 in.] -- minimum 50.8 mm [2 in.] from the front
edge. This location will eliminate unnecessary operator motion and help to avoid back strain and fatigue.
Orientation of the machine should be such that the “target area" is facing the front of the bench and is
parallel to the front edge (access to the back of the machine MUST also be provided).
DANGER
Machines should be securely bolted to the bench using the machine mounting holes shown in Figure 5. Hardware is customer
supplied. Machines should not extend beyond the front of the bench.
Operator's Chair
The operator's chair should swivel, and should have independent seat height and back rest adjustments.
The seat and back rest should be padded, and the back rest should be large enough to provide support
both above and below the waist line.
In use, the chair should be far enough under the bench so that the operator's back is straight and is
supported by the back rest.
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Foot Switch
When the operator is correctly positioned in front of a machine equipped with a foot switch, the foot should
rest on the switch comfortably. The foot switch should be movable, so that its location can be readily
changed when the operator shifts position to minimize fatigue. Placing the switch on a rubber mat keeps it
movable while preventing unintentional sliding.
The preferred foot switch location varies to some extent among operators. Some operators prefer the
switch located so that their foot rests on the switch when their feet are in the natural sitting position (calf of
leg perpendicular to the foot). Others prefer the leg to be slightly in front of the natural position. The
important thing to remember is that the foot should be at approximately 90° (right angle) to the calf when
resting on the switch. Those operators who prefer the foot switch slightly in front of the natural position
may require a wedge-shaped block placed under it.
Scrap Removal
A suggested method of scrap removal: place a tray on the right side of the machine, under the cast slot in
the frame, to capture the scrap chips.
4. OPERATION
4.1. Control Panel Operation
The basic control panel operation is as described in Figure 9. The control panel will be used to set up and
operate the machine (see paragraph 4.3. and paragraph 4.4.).
4.2. Applicator Installation
Install the proper applicator in the quick-change mounting base as follows:
CAUTION
Make sure that the precision adjustment lever has been returned to the “0" position before installing the applicator. Be sure
that the applicator has the proper feed cam prior to installation.
NOTE
Applicators from AMP-O-LECTRIC Model “K" terminating machines and Model “T" terminating machines can be used in these
machines by using a special replacement cam. Refer to Figure 2.
1. Loosen the quick-release T-handle (see Figure 5) and slide the applicator base clamp down.
2. Place the applicator on the quick-change base plate, then slide it back until the two notches in the
applicator base engage the stops at the back of the quick-change base plate. At the same time, guide
the ram post into the ram post adapter.
3. Slide the applicator base clamp UP and re-tighten the quick-release T-handle to secure the applicator
in place.
NOTE
When using Applicator PN 567200-2 (originally intended for use with AMP-O-LECTRIC Model “K" terminating machine),
loosen the quick-release T-handle, slide down the applicator base clamp, and remove the rear stop located on the left side of
the base plate. Install the rear stop (PN 354561-1), supplied with the air feed kit, at the alternate mounting position on the
base plate. See Figure 5.
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Speed Indication
Guard Status
Machine Status/
Error Code
Error Reset
Batch Count
Count Reset
Speed
Decrease
Jog
Speed
Increase
Main Power Switch
Decrease Speed -- Decrease the motor speed for normal cycle operation and for jogging.
Increase Speed --
Increase the motor speed for normal cycle operation and for jogging.
Error Reset -- Clears the displayed error code.
Count Reset -- Clears the batch count to 0.
Jog -- Causes the DC motor to rotate at the jog speed set by the Increase / Decrease Speed.
Speed Indication --
Each “>” represents a portion of the full operation or jog speed setting. Minimum speed is denoted
with a single “>. Maximum speed is denoted by “>>>>>>.”
Machine Status / Error Code Display -- Displays “OK” if there is no error code being displayed or “ERRxxx” when an
error
has occurred. The “xxx” represents a number corresponding to an error described in the error code table (Figure 17).
Guard Status Indication -- A solid “" indicates that the guard interlock is closed. An open icon in this display indicates
that
the guard interlock is open. The DC motor will not run when the guard interlock is open.
4. Set the crimp height and insulation crimp discs so that the letters and numbers on the applicator pad
align with the front pad on the ram post adapter.
5. If the applicator is an air-feed type, make sure the front door cover is closed, then connect the airlines
to the valves located on the back of the machine.
NOTE
Quick Disconnect Coupling PN 23238-1 is required to run air-feed applicators.
6. Adjust the reel support for side-feed or end-feed product, depending on the applicator being used.
7. Mount the terminal strip guide on the left sheet metal guard for side-feed product, or on the right sheet
metal guard for end-feed product, depending on the applicator being used.
8. Mount the terminal reel on the reel support. Thread the terminal strip through the guard and into the
applicator according to the instruction sheet included with the applicator. If necessary, adjust the
lubricator bowl.
9. Align the product reel to the applicator by adjusting the reel flanges.
10. Close the guard.
NOTE
The guard door must be closed in order to operate the machine. See paragraph 4.4.C.
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Figure 9
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4.3. Setup
Install a miniature applicator and terminals according to paragraph 4.2.
1. Turn on the main power using the switch located on the front of the control panel.
2. Be sure the guard is closed.
3. Jog the machine (as described in paragraph 4.3.B.) through a complete crimp cycle.
NOTE
Machine should be able to jog through the terminal and wire at maximum jog speed to determine crimp capacity.
4. Inspect the crimped terminal to verify that the terminal is being positioned properly within the
applicator.
5. Correct for any positioning errors according to the applicator instruction sheet, and repeat Steps 2
and 3 until a terminal is properly positioned.
6. Place a prepared wire in the crimp area and press the foot switch.
7. Inspect the completed crimp and make adjustments as necessary.
4.4. Mode Selection and Operation
The two basic modes of operation for these machines include: Full-Cycle, and Jog.
Full-Cycle Mode (Figure 9)
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Depressing the footswitch (with the guard closed) causes the crankshaft to be rotated (at a speed defined
by the speed control buttons), through a complete revolution. This completes one full machine cycle.
Jog Mode (Figure 9)
Pressing the Jog button causes the crankshaft to be rotated at a reduced speed in the forward direction
until the Jog button is released or the crankshaft completes the cycle. If the Jog button is released in midcycle and pressed again, the crankshaft will continue to rotate in the forward direction at the reduced
speed. If the machine does not complete the cycle, either adjust the speed control buttons (as described
below), or complete the cycle using the footswitch (at a speed determined by the speed control buttons)
after the Jog button has been pressed and released.
Holding the Jog button down for an extended period without completing the cycle will cause an error. To
clear the error, clear the problem area, and then press the Error Reset button. If the motor is stalled, it
may be necessary to manually cycle the machine to the home position. Refer to the CAUTION and
DANGER statements below for the proper manual cycling procedure.
CAUTION
While in the Jog mode, attempting to complete a crimp cycle with terminals and wire in the applicator may cause the motor to
stall. Although the machine can terminate some smaller terminals and wire, it may be necessary to turn “off" the machine and
manually cycle the machine to the home position. Manually cycle the machine by removing the power cord on the end of the
motor, engaging the hex key with a 6-mm hex wrench, and rotating the key to manually rotate the motor.
Be sure to remove the hex wrench and re-install the power cord before operating the machine. The machine will not run until
the power cord is in place. See Figure 3.
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4.5. Adjusting the Motor Speed
The speed of the motor is adjusted using the Decrease Speed and Increase Speed buttons on the membrane
keypad (see Figure 9). The Decrease and Increase buttons are used to adjust the motor speed for Full-Cycle
mode and for Jog mode. The speed setting in Full-Cycle mode is independent from the speed setting used in
the Jog mode. Both speed settings are retained in memory by the CPU / motor controller. During Full-Cycle
mode the last set motor speed is on the display. When the Jog button is pressed, the display will change to
show the last set Jog mode speed. The Jog mode speed will continue to be displayed until the footswitch is
pressed to change to Full-Cycle mode.
In Full Cycle mode, a single “>” shown on the display indicates the motor speed is set for 60% of the maximum
operating speed value. Each additional “>” on the display increases the motor speed by 8%. In Jog mode, a
single “>,” shown on the display indicates the motor speed is set for 10% of the maximum operating speed
value: each additional “>” shown increases the motor speed by 10%.
4.6. Crimp Height Adjustment
Refer to the instructions provided with the applicator to perform this adjustment. Refer to paragraph 6.3. for
procedures to adjust the crimp height using the machine precision adjustment feature.
4.7. End-Feed/Side-Feed Applicator Conversion
When changing from an end-feed applicator to a side-feed applicator (or from a side-feed applicator to an endfeed applicator), the reel support assembly must be moved to the opposite side of the machine. With the
terminal reel removed, lift and rotate the reel support bar to the opposite side of the machine. Mount the
terminal reel on the reel support and load the terminal strip into the applicator. Remove the metal terminal leadin and thumbscrews and move to the opposite side of the machine. Move the machine lubricator bowl to the
opposite side of the machine as required.
NOTE
Lubricator Bowl Assembly PN 354550-3 is an optional accessory. When using an Ocean Side-Feed or End-Feed applicator,
the lubricator assembly art numbers are 2119955-1 and 2119955-2, respectively.
5. PREVENTIVE MAINTENANCE
Preventive maintenance will keep the machine in good working order and ensure maximum reliability and
service from all of its components.
DANGER
To avoid personal injury, electrical and pneumatic power must be DISCONNECTED at the source prior to maintenance.
DANGER
The CPU/motor controller assembly contains a high voltage which remains for a short period of time, even after power has
been removed. Disconnect the electrical power source and wait several minutes before removing the screws to access the
CPU/motor controller assembly.
NOTE
A monthly mandatory safety check includes checking that opening the guard door during a cycle shuts down the machine and
prevents the terminator from cycling until the guard door is closed.
5.1. Cleaning
Clean any debris from the applicator area daily.
DANGER
Compressed air used for cleaning must be reduced to less than 207 kPa [30 psi] and effective chip guarding and personal
protective equipment (including eye protection) must be used.
If an air-feed assembly is installed, check and replace the air filter element if necessary.
Wipe off the guards with a clean soft cloth.
CAUTION
DO NOT USE ANY SOLVENT TO CLEAN THE GUARDS. Solvent could damage the guards.
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Lubrication Points
Lubrication Points
5.2. Lubrication
The moving parts of the machine require regular lubrication to ensure reliable service and long life. The
preferred greases are Chevron Ultra-Duty EP NLGI 2, Chevron Ulti-Plex EP NLGI 2, and Caltex Ultra-Duty EP
NLGI 2.
NOTE
Contact TE engineering for 2nd choice alternates.
CAUTION
It is important to only use Lithium-based grease with extreme pressure (EP) additives.
NOTE
For operation in temperatures below 10° C [50° F], it will be necessary to use a No. 1 grease.
Using a grease gun, apply grease every 250,000 cycles to the fittings at the following locations and as shown
in Figure 10:
the left side of the ram assembly;
the right side of the ram assembly;
the left side of the frame just behind the ram assembly at two places; and
NOTE
Give one pump of grease while the ram is near the top of its stroke and one pump of grease while the ram is near the bottom
of its stroke for best distribution of grease around the bearing.
the crimp height adjuster pivot pin.
Figure 10
6. ADJUSTMENTS
The following adjustments are necessary to maintain the machine in operating condition, and to set up the
machine after replacing parts.
Chevron, Caltex, and Lithium are trademarks of their respective owners. NLGI is the National Lubrication and Grease Institute.
DANGER
To avoid personal injury, ALWAYS disconnect electrical and air supplies before performing adjustments.
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SHUT HEIGHT GAGE (PN)
MACHINE PART NUMBERS
SHUT HEIGHT DIMENSIONS
APPLICATOR TYPE
679655-2
2161400-[ ]
2161500-[ ]
135.79 mm ±0.025
[5.346 ±.0010 in.]
TE-Type
Shut Height Dimension
(See Table Below)
6.1. Measuring the Shut Height
The shut height is the distance between the bottom surface of the ram post adaptor and the top surface of the
machine base plate as shown in Figure 11.
NOTE
Shut Height Gage PN 679655-2 (see the table in Figure 11) is recommended for measuring shut height (refer to Instruction
Sheet 408-8535 for instructions on use of the gage).
1. If installed, adjust the manual precision adjustment lever to the “0" setting.
2. Remove the power cord on the end of the motor.
3. Insert a 6-mm hex wrench into the end of the motor until it completely engages the hex key in the end
of the motor. Use the hex wrench to manually rotate the motor.
NOTE
Be sure to remove the hex wrench and re-install the power cord before operating the machine. The machine will not run
until the power cord is in place.
4. Follow the procedure for measuring the shut height as described in Instruction Sheet
5. Replace the switch actuator onto the end of the motor.
Figure 11
6.2. Shut-Height Adjustment
408-8535.
The shut height is pre-set at the factory and should not require further adjustment unless it is necessary to
replace parts. Before you make any changes to the machine, contact your local Field Service Representative,
or call the Support Center at 1-800-522-6752.
CAUTION
NEVER attempt to adjust the shut height without FIRST trying an applicator that is known to produce terminations of the
correct crimp height. If this applicator produces correct terminations, the trouble is in the original applicator and the shut height
MUST NOT BE CHANGED.
If it is determined that the shut height must be adjusted, use the following procedure:
DANGER
To avoid personal injury, ALWAYS turn “off" the machine and disconnect the power supply to the machine before making any
adjustments. If applicator is an air-feed type, DISCONNECT air lines to valve located on the right side of the machine.
1. Check shut height as described in paragraph 6.1.
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2. If the shut height is incorrect, proceed as follows:
a. Remove the two socket head cap screws which secure the ram post adaptor. Remove the ram
post adaptor and shims. Change the shim thickness as required to adjust the shut height. Shims
contain .051- mm [.002-in.] peel-type laminations.
NOTE
If additional shims are required, they can be ordered using the numbers PN 1338618-1.
b. Re-install the ram post adaptor. Insert both screws in the ram post adaptor and place the shims
over the screws and onto the adaptor post.
c. Re-install the socket head cap screws into the ram assembly to secure the ram post adaptor. Re-
tighten the screws.
3. Repeat Steps 1 and 2 as necessary until the proper shut height is attained.
NOTE
The miniature applicator is an integrated assembly consisting of upper tooling, lower tooling, and adjustment capability. The
applicator requires a fixed shut height; that is, the distance between the bottom of the ram and the base mount when the ram
is FULLY bottomed. The required adjustments for crimp height are made by using the wire and insulation discs within the
applicator. Refer to the instruction sheet supplied with the applicator for adjustment procedures.
6.3. Crimp Height Adjustment Using Precision Adjustment Mechanism
CAUTION
To avoid damaging the applicator, ALWAYS return the precision adjustment lever to the “0" position when finished using the
applicator.
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Figure 12
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GUARD INSERT
DIMENSION
PART NUMBER
DESCRIPTION
A
B
354529-2
Standard (Away from the Applicator)
7.80 [.307]
6.35 [.250]
1-679532-0
Standard (Close to the Applicator) – Shipped with the Machine
6.22 [.245]
5.08 [.200]
679994-2
Near Tape
6.35 [.250]
6.35 [.250]
679995-2
Away from the Tape
8.74 [.344]
6.35 [.250]
Tape Guard Insert Standard Guard Insert
1. Adjust the manual precision adjustment lever to “0" by pulling the lever away from the pivot pin. Lock
the lever in place by releasing it.
2. Install the applicator into the machine as described in paragraph 4.2.
3. Cycle the machine to crimp three sample terminations. Check the crimp height of the samples. If the
crimp heights are not correct, adjust the crimp height according to Step 4.
4. Adjust the crimp height by moving the precision adjustment lever (see Figure 12):
a. to the right to increase the crimp height; or
b. to the left to decrease the crimp height.
NOTE
Moving the precision adjustment lever in either direction will change the crimp height by approximately 0.013 mm [.0005 in.]
per step.
5. Repeat Steps 3 and 4 until the appropriate crimp height is obtained.
CAUTION
To avoid damaging the applicator, ALWAYS return the manual precision adjustment lever to the “0" position when finished
using the applicator.
6.4. Guard Insert Adjustment
A guard insert is supplied with the machine. Some applications may require a special insert. See Figure 13 for
available guard inserts.
Figure 13
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PART NUMBER
DESCRIPTION
PURPOSE
2161209-1
Air Feed Valve Kit
Required to run certain air-feed type applicators
354550-3
Lubricator Bowl Assembly
Pre-lubricates the strip
1428156-1
Shoulder Eye Bolt
Provides a lift point for machine installation
The guard contains two slots into which the inserts can be placed: the rear slot places the insert close to the
applicator; the front slot places the insert farther away from the applicator. The type of insert used determines
which slot is to be used. An insert placed into the wrong slot cannot be secured in place.
NOTE
Some special inserts are designed to mount in the standard insert slot. These inserts have the threaded holes at the top
corners and should be installed according to the instructions for the standard insert.
Standard Guard Insert PN 1-679532-0 and Guard Insert PN 679994-2
1. Slide the insert into the rear slot of the guard door. Secure the insert to the door with two screws
placed through the large square holes in the left guard door and into the threaded holes in the top of
the insert. Do not tighten the screws.
2. Move the insert horizontally and vertically as needed to align the slot with the crimp area of applicator.
3. Tighten the screws.
Guard Insert PN 354529-2 and Guard Insert PN 679995-2
1. Slide the insert into the front slot of the guard door. Secure the insert to the door with two screws
placed through the large square holes of the insert and into the threaded holes in the bottom of the left
guard door. Do not tighten the screws.
2. Move the insert horizontally and vertically as needed to align slot with crimp area of the applicator.
3. Tighten the screws.
7. MACHINE OPTIONS AND INSTALLATION OF THE AIR FEED VALVE ASSEMBLY
The following machine options are available for the AMP-3K and AMP-5K machines:
Figure 14
To install the Air Feed Kit PN 2161209-1, proceed as follows:
DANGER
To avoid personal injury, be sure to turn “off" the machine, and disconnect it from the power source.
NOTE
Some applications require the installation of an Oversized Guard Kit PN 1976900-1. These applications are primarily ones that
use two inch stroke air-feed cylinders.
Follow Step 2 “Installation Procedure for Customer Use” on the air feed kit print PN 2161209 included with Air
Feed Kit PN 2161209-1 (see Figure 15).
1. Disconnect power.
2. Mount the air valve to the flange on the side of the electrical box as shown.
3. Remove the six M4 bolts securing the cover to the electrical control box.
4. On the electrical box, punch out the gland nut knockout located below the air valve.
5. Install the gland nut (Item 25) and locknut (Item 26) in the knockout hole, with the locknut on the inside
of the electrical control box.
6. Attach the air feed (Item 21) cable to the air valve (Item 13) then route the air feed cable through the
gland nut shown.
7. Insert small end of Item 21 into socket "J17" on circuit board in area shown.
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8. Tighten gland nut "snugly" around wire.
Double Acting Air
Cylinder Connection
Air Feed
Assembly
Spring Return Air
Cylinder Connection
Manual
Override
Auxiliary Air
Connection
Manual
Water Drain
9. Secure cover to the electrical control box with six M4 bolts.
10. For metric air line fittings, remove Item 1. For English air line fittings, Item 1 remains.
11. If the air feed applicator requires the optional base plate clamp:
a. Install the optional base clamp (Item 11) onto the base plate.
b. Remove the back, left, base plate clamp.
12. Install the air feed applicator onto the baseplate and connect to applicable ports (see Figure 15).
13. Make sure slide valve is off (pulled away from filter).
14. Attach air supply hose to air valve assembly.
15. To turn air on, slide valve towards filter to turn air off; slide valve away from filter; make sure valve
lockout is away from slide valve.
16. To lock air in off position, turn air off and clamp lockout in location shown in Figure 15. Secure lockout
with a lock (customer supplied).
17. Reconnect power.
NOTE
The air can be turned “off” by moving the slide valve away from the filter.
Figure 15
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Four-Way Solenoid Valve
Air Feed Cable
Valve Lockout
Side Valve
Large Washer
Mounting Screws
Filter
Figure 16
8. TROUBLESHOOTING
Contact the Support Center at 1-800-522-6752.
8.1. Error Codes
See the table in Figure 17 for a listing of error codes.
ERROR CODE ERROR DESCRIPTION
E001 The host is inhibiting operation.
E002
The guard interlock is open.
E003 The insert interlock is open
E004
E005
E020
E021
The safety circuit is not operational.
Control panel is not communicating with the CPU board.
Movement of the TDC switch was not detected.
The TDC switch was not made.
E099 Host Module not detected
E100
Stuck keypad button
E101 Footswitch input stuck on
Figure 17
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Input Identifier
Input Description
g
Guard Interlock Input
i
Insert Interlock Input
s
Safety +24V Input
t
TDC Switch Input
f
Footswitch Input
Input Identifier
Decrease Speed
Increase Speed
Main Power Switch
Input Status
AC Line Voltage
8.2. Diagnostics
The control panel can be placed in a Diagnostics Mode to check operation of the machine inputs and to check
the detected AC line voltage. To place the control panel in the Diagnostics Mode.
1. Press and release Error Reset to clear any error.
2. Press and hold Error Reset for five seconds, until the control panel software version is displayed.
3. Release the Error Reset.
A screen similar to the one in Figure 18 will be presented. Each of the inputs is shown with an input identifier,
followed by an input status symbol. The input identifiers are listed in Figure 18 along with corresponding input
description. A solid dot indicates the input is “on.” A hollow dot indicates the input is “off.”
Press Error Reset to exit the diagnostic mode.
9. SOTWARE VERSION IDENTIFICATION
1. Be sure the machine is turned off.
2. Turn the power to the machine on.
When the display on the control panel turns on, the control panel software version will be displayed briefly,
followed by the CPU motor controller software version. Both versions follow the format “X.XX.XX.”
10. DISPOSAL
Contact TE for disposal.
Rev G
Figure 18
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11. REPLACEMENT AND REPAIR
Replacement parts and recommended spares are identified and listed in drawings and documentation
packages. To order replacement parts, call 1-800-522-6752, send a facsimile of your purchase order to
717-986-7605, or write to:
CUSTOMER SERVICE (038-035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105-3608
Call 1-800-522-6752 for customer repair service.
12. RoHS INFORMATION
Information on the presence and location of any substances subject to RoHS (Restriction on Hazardous
Substances) can be found at the following website:
http://www.tycoelectronics.com/customersupport/rohssupportcenter/
Click on “Find Compliance Status" and enter equipment part number.
13. REVISION SUMMARY
Updated to most current TE logo (header/footers)
Changed para 4.7. Note from Lubricator Bowl Assembly PN 354550-1 to -3, and added “When using an
Ocean Side-Feed or End-Feed applicator, the lubricator assembly part numbers are 2119955-1 and
2119955-2, respectively”.
Revised Figures 15 and 16
Rev G
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