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TE AMP 3K series Customer's Manual

Terminating machine
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© 2016 TE Connectivity family of companies
All Rights Reserved
*Trademark
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and/or company names may be trademarks of their respective owners.
AMP 3K* Terminating Machine 1725950-[ ] and
AMP 5K* Terminating Machine 1725900-[ ]
1. INTRODUCTION .................................................................................................................. 3
2. DESCRIPTION ..................................................................................................................... 4
2.1. Functional Description ................................................................................................. 5
2.2. Electrical Description ................................................................................................... 6
2.3. Machine Guard (Figure 7) ........................................................................................... 8
3. RECEIVING INSPECTION AND INSTALLATION ............................................................... 9
3.1. Receiving Inspection ................................................................................................... 9
3.2. Installation ................................................................................................................... 9
3.3. Considerations Affecting Placement of Bench Machines .......................................... 10
4. OPERATION ...................................................................................................................... 11
4.1. Machine Operation .................................................................................................... 11
4.2. Crimp Quality Monitor II (CQM II) .............................................................................. 11
4.3. Applicator Installation ................................................................................................ 14
4.4. Setup ......................................................................................................................... 14
4.5. Mode Selection and Operation .................................................................................. 15
4.6. Crimp Height Adjustment .......................................................................................... 17
4.7. End-Feed/Side-Feed Applicator Conversion ............................................................. 17
5. MACHINE FAULT CODES ................................................................................................ 17
6. PREVENTIVE MAINTENANCE ......................................................................................... 18
6.1. Cleaning .................................................................................................................... 18
6.2. Lubrication ................................................................................................................. 18
7. ADJUSTMENTS ................................................................................................................. 19
7.1. Measuring the Shut Height ........................................................................................ 19
7.2. Shut-Height Adjustment ............................................................................................ 20
7.4. Guard Insert Adjustment ........................................................................................... 22
8. MACHINE OPTIONS AND INSTALLATION ...................................................................... 24
8.1. Installation of Work Light Assembly Kit ..................................................................... 24
8.2. Installation of the Work Light Assembly Kit ............................................................... 26
8.3. Installation of Batch Counter Kit 1424267-1 .............................................................. 27
8.4. Installation of Air Feed Kit 1424266-1 ....................................................................... 28
9. TROUBLESHOOTING ....................................................................................................... 31
10. RoHS INFORMATION ........................................................................................................ 31
11. REVISION SUMMARY ....................................................................................................... 31
TOOLING ASSISTANCE CENTER 1-800-722-1111
READ THIS FIRST! ............................................................. 2
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.te.com.
Customer Manual
409-32034
16 SEP 16 Rev D
1 of 31

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Summary of Contents for TE AMP 3K series

  • Page 1: Table Of Contents

    1 of 31 All Rights Reserved For latest revision and Regional Customer Service, visit our website at www.te.com. *Trademark TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and/or company names may be trademarks of their respective owners.

  • Page 2: Safety Precautions

    409-32034 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.

  • Page 3: Introduction

    409-32034 STROKE PART CAPACITY APPLICATOR SHUT HEIGHT WORK BATCH LENGTH CQM II SPECIAL NUMBER (lbs) BASE (mm) LIGHT COUNTER (mm) 1725950-2 3000 41.25 135.79 ±0.025 1725950-3 3000 135.79 ±0.025 4-1725950-2 3000 41.25 135.79 ±0.025 4-1725950-3 3000 135.79 ±0.025 5-1725950-0 3000 Universal (Jam) 119.50 ±0.025 5-1725950-1...

  • Page 4: Description

    Transportation and Storage: Store in a clean, dry environment after coating all surfaces lightly with a rust preventing oil. Various TE applicators can be used in the AMP 3K and 5K terminating machines. Applicator instructions sheets are packaged with each applicator. The applicator instruction sheets provide information on applicator installation, care, and adjustment.

  • Page 5: Functional Description

    409-32034 CHANGEOVER CAMS FOR THE MACHINES ORIGINAL APPLICATOR FEED TYPE 1 5/8-in. [41.25 mm] 1 1/8-in. [30 mm] Stroke Machines Stroke Machines Pre-Feed 690602-6 1 1/8-in. Stroke Applicator for Model “K" Terminating Machine Post-Feed 690501-4 1 5/8-in. Stroke Applicator for Pre-Feed 690602-5 Model “T"...

  • Page 6: Electrical Description

    409-32034 Precision Crimp Height Adjustment Mechanism Universal Style AMP Style Applicator Applicator Base Plate Base Plate Quick-Release T-Handle Mounting Hole Base Plate for JAM Alternate Rear Stop Style Applicators Mounting Position Swing Handle Figure 4 3. The base plate provides the mounting surface on which the applicator is installed. The quick-release latching feature on machines with the AMP style base plate permits fast, easy installation and removal of the applicator.
  • Page 7 409-32034 Yellow Button Speed Indicator Speed Control Guard Open Control Knob Icon Icon Green Indicator Machine Ready Icon Fault Icon Guard Batch Disable Counter Button Icon (Optional) Icon Figure 5 A main power switch/circuit breaker (Figure 6) is located on the back of the machine. This switch connects ac power to the control system.

  • Page 8: Machine Guard (Figure 7)

    409-32034 Reel Support Hole DC Motor Terminal Power Strip Guide Receptacle Back Cover Power CPU/Motor Controller Switch/Circuit (Behind Back Cover) Breaker Figure 6 2.3. Machine Guard (Figure 7) 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.

  • Page 9: Receiving Inspection And Installation

    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. 3.2. Installation Remove all mounting bolts securing the machine to the shipping pallet.

  • Page 10: Considerations Affecting Placement Of Bench Machines

    409-32034 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.

  • Page 11: Operation

    409-32034 Figure 8 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. Machine Operation The machine is operated by the footswitch, the jog button, and the speed control knob. The jog button and the speed control knob are located on the control panel.
  • Page 12 409-32034 Cycling the Machine When the footswitch is pressed to cycle the machine, the machine looks at the monitor’s output relays, Relay 1 and Relay 2. The indicator light, DS2, on the machine’s CPU/Motor Controller Board indicates the status of Relay 2. The light will be turned on when Relay 2 is closed.
  • Page 13 409-32034 Yellow Indicator Guard Open Jog Button Speed Control Icon Knob Green Indicator Speed Control Icon Machine Ready Icon Jog Button Icon Fault Icon Optional Batch Counter Guard Disabled Icon The green and yellow indicators on top of the control panel indicate the machine status. When the green indicator is “on”...

  • Page 14: Applicator Installation

    409-32034 4.3. Applicator Installation NOTE These instructions apply to machines that have an AMP style base plate with the quick release feature. Machines with the Universal style base plate, do not have a quick release feature and require a hex wrench to install an applicator. Machines with the JAM style base plate use a swing handle to release applicators.

  • Page 15: Mode Selection And Operation

    409-32034 NOTE Machine should be able to jog through the terminal and wire at maximum jog speed. 3. Inspect the crimped terminal to verify that the terminal is being positioned properly within the applicator. 4. Correct for any positioning errors according to the applicator instruction sheet, and repeat Steps 2 and 3 until a terminal is properly positioned.
  • Page 16 409-32034 Adjusting the Jogging Speed Using the Speed Control Knob The default speed of the machine, when jogging, is set to a minimum value which is not defined by the initial position of the speed control knob. Adjusting the speed upward enables jogging at speeds greater than the default in case greater speeds are required to complete a cycle.

  • Page 17: Crimp Height Adjustment

    409-32034 4.6. Crimp Height Adjustment Refer to Paragraph 7.3. 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 end- feed applicator), the reel support assembly must be moved to the opposite side of the machine.

  • Page 18: Preventive Maintenance

    Chevron Ultra-Duty EP NLGI 2, Chevron Ulti-Plex EP NLGI 2, and Caltex Ultra-Duty EP NLGI 2. NOTE Contact TE Engineering for 2 choice alternates. CAUTION It is important to only use Lithium-based grease with extreme pressure (EP) additives.

  • Page 19: Adjustments

    409-32034 Precision Crimp Height Adjustment Mechanism Lubrication Points Lubrication Points Figure 11 7. ADJUSTMENTS The following adjustments are necessary to maintain the machine in operating condition, and to set up the machine after replacing parts. DANGER To avoid personal injury, ALWAYS disconnect electrical and air supplies before performing adjustments. 7.1.

  • Page 20: Shut-Height Adjustment

    409-32034 Precision Crimp Height Adjustment Mechanism SHUT HEIGHT GAGE SHUT HEIGHT BASE PLATE PART NUMBER DIMENSIONS STYLE 135.79 mm ±0.025 mm 679655-2 [5.346 ±.0010 in.] UNIVERSAL 119.50 ±0.025 mm 679655-3 [4.7047 ±.0010 in.] Figure 12 7.2. Shut-Height Adjustment The shut height is pre-set at the factory and should not require further adjustment unless it is necessary to replace parts.

  • Page 21: Crimp Height Adjustment Using Precision Adjustment Mechanism

    409-32034 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.

  • Page 22: Guard Insert Adjustment

    409-32034 Figure 13 7.4. Guard Insert Adjustment A guard insert is supplied with the machine. Some applications may require a special insert. See Figure 14 for available guard inserts. The guard contains two slots into which the inserts can be placed: the rear slot places the insert close to the applicator;...
  • Page 23 409-32034 Tape Guard Inset Standard Guard Inset “A” “B” “B” “A” GUARD INSERT DIMENSION PART NUMBER DESCRIPTION 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...

  • Page 24: Machine Options And Installation

    Monitor’s Crimping Process TE CQM II Figure 15  Contact TE Engineering (1-800-722-1111) for CQM II part number. NOTE In addition to the previously listed options, the following machine options are available only for Machines that have a universal style base plate:...
  • Page 25 409-32034 Socket Screws Provided with Work Light Kit Work Light Kit Knockout Holes Work Light Kit (Optional) Batch Counter Kit (Optional) User Interface Assembly (Removed from Machine) Red Reset Button PC Board J3 Connector J1 Connector User Interface Assembly (As Viewed from the Bottom)) Figure 16 8.

  • Page 26: Installation Of The Work Light Assembly Kit

    409-32034 11. Install the user interface assembly into the frame and secure using the two socket head screws. CAUTION Be sure the interface assembly wiring harness is not pinched or kinked. 12. Close the clear guard on the machine. 13. Connect the machine to the power source and turn the machine "on." 8.2.

  • Page 27: Installation Of Batch Counter Kit 1424267-1

    409-32034 Figure 18 8.3. Installation of Batch Counter Kit 1424267-1 DANGER To avoid personal injury, be sure to turn "off" the machine, and disconnect it from the power source. 1. Open the clear guard on the machine to gain access to the two socket head screws securing the user interface to the frame.

  • Page 28: Installation Of Air Feed Kit 1424266-1

    409-32034 9. Install the user interface assembly into the frame and secure using the two socket head screws. CAUTION Be sure the interface assembly wiring harness is not pinched or kinked. 10. Close the clear guard on the machine. 11. Connect the machine to the power source and turn the machine "on." User Interface Assembly (Removed from Machine) Batch Counter Kit...
  • Page 29 409-32034 2. Remove the control panel from the machine and pivot it in order to view the control board. 3. Insert the small end of the air feed cable assembly (see Customer Drawing 1424266) into the J7 socket. See Figure 20. 4.
  • Page 30 409-32034 Slide Valve Large End of Air Feed Cable Assembly 1424287-1 Four-Way Solenoid Valve Filter Air Feed Bracket Figure 21 9. Connect the air lines to the applicable ports. 10. Turn the air "on" by moving the slide valve toward the filter. NOTE The air can be turned "off "by moving the slide valve away from the filter.

  • Page 31: Troubleshooting

    Revisions to this customer manual include:   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”.

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Amp 5k series

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