463310-4_技术文档

Customer Manual

AMP-O-MATIC* Side-Feed Stripper-Crimper III

Machine No. 1320895-[ ]

409-10012

28 DEC 11 Rev E

SAFETY PRECAUTIONS READ THIS FIRST! . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

A.

1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2. DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3. RECEIVING INSPECTION AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4. MACHINE OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

5. PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

6. ADJUSTMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

7. REPAIR AND REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

8. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

9. OPTIONAL PNEUMATIC COUNTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

10. ROHS INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

11. REVISION SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

*Trademark

TOOLING ASSISTANCE CENTER

1-800-722-1111

This controlled document is subject to change.

For latest revision and Regional Customer Service,

visit our website at www.te.com

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LOC B

TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners.

409-10012

DANGER

STOP

SAFETY PRECAUTIONS AVOID INJURY

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 appropriate ear protection.

• ALWAYS wear approved eye protection when operating powered equipment.

• ALWAYS keep guard(s) in place during normal operation.

• ALWAYS insert power plug into a properly grounded receptacle to avoid electrical shock.

• ALWAYS turn off the main power switch and disconnect electrical cord from the power source when

performing maintenance on the equipment.

• NEVER wear loose clothing or jewelry that may catch in moving parts of the application equipment.

• NEVER insert hands into installed application equipment.

• NEVER alter, modify, or misuse the application equipment.

TOOLING ASSISTANCE CENTER

CALL TOLL FREE 1-800-722-1111 (CONTINENTAL UNITED STATES AND PUERTO RICO ONLY)

The Tooling Assistance 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 TOOLING ASSISTANCE CENTER

When calling the Tooling Assistance 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 Tooling Assistance 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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1320895-1

1320895-2

1320895-3

1320895-4

AMP-O-MATIC Side Feed Stripper-Crimper III Machine (without Crimp Quality Monitor)

AMP-O-MATIC Side Feed Stripper-Crimper III Machine (with Crimp Quality Monitor)

C.E. Version AMP-O-MATIC Side Feed Stripper-Crimper III Machine (without Crimp Quality Monitor)

C.E. Version AMP-O-MATIC Side Feed Stripper-Crimper III Machine (with Crimp Quality Monitor)

Figure 1

1. INTRODUCTION

This manual provides the information required for operation and maintenance of AMP-O-MATIC* Side Feed

Stripper-Crimper III Machine, No. 1320895-[ ]. See Figure 1. Information includes: description; receiving

inspection and installation; machine operation; preventive maintenance; adjustments; repair and replacement;

and Documentation Package. The -2 machine is available with the Crimp Quality Monitor (CQM). For further

information, contact your TE Connectivity Field Representative.

Measurements in this document are in metric units [with U.S. customary units in brackets].

NOTE

i

The compact 68 kilogram [150-lb] (approximate) machine is intended for bench-top operation. The size is

approximately 355 mm wide x 457 mm deep x 838 mm high [14 in. wide x 18 in. deep x 33 in. high], including

the reel support (less terminal reel). For operation, the machine requires a constant air supply of 552 to

690 kilopascals (kPa) [80 to 100 psi] with adequate volume (1.6 liters/sec. [3.5 scfm]) to maintain a minimum

of 552 kPa [80 psi] throughout the cycle of operation. Electrical power is not required for machine operation,

however electrical power is required for the work lamp to light the “target area.”

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Retain Documentation Package1338092-1 for reference and ordering replacement parts.

NOTE

i

Although not supplied or sold by TE, a pneumatic counter can be installed by the customer. Refer to Section 9,

OPTIONAL PNEUMATIC COUNTER.

When reading this manual, pay particular attention to DANGER, CAUTION, NOTE statements.

Denotes an imminent hazard which may result in moderate or severe injury.

DANGER

STOP

Denotes a condition which may result in product or equipment damage.

CAUTION

!

Highlights special or important information.

NOTE

i

Dimensions in this manual are in metric units [with U.S. customary units in brackets].

NOTE

i

For information beyond the scope of this manual, call the Tooling Assistance Center at 1-800-722-1111.

2. DESCRIPTION

2.1. Physical Description (Figure 2 and Figure 3)

The machine is supported on four leveling pads and is totally enclosed in a plastic cover, except for the reel

support which extends above for easy installation of terminal reels. The terminal strip from the reel passes

around the stock guide on the left side of the machine, then enters the applicator inside the front door. The front

door is hinged for easy access to the applicator tooling and “target area” which is visible through the clear door.

During operation, wires are inserted through the opening in the window into the “target area” for termination.

The machine consists of five major assemblies: the machine assembly, wire gripper assembly, stripper

assembly, air-valve assembly, and filter/regulator assembly. Descriptions of the assemblies are included in this

manual. Also included is a description of typical side-feed applicator used in the machine.

This machine is provided with a lockout valve. This disables the machine to prevent injury while troubleshooting or

performing maintenance. When the valve is in the closed position, a hole allows installation of a lock.

NOTE

i

A. Machine Subassembly

The machine assembly consists of a cast frame which provides the mounting facilities for the pneumatic

system and the mechanically operated components, including the applicator. Between the vertical frame

members is the main cylinder which provides the power required by the applicator for crimping the terminals.

This is accomplished through a linkage to the ram which is directly connected to the applicator ram. The

linkage is also mechanically connected to the terminal feed mechanism, and the scrap shear for operation

during the crimping cycle.

The front of the frame provides the mounting facilities for the easily replaced applicators. In front of the

applicator is the wire gripper assembly which is actuated by an air cylinder to secure the wire during the

stripping and crimping action.

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The lockout valve, extending through the back of the machine cover, supplies air pressure to the two filters

and one regulator mounted on the right side of the frame. The gage is readable through the clear door. No air

line lubricator is required because the cylinders and valves are designed to operate on dry air. The air logic

components are mounted on the left side of the frame. The terminal feed mechanism is also mounted on the

left side of the frame in alignment with the applicator. It is actuated by the applicator ram to feed the terminal

strip into the “target area.” A terminal lubricator assembly is included with the machine.

Terminal Reel

Reel Support

Machine Frame

Terminal Strip

Power Jack

Air Supply Connection

Safety Valve

(LV5)

Operating Pressure

Filter/Regulator

Lockout Valve

Operating

Pressure

Gage

Auto-Hand Knob

Light Switch

Filter

“Target Area”

(Figure 8)

Auto Mode Sensitivity Valve

(LV4)

Stripping Mechanism

Threshold Sensor

Scrap Shear

Feed Return

Adjustment Screw

Leveling Pad

(Typ 4 Places)

Figure 2

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Reel Support

Power Valve (P2)

One Shot Valve

Air Logic Components

(RV1 and RV2)

Stock Guide

Terminal Feed

Mechanism

(Figure 10)

Limit Valve

(LV2 and LV3)

(Hidden)

Power Valve (P3)

Limit Valve (LV1)

Terminal Lubricator

Wire Gripper Power Valve

and Pressure Adjust

Stripping Mechanism

Power Valve (P3)

Figure 3

B. Stripping Mechanism Subassembly (Figures 10 and 11)

Beneath the main cylinder, and between the vertical frame members is the stripping mechanism which slides

in gibs. The stripping blades are actuated (closed and opened) by the stripping cylinder mounted at the back

of the mechanism. After closing of the blades, the mechanism is moved to the rear by a separate air cylinder,

to strip the insulation from the wire being terminated. The wire sensor, acting as a wire stop, is mounted at the

back of the strip blades. When the machine is being operated in the automatic mode, selected by the AUTO-

HAND knob on the front of the machine, the wire placement is detected by the wire sensor and automatically

cycles the machine, provided that the foot valve is being held depressed. The use of the sensor ensures exact

positioning of the wire for each termination.

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Wire Disc

Ram Post

Applicator Ram

Assembly

Pads

Insulation Disc

Front Shear

Depressor

Applicator Ram

Crimper Bolt

Terminal Hold-Down

Insulation Crimper

Wire Crimper

Stock Drag

Slot

Terminal Support

Strip Guides

Base Plate

Anvil

Lower Tooling

Assembly

Floating Shear (Front)

Figure 4

C. Applicator (Typical, Figure 4 and Figure 10)

The side feed applicators used in this machine are the pre-feed type, and are interchangeable to provide a

wide range of terminations. The crimpers, anvil, and the rear floating shear (when used) are the same as

those used in the heavy duty miniature quick-change applicators. The upper portion of the applicator is the

applicator ram containing the upper tooling. The lower portion is the base plate which supports the anvil (lower

tooling), the strip guides, and the stock drag. The upper and lower portions have identification tags which

carry identical serial numbers to prevent mixing of portions with those of other applicators.

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The applicator ram is held in the machine frame by a ram cap. The ram post is inserted between the bosses of

the machine ram which contact a pair of pads on the wire disc. There may be as many as four pairs of pads (A

through D - each pair is a different height) to provide four different crimp heights per applicator.

Refer to the applicator parts list for applicable setting per wire size. The pad letter visible at the front and center

of the applicator indicates the setting to obtain the specified crimp height. Under the wire disc is the insulation

disc (when applicable) which has eight pads (1 through 8) on the bottom side. Each pad is a different height. The

lowest number is for the loosest crimp. Each pad, when aligned with the insulation crimper, provides a different

insulation crimp height. The wire crimper, insulation crimper, spacers, and front shear depressor are attached to

the ram by the crimper bolt. The wire crimper is stationary in relation to the ram, while the insulation crimper is

free floating to permit variations between the two crimpers. On the back of the ram is the cam which operates

the terminal feed mechanism.

The lower portion of the applicator is positioned on the machine base plate by two dowel pins and retained with

quick release left and right hold-downs. So that both pins and sockets may be terminated in the applicator

without re-adjusting each time, the applicator provides an adjustment for the strip guide plate, and also the scrap

guide. These may be adjusted to minimize the effects of differences in camber of the various carrier strips. The

design of the front floating shear is unique to this applicator.

The terminals used with the applicators in this machine are reeled the same as those on TE Miniature

Quick-Change Applicators.

NOTE

i

2.2. Functional Description

It shall be assumed that the machine has been properly installed, loaded with terminals, connected to the air

supply, and is ready for production operation as described in Section 4.

The following sequence describes the machine through one complete cycle of operation. Refer to the pneumatic

diagram, drawing 768561 in the Documentation Package, for sequence of component operation.

1. If the machine is being operated in the automatic mode, the operator depresses and holds the foot valve.

This step does not apply for the manual mode of operation.

2. The operator inserts the wire through window into “target area” until it contacts the wire sensor (wire stop),

keeping wire as low and horizontal as possible.

3. If machine is being operated in the manual mode, operator depresses foot valve momentarily to start

machine cycle. In the automatic mode, the machine starts to cycle when the wire contacts the wire sensor,

providing the foot valve is depressed.

4. Wire grippers close to secure wire and stripping blades close to cut insulation.

5. Stripping mechanism starts to rear, pulling insulation from wire.

6. The ram starts to move downward.

7. As the ram fully bottoms, it crimps the terminal onto the wire. Stripping blades and wire grippers open.

8. The ram is then raised to its original position, and the terminated wire is released.

9. The stripping mechanism is moved toward the front after an adjustable delay for wire removal.

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3. RECEIVING INSPECTION AND INSTALLATION

3.1. Receiving Inspection

The machine is thoroughly inspected during and after assembly. Before it is shipped, a final series of tests and

inspections are made to ensure proper functioning. Still, the following inspection should be performed as a

safeguard against problems during shipment.

1. Carefully uncrate the machine and place it on a sturdy bench where their is enough light to permit a

careful examination.

2. Remove the cover, and thoroughly inspect the entire machine for evidence of damage that may have

occurred during transit. If the machine is damaged, file a claim against the carrier and notify TE immediately.

3. Check all components and parts to be certain they are secure.

4. Check wiring for loose connections and for frayed or broken wire and insulation.

5. Check all air lines for evidence of loose connections or damage.

3.2. Machine Requirements

Figure 5 lists the power requirements for the AMP-O-MATIC Stripper-Crimper III Machine, along with the

machine's approximate weight and size. In addition, Figure 5 lists approximate machine rates.

115 Vac, 60 Hz single-phase power (-1 and -2 Machines)

Electrical Requirements:

230 Vac, 50 Hz single-phase power (-3 and -4 Machines)

Constant air supply of 552 to 690 kilopascals (kPa) [80 to 100 psi] with adequate

volume (1.6 liters/sec. [3.5 scfm]) to maintain a minimum of 552 kPa [80 psi]

throughout the cycle of operation

Air Supply Requirements:

355 mm [14 in.] wide x 457 mm [18 in.] deep x 838 mm 33 in.] high including the reel

support (less the terminal reel).

Machine Size:

Approximate Machine Weight:

68 kilograms [150 lbs]

Approximately 1000 leads per hour for 24 AWG jacketed cable

with prepared 25.4 mm [1 in.] breakout.

Number of Finished Assemblies Per Hour:

Approximately 1400 leads per hour for discrete wire.

Figure 5

3.3. Considerations Affecting Machine Placement

Proper location of the machine in relation to the operator is essential to both safety and efficiency. Studies have

repeatedly shown that fatigue will be reduced and efficiency increased if particular attention is paid to the bench,

the operator's chair, and the placement of the foot valve if one is used.

A. Bench

A sturdy bench 711 to 762 mm [28 to 30 in.] high aids comfort by allowing the operator's feet to rest on the

floor and the weight and leg position to be easily shifted. The bench should have rubber mounts to reduce

noise. The open area under the bench should allow the chair to slide far enough in for the operator's back to

be straight and supported by the back rest.

B. Machine Location on Bench

The machine should be located near the front of the bench, and the machine work area (the area where the

product is applied) should be 152 to 203 mm [6 to 8 in.] from the front edge. Access to the back of the

machine must be provided for maintenance purposes in most cases.

C. Operator's Chair

The operator's chair should swivel, and the seat and back rest should be padded and independently

adjustable. The back rest should be large enough to support the back both above and below the waist.

In use, the chair should be far enough under the bench so that the operator's back is straight and supported

by the back rest.

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D. Foot Valve (When Used)

When the operator is correctly positioned in front of the machine, the foot should rest on the valve comfortably

and easily. The valve should be placed on a rubber mat; this allows it to be movable and permits the operator

to shift positions to minimize fatigue, while at the same time the mat prevents the valve from sliding

unintentionally.

The preference for locating the switch varies among operators. Some like the valve located so that their foot

rests on the valve when their legs are in the natural sitting position (calf perpendicular to the floor). Others

prefer it slightly in front of the natural position. The important thing is that the foot be about 90_ to the calf

when resting on the valve. Those who prefer the valve slightly forward may require a wedge-shaped block

placed under it.

Figure 6 shows proper location and position. Figure 7 shows a typical layout for the efficient handling of

materials.

Figure 6 shows the physical considerations as recommended,

The plan view, Figure 7, identifies typical locations for “supply”

and the operator in a desirable position. Note that the chair height

and “applied product,” and serves as an aid in visualizing the

and back rest are properly adjusted, and that the chair is properly

convenience in materials handling afforded by proper setup and

located in respect to the bench. Thus, the operator's back is

correct operator positioning.

straight, and supported by the chair. Note also that the operator's

upper arms are in a direct line with the torso.

Figure 6

Figure 7

4. MACHINE OPERATION

This section pertains to loading and unloading of terminal strip, and operation of the machine in production use.

It shall be assumed that the machine has been properly installed in accordance with Section 3.

4.1. Terminal Strip Loading and Unloading (Figure 8)

A. Loading

1. Place reel of terminals on reel support and secure with flange. Strip must unreel and enter left side of

machine with wire barrels of terminals toward front of machine and with open “U” up.

2. Turn drag release lever upward to raise stock drag.

3. Feed terminal strip through strip guides until lead terminal is over anvil, then pull back slightly on strip to

assure feed pawl is properly engaged in feed point of strip.

4. Turn drag release lever down to apply drag to terminal strip.

5. After making several terminations, make sure carrier strip enters scrap shear to the right of applicator.

B. Unloading

1. Release stock drag.

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Shut Height Adjustable

Locking Screw

Machine Ram

Ram Speed

Adjustment

Shut Height Disc Indicator

Normal Gripper Pressure

(138-276 kPa

[20-40 psi])

-1, -3 Ram Cap

†

-2, -4 CQM Ram Cap

Adjustable Wire

Gripper Assembly

Feed Mechanism

Typical Applicator Ram

Crimpers

Target Area

Scrap Shear

Wire Locator

Terminal Strip

Foot Switch

Gripper Height

Lock Screw

Gripper Height

Adjusting Screw

Stock Drag

†

Crimp Quality Monitor

Figure 8

2. While raising and holding feed finger up, pull terminal strip back through strip guides until clear.

3. Roll terminal strip onto reel to prevent distortion until loaded again into machine.

4.2. Production Setup (Figure 8)

1. Check the wire disk pad settings and stripping blades for size of wire to be run.

2. Place an adequate supply of wire within easy reach of the operator's position.

3. Be sure that an adequate supply of terminals is on the reel.

4. Connect air supply and lift lockout valve to “OPEN”. Turn work light “ON”.

Machine assembly may move when the air is turned on. To avoid personal injury, keep clear of movable tooling when

performing Step 4.

DANGER

STOP

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5. Check operating pressure for 552 kPa (80 psi). If necessary, remove rear cover and adjust the regulator.

6. Select the desired mode of operation with AUTO-HAND knob on front of machine.

4.3. Production Operation

1. If operating in the automatic mode, depress and hold foot valve.

2. Insert a wire into the “target area” and against wire stop, keeping wire as low and straight as possible

(perpendicular to front of machine). If operating in the automatic mode, machine will cycle when wire contacts

the wire stop. If operating in the hand mode, momentarily depress the foot valve to cycle the machine.

Remove terminated wire at end of cycle.

If the machine does not cycle in the automatic mode when the wire stop is touched by a piece of wire, refer to the

sensitivity adjustment in Paragraph 6.12.

NOTE

i

3. Repeat steps 1 and 2 until desired number of wires has been run. Periodically inspect for proper

terminations and for correct height. Measure crimp height as described in instruction sheet 408-7424.

4. At completion of run, slide lockout valve “closed”. This is required so that the pre-filter will drain itself. If

machine is not to be used again in a short period of time, turn work lamp “off.”

5. PREVENTIVE MAINTENANCE

Preventive maintenance consists of cleaning, inspection, and lubrication of the machine to maintain it in

continuous service with a minimum amount of repairs and/or down time. The frequency of maintenance shall be

by shift or weekly and monthly.

To avoid personal injury, ALWAYS DISCONNECT POWER to the machine before performing any maintenance. Turn off

the main power switch/circuit breaker. ALWAYS CLOSE LOCKOUT VALVE, to disconnect air supply from machine.

DANGER

STOP

5.1. Daily Inspection

1. Close lockout valve and disconnect air supply.

2. Open front door of machine.

3. Visually inspect machine for general appearance and functional operation.

4. Close front door of machine.

5. Connect air supply and open lockout valve.

6. Crimp two or more terminals and closely inspect the terminations for evidence of damaged tooling.

5.2. Daily Cleaning

1. Close lockout valve and disconnect air supply.

2. Open front door of machine.

3. Using a small brush, remove all pieces of insulation and carrier strip chips, especially in and around the

“target area.”

4. Close front door of machine.

5. Connect air supply.

5.3. Weekly Inspection And Cleaning

1. Close lockout valve and disconnect air supply.

2. Remove machine cover.

3. Check filters in air system for moisture and contamination. The micro filter drains automatically when it

reaches a given level.

4. Remove applicator as described in Paragraph 7.1, Applicator Replacement.

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5. Thoroughly inspect the machine for loose, damaged, or worn parts. Special attention should be paid to the

applicator tooling and scrap shear; replace tooling if necessary as described in Section 7, REPAIR AND

REPLACEMENT.

6. Using a small brush, remove all pieces of insulation and carrier strip chips, in and around the

entire machine.

5.4. Monthly Cleaning, Inspection and Lubrication

1. Close lockout valve, and disconnect the air supply.

2. Remove the machine cover and applicator ram.

3. Remove the stripping assembly and proceed as follows:

a. Thoroughly clean both the stripping assembly and the area in and around the gibs.

b. Inspect stripping assembly for damaged parts.

c. Lightly oil the blade holders.

d. Remove excess lubricant.

4. Install the stripping assembly.

5. Remove the wire grippers and proceed as follows:

a. Thoroughly clean the assembly, removing all insulation strip ends and wire strands. Pay particular

attention to the area between the gripper actuator levers and the air cylinder housing.

b. Inspect the assembly for worn or damaged parts; replace if necessary.

c. Lightly oil all pivot points.

d. Check the grippers for proper alignment and adjust as required.

6. Install gripper assembly.

7. Remove the spool and bumper “O” rings from the one shot valve (see Figure 9) and clean and lightly oil

with two drops of a SAE 5 or 10 non-detergent non-synthetic oil.

For the following refer to the lubrication chart for the location of the grease fittings and oil points.

NOTE

i

8. Using a grease gun with multipurpose grease, lubricate the two fittings for the stripping mechanism slide in

Figure 11 and the three fittings on the ram linkage are found in Figure 9; to gain access to some of these

fittings, the ram must be at the bottom of its stroke, not shown.

9. Apply a few drops of oil to all pivot points using SAE 20 non-detergent oil.

10. Fill terminal lubricator with lubricant part number E807 from:

STONER INCORPORATED

PO BOX 65

QUARRYVILLE, PA 17566

Phone 717-786-7355

11. Remove excess lubricant.

DO NOT USE AIR LINE LUBRICANT. All cylinders and valves are designed to operate on clean dry air.

NOTE

i

12. Apply a thin film of grease to the four corners of the applicator ram and the face of the feed cam.

13. Install applicator and ram as described in Paragraph 7, REPAIR AND REPLACEMENT.

14. Install machine cover.

15. Load terminals in applicator as described in Paragraph 4, MACHINE OPERATION.

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Main Cylinder

Rear Pivot Points

One-Shot Valve

Block Stabilizer

Ram Cap

Ram Linkage

(Hidden)

Feed Arm Assembly

Multipurpose grease

SAE 20 non-detergent oil

SAE 5 or 10 non-detergent, non-synthetic oil for the one-shot valve

Figure 9

16. Connect air supply and open lockout valve.

17. Close front door of machine.

18. Operate the machine as described in Section 4, to determine if the unit is operating properly.

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6. ADJUSTMENTS

The following adjustments may be necessary to maintain the machine in continuous service, or in the event it is

necessary to replace parts and/or components.

To avoid personal injury, ALWAYS DISCONNECT POWER to the machine before performing any maintenance.

Turn off the power at the main power switch/circuit breaker. ALWAYS CLOSE LOCKOUT VALVE, to disconnect air

supply from machine.

DANGER

STOP

6.1. Wire Crimp Height Adjustment (Figure 4)

1. Open front door of machine to gain access.

2. Select pad letter (A, B, C, or D) specified on Applicator Parts List (Log), supplied with the particular

applicator installed in machine, for AWG wire size and terminal being used.

3. Turn wire disc (upper disc) so that selected pad letter is visible to FRONT and center of applicator. This

provides the proper crimp height for terminal and wire size being used.

4. After making insulation crimp adjustment as described in Paragraph 6.2, make several test crimps by

operating machine as described in Section 4, then perform the following:

a. Inspect terminations for rough or sharp edges around crimped barrels (flash), deformed crimps, bent

terminals, or other defects caused by worn or broken tooling. If necessary, replace tooling as described

in Section 7.

b. If terminations appear normal, measure crimp height of each termination as described in instruction

sheet 408-7424. Crimp height must agree with measurement specified on Applicator Parts List (Log)

supplied with the applicator being used. Record crimp dimensions for reference.

c. If crimp height is INCORRECT, remove applicator and install one that is known to produce

terminations of CORRECT crimp height, as described in Paragraph 7.1, Applicator Replacement. Make

several test crimps and repeat Step b. If crimp heights are still INCORRECT for this applicator, the

problem is machine shut height (see Step d.). Contact your TE Representative, or call the Tooling

Assistance Center: 1-800-722-1111. If the crimp height is CORRECT for this applicator, problem is in

original applicator, and crimp height repair is described in Section 7.

d. The “shut height fine adjust” may be used, for example, when an applicator is not properly shimmed

for the machine shut height setting. The factory set machine (1320895) is 135.79 mm [5.346 in.]. To fine

adjust the shut height, unlock the screw adjust. Insert dowel pin into holes of disc indicator (33) and move

as required; each increment on disc indicator is 0.013 mm [.0005 in.].

5. During extensive operation, periodically repeat Step 4 to make sure applicator is producing

correct terminations.

6.2. Insulation Crimp Height Adjustment (Figure 4)

The insulation crimp height adjustment (when applicable) must be made in relation to wire crimp height as

described in Paragraph 6.1. To adjust, turn insulation disc (lower disc) to align number (1 through 8) with top of

insulation crimper on applicator ram. The loosest crimp is produced at No. 1 setting and the tightest at the No. 8

setting. To find a satisfactory insulation crimp for any wire insulation outside diameter, start with No. 1, making

test crimps. Increase setting one number at a time until desired crimp height is obtained. The crimp should hold

the insulation firmly without cutting into it.

6.3. Terminal Strip Feed Adjustment (Figure 10)

Proper adjustment of the terminal strip feed is achieved when the applicator ram is fully raised and the feed

finger is fully extended to CENTER the lead terminal over the anvil. Adjustment may be necessary (especially

when changing applicators) due to variations in the feed points of different terminal strips. The location of the

pivot shaft in the adjusting plate for the feed arm may be a determining factor to obtain proper adjustment. There

are three adjustment positions in which the pivot shaft may be located. In most cases the middle hole is used.

The bottom position provides the SHORTEST feed finger stroke and the top position provides the LONGEST.

When performing the following procedure, and it is impossible to obtain the proper adjustment, determine if a

LONGER or SHORTER stroke is required.

15 of 26

Rev E

409-10012

Terminal Feed-Back

Stop Adjustment

Pivot

Block

Forward Limit

Adjustment Knob

Feed Finger

Wire Grippers

Lock

Knob

Wire Locator

Rear Strip

Guide

Front Strip Guide

Strip Guide Plate

Adjust Screw (Hidden)

Feed Pawl

Figure 10

1. Determine which direction the lead terminal must be moved (advanced or retracted).

2. Loosen small lock knob under larger adjusting knob. See Figure 10.

3. To advance lead terminal, turn forward limit adjustment knob COUNTERCLOCKWISE. To retract, turn knob

CLOCKWISE.

When making adjustment, keep terminal strip pulled back against feed pawl, especially during retraction adjustment.

NOTE

i

4. At completion of adjustment, tighten lock screw.

5. Make several test crimps by operating machine as described in Section 4. Observe for proper feeding of

terminal strip and centering of lead terminal over anvil. Check retraction of feed finger for slight overtravel of

feed point in terminal strip. If no overtravel exists, or if excessive, perform Step 6. If satisfactory, adjustment is

complete.

6. For more feed return, turn feed return adjustment screw OUT (refer to Figure 2). For less, turn it IN. Perform

several test crimps while making adjustment to assure feed return is proper.

16 of 26

Rev E

409-10012

6.4. Strip Guide Plate, Bell Mouth and Feed Pawl Adjustments (Figure 10)

This procedure moves the plate on which the strip guides are mounted. Since the terminal strip is fed into the

“target area” from between the strip guides, it is moved toward the front or back when the plate is moved in

either direction. The adjustment of the feed pawl to match any change in the position of the front strip guide is

also described here.

1. Determine the direction and amount of adjustment required.

2. From bottom side of base plate, loosen screw securing strip guide adjustment block to strip guide plate.

3. Turn strip guide plate adjustment screw in the direction and the amount required, as determined in Step 1.

CLOCKWISE moves the terminal strip toward the rear, COUNTERCLOCKWISE moves it toward the front.

With a piece of terminal strip inserted, and the lead terminal over the anvil, the insulation barrel of the lead

terminal should be as close as possible to the floating shear. Tighten screw to secure strip guide plate to strip

guide adjustment block after adjustment.

4. Adjust feed pawl by loosening screw securing it to feed finger (holder). Move feed pawl toward front or back

until it drops FREELY into slot in front strip guide, then tighten screw to secure.

6.5. Strip Guide Adjustment (Figure 10)

This adjustment is not often required, because it is only needed when the strip guides are not parallel to each

other, or when there is a variation in the strip width.

The strip guides were correctly positioned on the strip guide plate when the applicator was built, and normally do not need

adjustment. DO NOT use this procedure for front-to-rear positioning of terminal strip; refer to Paragraph 6.4.

NOTE

i

1. Open front door of machine.

2. Wedge feed pawl up to clear front strip guide.

3. Loosen screws securing strip guides to strip guide plate.

4. Move one or both strip guides as required, making sure they are parallel with each other, then tighten

screws to secure.

5. Check guides to be sure they are parallel, and that terminal strip can move freely between them with a

minimum amount of clearance. Repeat Step 4 if necessary.

6. Adjust feed pawl as described in Paragraph 6.4.

6.6. Shear(s) and Shear Holder(s) Adjustments

The front floating shear should be just far enough from the anvil to allow it to move freely up and down. If in this position, it

should not require adjustment. The rear shear is more likely to need adjustment because of possible differences in

NOTE

terminal strip widths.

i

1. Open front door of machine.

2. Remove applicator ram.

3. Close lockout valve and disconnect air supply.

4. Remove lower portion of applicator as described in Section 7.

5. With a length of terminal strip inserted, and the lead terminal over the anvil, check to see if floating shear(s)

will cut terminal from carrier strip at the proper location(s). If necessary, make the following adjustment.

6. From bottom side of base plate, loosen screws securing shear holder to base plate, then move shear

holder and shear in the desired direction. Tighten screws after adjustment to secure shear holder.

7. Repeat Step 5 to be assured of proper adjustment.

17 of 26

Rev E

409-10012

6.7. Stripping Blade Closure Adjustment (Figure 11)

The stripping blades must be adjusted to a depth that will permit them to cut the insulation and strip it from the

conductor, but they MUST NOT nick or scrape the conductor during cutting or removal of insulation. When

changing from one wire size (AWG) to another, it will be necessary to adjust the closure. Adjust stripping blade

depth as follows:

This machine has been set up for stripping 24 AWG PTFE insulated wire. Stripping blades for stripping the middle wire

size specified on the parts list are supplied with the applicator.

NOTE

i

1. Open front door to gain access to machine.

2. Insert blade of screwdriver into strip blade closing adjustment screw. For more closing (smaller wire), turn

screw CLOCKWISE. For less closing (larger wire), turn screw COUNTERCLOCKWISE.

DO NOT turn adjusting screw more than a few degrees (“clicks”) at a time between test crimps, especially when adjusting

for greater depth, to avoid dulling stripping blades by cutting or scraping conductor.

CAUTION

!

3. Close front door of machine after completing adjustment.

4. Make several test crimps by operating machine as described in Section 4 to determine if stripping blade

closing is correct.

5. Repeat as necessary, Steps 1 and 2. Close front door when adjustment is satisfactory.

6.8. Wire Strip Length Adjustment (Figure 11)

The wire strip length required may vary between applicators, and between terminals.

When necessary, adjust strip length as follows:

1. Make several test crimps by operating machine as described in Section 4 to determine if a longer or shorter

strip length is required.

2. To shorten strip length, turn adjustment screw CLOCKWISE. To lengthen, turn adjustment screw

COUNTERCLOCKWISE. This moves the strip blades in relation to the position of the terminal for stripping the

insulation between the wire and insulation crimpers. Each “click” is approximately 0.13 mm [.005 in.].

Although the wire stop is attached to the stripping mechanism, this adjustment DOES NOT have any effect on the normal

location of the wire stop. Refer to Paragraph 6.9 for wire stop adjustment.

NOTE

i

6.9. Wire Stop Adjustment (Figure 11)

The wire stop has been pre-adjusted at the factory and should not require further adjustment for regular

terminals. Adjustment may be required when using wire such as twisted pair, which will be straightened by the

action of the stripping blades. Before making this adjustment, make sure that: (1) the terminals are correctly

positioned (proper bellmouth and cutoff tab); (2) the strip length adjustment is correct; and (3) the stripping

blades are not touching the wire stop.

1. Turn screw CLOCKWISE to move wire stop back or turn it COUNTERCLOCKWISE to move wire stop

forward. In either direction, only a few degrees should be sufficient. One full revolution equals approximate

0.81 mm [.032 in.].

2. Perform several test crimps by operating machine as described in Section 4. Inspect terminations, and

repeat procedure if necessary.

18 of 26

Rev E

409-10012

Terminal Stripper

Strip Length

Adjustment Screw

Stripping Blades

Closing Adjustment

Screw

Grease Fitting

Paragraph 5.4)

Grease Fitting

Paragraph 5.4)

Wire Stop

(Wire Sensor)

Wire Stop

(Wire Sensor)

Adjustment Screw

Wire Locator

Stripping Blade‡

Feed Finger

Stripping Blade‡

Front Strip Guide

‡ Not Included with Machine (See Applicator Log)

Figure 11

19 of 26

Rev E

409-10012

The adjustable wire gripper subassembly allows regulation of incoming line pressure for two reasons: 1) to prevent

insulation damage to an increased range of wire sizes, insulation types, and thicknesses; and 2) to permit retention of

larger-size wire for stripping.

NOTE

i

6.10. Main Cylinder Speed Adjustment (See Drawing 768561)

The speed of the ram on the downward stroke is controlled by the flow control adjustment screw on power valve

(P2). This is the front screw on the front valve near port “B.” Turning the screw CLOCKWISE will slow the stroke.

The rear screw on this valve (near port “A”) controls the speed on the upstroke.

6.11. Closing Delay Adjustment for Stripping Blades (Figure 2)

The machine cover must be removed to perform this adjustment. The stripping blades must not close prior to the

closing of the wire grippers. This is controlled by the adjustment screw in the front port (P1B) of the power valve

P1 (rear of machine). If the stripping blades are closing before the wire grippers are fully closed, turn the

adjustment screw CLOCKWISE as required to slow the closing action of the stripping blades. Re-install machine

cover when adjustment is satisfactory.

6.12. Auto Mode Sensitivity Adjust

The auto mode sensitivity valve is on the right side of the machine casting. See Figure 2.The adjustment screw

is on the rear of the auto sensor. To INCREASE the sensitivity, turn screw COUNTERCLOCKWISE (1/4 to 1/2

turn from closed). To DECREASE the sensitivity, turn screw CLOCKWISE.

6.13. Stripping Mechanism Speed Adjustment (Figure 2)

The speed of the stripping mechanism on the forward stroke is controlled by the flow control adjustment screw

on the power valve, P3. The screw is on the front near Port B.

7. REPAIR AND REPLACEMENT

This section pertains to making repairs and replacing parts to maintain the machine in continuous service. The

following procedures are limited to applicator replacement, tooling replacement in the applicator, and the

replacement of machine parts that are recommended spares. Repair information contained herein applies to the

pneumatic system, and to correcting the crimp height, when required.

For repairs and replacements not covered in this section refer to the Documentation Package. A careful study of

the drawing containing the part(s) in question will help to determine the extent of disassembly required to

accomplish the repair or replacement. Following re-assembly, refer to Section 6 for adjustments necessary

before operating the machine.

When ordering replacement parts, call the Tooling Assistance Center, listed in the front of the manual.

TO AVOID PERSONAL INJURY ALWAYS DISCONNECT POWER to the machine before performing any maintenance.

Turn off the power at the main power switch/circuit breaker. ALWAYS CLOSE LOCKOUT VALVE to disconnect air supply

from machine.

DANGER

STOP

7.1. Applicator Replacement (Figure 3)

If only the applicator ram is to be removed, it is not necessary to remove cover from machine. Just open front

door for access.

NOTE

i

1. To remove applicator ram from machine, loosen four screws and lock washers securing ram cap. Pull ram

cap upward then forward until clear of machine ram, then lift out. Manually actuate feed mechanism to take

pressure off feed cam.

2. Push down lockout valve and disconnect air supply.

3. If removing lower portion of applicator, unload terminal strip as described in Section 4.

4. Ram must be fully raised.

20 of 26

Rev E

409-10012

5. To remove lower portion of applicator, perform the following:

a. Manually retract stripping mechanism to clear applicator.

b. Remove terminal lubricator.

c. Rotate hold-down, to the left side of the applicator, CLOCKWISE to release applicator.

d. Lift lower portion of applicator to clear alignment pins, then lift feed finger and remove from the left side

of machine.

6. Install applicator in machine in the reverse order of removal.

After installing lower portion of applicator, momentarily apply air pressure to machine. This will extend stripping

mechanism and fully raise machine ram to provide clearance for installing applicator ram.

NOTE

i

7. Before operating machine, check applicator adjustments as described in Section 6.

7.2. Applicator Upper Tooling Replacement

The applicator upper tooling consists of a wire crimper and an insulation crimper attached to the applicator ram.

To replace, perform the following:

1. Remove applicator ram as described in Paragraph 7.1.

2. Remove crimper bolt securing crimpers and related parts to applicator ram. Note orientation of ALL parts

for installation purposes.

3. Install new tooling as required, and re-install applicator ram in the reverse order of removal. DO NOT

tighten crimper bolt at this time.

4. Form a piece of heavy paper over anvil.

5. Close flow control at power valve P2B to stop ram, then open flow control 1/4 turn.

6. Connect air supply and open lockout valve. Manually actuate safety valve, LV5 door switch, while pressing

foot valve to bring machine ram down slowly under power. Release safety valve and make sure insulation

crimper does not strike floating shear.

7. Tighten crimper bolt to secure crimpers in position. Paper over anvil will center crimpers in proper

alignment.

8. Open flow control of valve P2B two turns to return ram for production speed, and proceed as follows:

a. Temporarily engage LV5 switch.

b. Remove paper from over anvil.

9. Load terminal strip and operate machine, as described in Section 4, to check for proper crimping. Make any

adjustments deemed necessary.

7.3. Applicator Lower Tooling (Anvil) Replacement

The applicator lower tooling is the anvil attached to the base plate. To replace, perform the following:

1. Remove applicator from machine as described in Paragraph 7.1.

2. Remove screw from under base plate securing anvil. Note orientation of anvil for installation purposes.

3. Install new anvil, and re-install applicator in machine in the reverse order of removal.

4. Loosen crimper bolt and align crimpers as described in Paragraph 7.2.

5. Check applicator adjustments, as described in Section 6, BEFORE operating machine under power.

7.4. Stripping Blades and Stabilizer Bar Replacement (See Drawing 854100)

1. Push down lockout valve and disconnect air supply.

2. Open front door of machine to gain access.

21 of 26

Rev E

409-10012

3. Remove screw securing each stripping blade (refer to applicator Parts List), and stabilizer bar (Item No. 64)

on RIGHT side, to blade mounting blocks. Note orientation of blades and stabilizer bar for installation

purposes. Make sure blades are seated in the recess of the blade mounting block.

4. Install new blades and/or stabilizer bar in the reverse order of removal.

5. Adjust stripping blade closure as described in Section 6.

6. Close front door of machine after completing adjustments.

7.5. Feed Pawl Replacement (See Drawing 1320895)

The feed pawl (Item No.130) is attached to the feed finger (133) and engages in the feed points of the terminal

strip to advance the strip one position for each cycle of the machine. To replace, perform the following:

1. Push down lockout valve and disconnect air supply.

2. Open front door of machine to gain access.

3. Remove screw (131) and washer (127) securing feed pawl to feed finger.

4. Install new feed pawl in the reverse order of removal. BEFORE tightening screw, move feed pawl as

required to align tip with feed point in terminal strip. When properly centered in strip guide, the feed pawl can

be raised and moved to front or back.

5. Perform several test cycles, by operating machine as described in Section 4, to assure proper feeding of

terminal strip and positioning of lead terminals over anvil. If necessary, adjust feed as described in Section 6.

7.6. Shear Blade and Shear Plate Replacement (See Drawing 1320895)

1. Push down lockout valve and disconnect air supply.

2. Remove scrap guide, and remove shear assembly from base.

3. To replace shear plate (Item No. 84), remove four screws (85) securing scrap guides (86), (87), and shear

plate. Install new shear plate in the reverse order of removal.

4. To replace shear blade (81), remove retaining rings and groove pin, then lift blade out of holder (82). Install

new blade in the reverse order of removal.

7.7. Crimp Height Repair

Beneath the insulation disc on top of the applicator ram is one or more washers which may require replacement.

1. Subtract specified crimp height from the average crimp height of those recorded during wire crimp

adjustment in Section 6. This will be the thickness of washer(s) (Part No. 690125-1) to be ADDED to

thickness of existing washers under insulation disc.

2. Remove applicator ram from machine as described in Paragraph 7.1.

3. Turn ram upside down and secure ram mounting post.

4. Loosen setscrew in side of applicator ram securing ram mounting post, then unscrew ram body from post

leaving insulation disc and wire disc in position.

DO NOT REMOVE insulation and wire discs from ram mounting post. There are detent balls and springs installed which

may pop out and become lost if discs are removed.

CAUTION

!

5. Install a thickness of washer(s) on ram mounting post as determined in Step 1. If necessary, replace with

completely new washer of a thickness equal to the old washer plus the additional thickness determined in

Step 1.

6. Install ram body on post and tighten by hand until snug.

22 of 26

Rev E

409-10012

7. Check to determine that numbers on wire disc and letters on insulation disc are properly aligned over

insulation crimper. The discs are retained in position by the detent balls. If necessary, turn ram body back

slightly until proper alignment is obtained, then tighten setscrew to secure ram body to post.

Rotate wire disc and insulation disc to other positions, and when “click” of detent ball is heard in each position, check for

centering of letter or number on insulation crimper.

NOTE

i

8. Install applicator ram in machine, as described in Paragraph 7.1.

9. Adjust wire crimp and insulation crimp as described in Section 6.

10. Make several test crimps and measure crimp height to assure it is satisfactory before placing machine

in service.

7.8. Pneumatic System Repairs

To make necessary repairs, make proper connections, and replace parts to the pneumatic system, refer to the

pneumatic drawing 768561 found in the Documentation Package.

7.9. Spare Parts

A. Spare Machine Parts

This list includes the wearable parts which are recommended customer spares:

ITEM

PART NUMBER

6-21084-3

2-22282-8

694433-8

DESCRIPTION

O-RING, 1/16 in. ID x 1/8 in. OD (Air Detect Nozzle)

SPRING, Compression, Terminal Stripper

PAWL, Feed

QUANTITY

1

2

3

4

2

1

854257-1

LAMP, Annunciator, Modified

It is customer's responsibility to stock and replace items identified as recommended spare parts in the list above and on

the drawings in the machine Documentation Package listed below in Section 8. Refer to the General Machine Policy in the

front of the manual.

NOTE

i

B. Spare Stripping Blades

Stripping blades are a wearable part of any AMP-O-MATIC Stripper-Crimper applicator. To replace standard

strip-blades, order two of the part number required for your wire size (AWG):

WIRE SIZE (AWG)

PART NUMBER

- -

WIRE SIZE (AWG)

PART NUMBER

463310-4

WIRE SIZE (AWG)

PART NUMBER

463310-7

12

14

16

18

20

22

24

26

28

463310-2

463310-3

463310-5

463310-8

463310-6

463310-9

C. Parts Lists (See Documentation Package 1338092-1)

When necessary to order replacement parts for the applicator, ALWAYS refer to the parts list and exploded

view drawing supplied with the particular applicator installed in the machine.

When necessary to order replacement parts for the machine, identify the part(s) on the appropriate print in the

Documentation Package by item number, then refer to the corresponding parts list by item number for the part

number, description, and quantity required per assembly or subassembly. DO NOT order parts by item

number. Item numbers are used for reference ONLY, and are subject to change.

A careful study of the Documentation Package drawings, prior to attempting disassembly, will eliminate

unnecessary removal of parts when making repairs or replacement.

23 of 26

Rev E

409-10012

8. TROUBLESHOOTING

Figure 12 contains a list of possible problems, along with the causes of the problems and the remedies.

Lockout valve must be closed and air must be disconnected when cleaning, lubricating, or replacing any components,

or when repositioning any misaligned parts.

CAUTION

!

To avoid personal injury, KEEP HANDS CLEAR OF ALL MOVING COMPONENTS (ram, stripping assembly, and

grippers) during troubleshooting with air pressure applied.

DANGER

STOP

The following conditions are required to troubleshoot the machine in the manual mode:

1. Air supply connected;

2. Lockout valve open;

3. Minimum of 552 kPa [80 psi] on gage;

4. Front door closed; LV5 activated;

5. Remove applicator if it is felt that it may be the cause of the problem.

9. OPTIONAL PNEUMATIC COUNTER

9.1. Description

An optional pneumatic counter may be installed on the machine to total the machine cycles, and this total equals

the number of wire terminations. The counter is not supplied by TE. It may be purchased from:

ARO CORPORATION

1 ARO CENTER

BRYAN, OH 43506

When ordering the counter from the manufacturer, specify Model 59095-1, Catalog No. A-8078-L.

9.2. Pneumatic Counter Installation

The counter may be attached to the machine at any location that will not interfere with the machine operation.

Connect an air line between the counter and port 5 on power valve P1. Refer to Paragraph 2.2, Functional

Description, and to pneumatic drawing 768561.

10. 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.te.com/customersupport/productcompliance/

Click on “Check Compliance Status” and enter equipment part number.

11. REVISION SUMMARY

Since the previous version of this manual, the following changes were made:

• Replaced trademark references to PTFE.

• Updated product compliance website information.

• Simplified table of contents on first page.

• Updated document to corporate requirements.

24 of 26

Rev E

409-10012

PROBLEM

CAUSE

REMEDY

Machine will not start; No air “HISS” Air NOT present at RV1, Port A, Line 1 when Clean or replace blocked filter.

or “POP” at foot switch when

depressed.

foot valve is depressed.

Repair blocked or open lockout valve, 552 kPa [80 psi]

on meter.

Defective or OPEN foot valve.

Defective “Hand/Auto” switch.

S1 Defective.

Door OPEN.

Air NOT present at RV2, Port 3, Line 2.

LV5 defective or misadjusted.

NOTE: LV5 must be engaged for troubleshooting from this point on.

Air NOT present at RV2, Port 2, Line 3,

when foot valve is depressed.

Clean/Lubricate or replace RV2.

Threshold sensor.

Air NOT present at P3, Port B, Line 5.

Clean/Lubricate or replace defective RV1.

Clean/Lubricate or replace defective P1.

Gripper and blades WILL NOT close when

foot valve is depressed.

Grippers and blades close, then

machine stops.

Air NOT present at P3, Port B, Line 5.

Clean/Lubricate or replace defective LV1.

Reposition misaligned LV1.

Clean/Lubricate or repair stripping assembly.

Clean/Lubricate or replace defective P3.

Air present at P3, Port B, Line 5.

Air NOT present at P2, Port A, Line 6.

Air present at P2, Port A, Line 6.

Replace defective retract cylinder.

Reposition misaligned LV6.

Grippers and blades close and

retract, then machine stops.

Replace defective LV6.

Clean/Lubricate or replace defective P2.

Defective main cylinder; call Technical Assistance

Center for assistance. See Page 2.

Ram down, machine stops, blades Ram not completely down.

and grippers close.

Inspect for loose or binding/broken linkage - lubricate.

Defective main cylinder; call Technical Assistance

Center for assistance. See Page 2.

Air NOT present at P1, Port B, Line 7

Repair/Replace Defective LV2

Air is present at P1, Port B, Line 7.

Clean/Lubricate or replace defective P1.

Clean/Lubricate or repair stripping assembly.

Clean/Lubricate or replace defective strip blade

cylinder.

Air is present at P1, Port A, and B.

Clean RV2.

Ram down, machine stops, blades Air NOT present at P2, Port B, Line 8.

Replace defective LV3.

Clean/Lubricate or replace defective P2.

and grippers open.

Air is present at P2, Port B, Line 8.

Inspect for loose or binding/broken linkage - lubricate.

Figure 12 (Cont’d)

25 of 26

Rev E

409-10012

PROBLEM

CAUSE

REMEDY

Blades retracted, ram up, machine Air NOT present at P3, Port A, Line 9.

stops.

Repair/Replace defective LV3.

Clean/Lubricate one shot valve. Replace one-shot

valve.

Air is present at P3, Port A, Line 9.

Clean/Lubricate or replace P3.

Inspect for loose or binding/broken linkage - lubricate.

Adjust wire gripper adjust assembly.

Gripper jaws DO NOT close,

machine cycles properly.

No air pressure at Port A of gripper

regulator.

Clean/Lubricate wire gripper adjust assembly.

Replace wire gripper adjust assembly.

Air pressure at Port A of gripper regulator.

Inspect wire gripper assembly for broken/worn parts.

Clean/Lubricate wire gripper assembly.

Clean/Lubricate gripper cylinder.

Replace defective gripper cylinder.

Machine works in HAND mode,

does NOT work in AUTO.

No air bleed at the target area in AUTO

mode when foot valve is depressed.

HAND/AUTO selector switch failed or broken.

Air bleed needle valve adjusted too low or failed.

Blockage of the air nozzle assembly.

Air line disconnected from nozzle or damaged.

Reduce air flow.

Excessive air bleed at the target area in

AUTO mode with foot valve depressed.

No movement of the target actuator when

touched by the wire.

Clean actuator dowel pin.

Replace actuator dowel pin.

Reduce air flow.

Adjust nozzle position.

Machine works in AUTO mode,

NOT in HAND mode.

Air bleed present at the target area when the HAND/AUTO selector switch failed.

foot switch is depressed in the HAND mode.

Clean/Lubricate S1 valve.

Replace defective S1.

Figure 12 (End)

26 of 26

Rev E


型号：	463310-4
厂家：	TE CONNECTIVITY
描述：	AMP-O-MATIC Side-Feed Stripper-Crimper
文件：	总26页 (文件大小：671K)
中文：	中文翻译
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