1. Manuals
  2. Brands
  3. TE Connectivity Manuals
  4. Industrial Equipment
  5. AMP-O-LECTRIC G
  6. Customer's manual

TE Connectivity AMP-O-LECTRIC G Customer's Manual

Terminating machines
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
© 2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company
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-O-LECTRIC* Model "G" Terminating
Machines 122754-1 Through -5
SAFETY PRECAUTIONS
A.
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1. Functional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2. Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. RECEIVING INSPECTION AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1. Receiving Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2. General Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4. INTERFACING WITH KOMAX MACHINE VIA CONNECTOR J3 . . . . . . . . . . . . . . . . . . . 11
5. OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.1. Applicator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.2. Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.3. Manual Cycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.4. Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.5. Manual Precision Adjustment Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.6. Switching Between End and Side Feed Applicators . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6. PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.1. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.2. Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7. ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.1. Measuring Shut Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.2. Shut-Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.3. Precision Adjust Crimp Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.4. Tonk Lever Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.5. Drive Belt Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
9. REVISION SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Komax is a trademark.
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
409-5861
21 JUN 11 Rev B
1 of 26
LOC B

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the AMP-O-LECTRIC G and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for TE Connectivity AMP-O-LECTRIC G

Summary of Contents for TE Connectivity AMP-O-LECTRIC G

  • Page 1: Table Of Contents

    All Rights Reserved 1-800-722-1111 For latest revision and Regional Customer Service, *Trademark visit our website at www.te.com 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.
  • Page 2 409-5861 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.

  • Page 3: Introduction

    409-5861 Figure 1 1. INTRODUCTION This manual contains information on the installation, operation, and maintenance of the AMP-O-LECTRIC Model “G" Terminating Machines 122754-1 through -5. See Figure 1. Terminating Machines 122754-1 and -2 are designed to be used with Komax Model 40 machine, Terminating Machines 122754-3 and -4 are designed to be used with Komax Model 43 machine, and Terminating Machine 122754-5 is a generic unit designed to be used on other lead-making machines to crimp terminals to wire.

  • Page 4: Description

    409-5861 Read this manual thoroughly before operating the terminating machine. The performance of this terminating machine will depend largely upon the intelligent use of the information contained in this manual. 2. DESCRIPTION 2.1. Functional AMP-O-LECTRIC Model "G" terminating machines are designed to accept a variety of end-feed and side-feed miniature applicators, as well as applicators that are used with the AMP-O-LECTRIC Model "K"...
  • Page 5 409-5861 Operator Control Panel Batch Counter 16-Character Total Cycle Display Counter Mode Icons Lights Function Buttons  FUNCTION BUTTONS Function POWER Allows the controller to provide power to the motor. MODE Selects the current mode of operation by stepping through the four choices indicated.
  • Page 6 409-5861 The CPU/motor controller is located under the top cover of the terminating machine. The controller is a modular unit that contains all of the electronics necessary to operate the terminating machine. There are seven circular plastic connectors (CPC) located on the electrical control box. See Figure 4. The interface connection to the crimp quality monitor (CQM), connector J1, is located on the left side of the terminating machine, just below the top cover.

  • Page 7: Receiving Inspection And Installation

    It it recommended that the machine be inspected immediately upon its arrival at your facility to ensure it has not been damaged during shipment. If damage is evident, notify TE Connectivity immediately. 3.2. General Installation The AMP-O-LECTRIC Model “G”...

  • Page 8: Installing Terminating Machines 122754-1 And -2 Into Komax Model 40 Machine

    409-5861 Do not attempt to cycle the terminating machine with the lift eye in place. Damage to the machine could occur if the lift eye CAUTION  is not removed prior to operation.  4. Insert the reel support post into the hole in the top of the machine and turn the post clockwise until the threads begin to bottom out.
  • Page 9 409-5861 5. Loosen the three mounting screws securing the eject stacker cylinder and adjust it away from the terminating machine as far as possible. Tighten the mounting screws. See Figure 7. Check for proper clearance throughout the movement range of the stacker jaws. 6.

  • Page 10: Installing Terminating Machines 122754-3 And -4 Into Komax Model 43 Machine

    409-5861 3.4. Installing Terminating Machines 122754-3 and -4 into Komax Model 43 Machine 1. Install the interface cable (part number 189070-1) and power cable (part number 189276-1). 2. Attach the remote display unit to the reel support post. Slide the display assembly over the post and position as desired.

  • Page 11: Interfacing With Komax Machine Via Connector J3

    409-5861 4. INTERFACING WITH KOMAX MACHINE VIA CONNECTOR J3 This section describes all of the input and output signals used to interface with the Komax machine via connector J3 (parent machine interface). Pin 1 Tooling Up and Error Code Bit 0 This pin has two uses.
  • Page 12 409-5861 Pin 9, 15 Start (Full and Split Cycle) This signal is used to start the terminating machine. In the full cycle mode, the machine completes one cycle for each start signal. In split cycle mode, the machine moves from home to the split cycle position or the split cycle position to home when a start signal is received.

  • Page 13: Operation

    409-5861 5. OPERATION 5.1. Applicator Installation Make sure that the manual precision adjustment lever has been returned to the 0.00-mm [.000-in.] position before CAUTION  installing the applicator. Refer to Paragraph 7.3.  1. Loosen the thumbscrew on the applicator base clamp and slide the clamp down. See Figure 9. 2.
  • Page 14 409-5861 Thumbscrew for Ram Lock Mechanism Applicator Ram Ram Post Adaptor Applicator Pad Front Pad of Ram Post Adaptor Rear Stop(s) Thumbscrew Base Plate of Model “G” Terminating Machine Typical Applicato Applicator Base Clamp Figure 10 4. Slide the applicator base clamp UP and re-tighten the thumbscrew to secure the applicator in place. When using Applicator 567200-1 (originally intended for the AMP-O-LECTRIC Model "K"...

  • Page 15: Setup

    409-5861 8. Mount the terminal reel onto the reel support. Thread the terminal strip into the applicator according to the applicator instruction sheet supplied with the applicator. If necessary, adjust lubrication bowl. 9. Align reel brake to lead-in to applicator. 10.
  • Page 16 409-5861 Operating Modes on Operator Control Panel Batch Counter 16-Character Total Cycle Display Counter Mode Icons Lights Function Buttons  FUNCTION BUTTONS Function FULL CYCLE When the manual cycle button is pressed in this mode, or a cycle signal is received from the parent machine, the crankshaft will rotate at full speed through a full revolution.

  • Page 17: Manual Precision Adjustment Lever

    409-5861 5.5. Manual Precision Adjustment Lever The manual precision adjustment lever is used to adjust the crimp height. For adjustment procedures, refer to Paragraph 7.3, Precision Adjust Crimp Height Adjustment. 5.6. Switching Between End and Side Feed Applicators When changing from end feed to side feed applicators or side feed to end feed applicators, the reel support assembly and the dereel assist motor assembly must be relocated to the opposite side of the terminating machine.

  • Page 18: Adjustments

    409-5861 To avoid personal injury, exercise caution when machine is connected to power supply and terminating machine is turned DANGER   STOP Excess grease may drip down applicator if the grease is not removed from the ram slides, gibs, and frame. When NOTE lubrication is complete, re-connect the power supply to the machine and turn on the power to the terminating machine with the main power switch/circuit breaker.
  • Page 19 409-5861 1. Adjust the manual precision adjustment lever to -0.051 mm [-.002 in.] BELOW the 0.00-mm [.000-in.] setting. Refer to Paragraph 7.3. 2. Using a clean dry cloth, wipe the top and bottom surfaces of the shut height gage, the base plate, and the lobes on the bottom of the ram post adaptor.

  • Page 20: Shut-Height Adjustment

    409-5861 Ram Post Adaptor Shut Height Gage Lobes Locator Plate Cutout of Locator Plate Figure 14 Ram Post Adaptor Fully Bottomed on Shut Height Gage Figure 15 7. After shut height is verified, reset the manual precision adjustment lever to the 0.00-mm [.000-in.] position.

  • Page 21: Precision Adjust Crimp Height Adjustment

    409-5861 1. Check shut height of terminating machine using Shut Height Gage 679655, as described in Paragraph 7.1, Measuring Shut Height. 2. If the shut height is incorrect, proceed as follows: a. Remove the two socket head cap screws which secure the ram post adaptor (part number 354513-1) to the ram assembly.
  • Page 22 409-5861 Lubrication Point Adjustment Lever Reading (“+” Above 0.00-mm [.000-in.] Setting) Read Half Step Read Half Step +0.064 mm +0.051 mm [+.0025 in.] [+.002 in.] Dial Indicator Plate Adjustment Lever Reading (“-” Below 0.00-mm [.000-in.] Setting) Manual Precision Adjustment Lever Positioned on 0.00 mm [.000 in.] Read Half Step Read Half Step...

  • Page 23: Drive Belt Tension Adjustment

    409-5861 7.5. Drive Belt Tension Adjustment Adjust the drive belt tension as follows: 1. Position the motor closer to or farther from the upper pulley. Loosen the motor mounting bolts and allow the weight of the motor to automatically tension the belt. 2.

  • Page 24: Troubleshooting

    409-5861 8. TROUBLESHOOTING Refer to the following table for problems, possible cause, and remedy. PROBLEM POSSIBLE CAUSE REMEDY AC POWER FAILURE The motor relay circuit (connected to J3) has Check if the motor relay connections in jumper opened. positions 11 and 22 and 16 and 24 are seated properly into J3 (parent interface connector).
  • Page 25 409-5861 PROBLEM POSSIBLE CAUSE REMEDY GUARDS FAILED This message refers to the guards included on Check that the jumper is installed connecting or the bench version of this machine. When the positions 4 and 5 of J2. Also, check that the GUARD SW TIMEOUT main guard interlock and the insert guard jumper is installed connecting positions 13 and...

  • Page 26: Revision Summary

    409-5861 PROBLEM POSSIBLE CAUSE REMEDY SW 1 NOT MADE During a normal cycle, the braking switch (SW 1) Check for proper alignment of the vane as it turns on and then is expected to turn off again.  rotates through the switch. If the vane has struck If by the end of the cycle SW 1 has not turned on, the switch, it may need to be replaced.

This manual is also suitable for:

122754-1122754-2122754-3122754-4122754-5

Table of Contents