Download
Share
Print this page
  1. Manuals
  2. Brands
  3. AMP Manuals
  4. Industrial Equipment
  5. 4
  6. Customer's manual

AMP 4 Customer's Manual

Horizontal terminating machine, including optional wire stuffer assembly
Hide thumbs

Advertisement

Quick Links

Download this manual
AMP* Horizontal Terminating Machine
CM 5388
Model 4, No. 469181–[ ] and No. 463734–[ ]
01 MAY 90 Rev O
Including CM 5388–2, Rev D, Optional Wire
Stuffer Assembly No. 469853–1 & –2

Advertisement

loading
Need help?

Need help?

Do you have a question about the 4 and is the answer not in the manual?

Questions and answers

Summary of Contents for AMP 4

  • Page 1 AMP* Horizontal Terminating Machine CM 5388 Model 4, No. 469181–[ ] and No. 463734–[ ] 01 MAY 90 Rev O Including CM 5388–2, Rev D, Optional Wire Stuffer Assembly No. 469853–1 & –2...
  • Page 2 Technical Publications. To obtain a copy of this document, internal customers mail Requisition Form (AMP 168) to Literature Distribution 84–13. External customers call the Customer Support Center at (717) 780–4444. * Trademark of AMP Incorporated Copyright 1978, 1980, 1985, 1987, 1990 by AMP Incorporated. All International Rights Reserved.
  • Page 3 Prepared by T echnical Publications, AMP Incorporated CM 5388, Rev D...
  • Page 4 Typical Machine Without Wire Stuffer NOTE: Frontispiece. AMP Horizontal T erminating Machine Model 4 CM 5388, Rev D...
  • Page 5 DANGER SAFETY PRECAUTIONS PREVENT INJURY Safeguards are designed into AMP machines to protect operating personnel from most hazards during normal machine operation. However, as with most machinery, certain precautions must be taken by the operator and repairman. Never insert hands into an installed machine/applicator, or any part of a machine that is operated by electricity or com pressed air, without first pulling the machine power cable plug from the outlet receptacle and/or shutting off the com pressed air at the line valve and disconnecting the air hose.

  • Page 6: Receiving Inspection And Installation

    RECEIVING INSPECTION AND INSTALLATION Receiving Inspection The machines are thoroughly inspected during and after assembly. Prior to packaging and shipping, a final series of tests and inspections is made to ensure proper functioning. While the machine should require no adjustments before placing it in operation, the following inspection should be performed as a safeguard against potential problems generated in transit.
  • Page 7 Machine Location on the Bench The machine should be located near the front of the bench and securely bolted to remain stationary. The target area (tooling area where the terminal is applied) should be 6 to 8 in. from the front edge. This elimi nates unnecessary operator motion and helps prevent back strain and fatigue.

  • Page 8: Machine Installation

    Machine Installation With the considerations outlined in Paragraph B, locate the machine in a well-lighted area with adequate electrical power and air supply. After positioning the machine on a sturdy bench, it is advisable to secure it with bolts or screws to prevent movement.

  • Page 9: Table Of Contents

    ............. 3.4.
  • Page 10 ........Terminals Used with the AMP Horizontal Terminating Machines .
  • Page 11 CM 5388, Rev D...

  • Page 12: Introduction

    Section 4 contains step-by-step instructions for the machine operator. Maintenance personnel will find, in addition to Section 6, Preventive Maintenance, necessary and helpful information in Section 2 for diagnos ing cycling problems, and in Section 5 for making adjustments.
  • Page 13 THE MACHINE NUMBERS IN COLUMN (B) HAVE BEEN SUPERSEDED BY THE RESPECTIVE MACHINE NUMBERS IN COLUMN (A). 469181-4 AND -6 HAVE BEEN SUPERSEDED BY 1-469181-3 AND 1-469181-5 RESPECTIVELY . THE ONLY DIFFERENCE BETWEEN THE SUPERSEDED MACHINES AND THE LATER MODELS IS IN THE ANVIL HOLDER.

  • Page 14: Major Groups And Subassemblies

    The anvil holder is mounted to the machine frame. The anvil is held in place in the anvil holder by the stripper plate (15). The wire positioner (4) is mounted on the anvil holder and helps ensure that the wire is positioned for a perfect crimp.

  • Page 15: Switches And Controls

    Air pressure supplied to the machine passes through the air filter to provide clean air for the air valves, pilot actuators, and the air cylinders. For electrical connections to the solenoid valves, refer to Figure 8-4. 2.2. Switches and Controls (Figure 2-1) All switches and controls for operating the machine are located at the front within easy reach of the operator.
  • Page 16 Fuse and Fuse Holder (F1) The fuse protects the machine circuitry in the event of a short" within the wiring or one of the electrical components. Should the machine fail to operate and the indicator lamp does not light when the RUN pushbutton is depressed, FIRST check the fuse and replace if necessary. Feed Switch (S2) The feed switch is operated by depressing the FEED pushbutton.

  • Page 17: Functional Description

    17357-1 CONTROL FILTER 23054-1 IN NO FLOW CONTROL 461439-1 STRIPPER & RET PL 26863-1 PILOT ACTUATOR AIR SUPPLY Fig. 2-2. Machine Pneumatic Diagram When the foot switch (S3) is depressed, power is supplied through the closed" switch (S4) to energize the ram extend solenoid valve (L3). This diverts air pressure through the valve to the extension side of the ram cylinder.

  • Page 18: Machine Electrical Schematic

    With switches (S5 and S6) closed," the terminal feed solenoid valve (L2) is energized. This diverts air pres sure through the valve to the retraction side of the feed cylinder to retract the feed finger and allow switch (S4) to open" and break the circuit to the ram extend solenoid valve (L3). This also supplies air pressure to pilot actuators "close"...

  • Page 19: Machine Setup Procedures

    The machine is now back in the standby condition and all solenoid valves are de-energized. Air pressure is being supplied to the retraction side of the ram cylinder and to the extension side of the feed cylinder and pilot actuator on switch (S4). With the machine in the standby condition, terminals can be fed into the target area"...

  • Page 20: Preloading Alignment Check

    3.2. Preloading Alignment Check (Figure 3-1) BE SURE the electrical and air supply are disconnected before starting DANGER this procedure. Remove anvil guard (2) and ram guard (3) by removing screws (1) securing each to the machine frame. Remove the four screws (14) securing the anvil holder (17) to the frame. Remove stripper plate (15) from anvil holder (17) and remove the anvil (16);...

  • Page 21: T Erminal Strip Loading

    3.3. Terminal Strip Loading (Figure 3-2) MAKE SURE the electrical plug and air supply are disconnected. DANGER Place a reel of the correct type of terminals on the reel support so the terminal strip enters the groove in back of the feed plate with the open U" toward the back of the machine. Rotate the drag lever to release and hold drag open (back), then feed terminal strip through strip guide, and groove in feed plate until the end reaches the feed finger.

  • Page 22: Machine Checkout

    Tighten locknut after making adjustment. Check ram rest switch S5, on ram retaining plate (4), to be sure it is actuated open" by socket head cap screw (13). If necessary, adjust switch as described in Section 5.

  • Page 23: Wire Placement In Target Area

    After the ram has fully retracted, remove the terminal and inspect it in accordance with Para graph 3.4. If necessary, make any adjustments that may be required as described in Section 5. At completion of this check, perform automatic crimping check as described in Paragraph 3.4,D.

  • Page 24: T Ermination Inspection

    Paragraph 3.4,C except that the manual ram advance control must be fully open, pushbutton depressed, foot switch depressed cycle machine. T erminations must conform to the requirement set forth in Paragraph 3.5. If necessary, make any adjustments that may be required as described in Section 5.

  • Page 25: Crimp Height Comparator

    Figure 3-6. The crimp height must be within +/-.003 in. of the measurement specified for the type terminal and size wire being used, as obtained from your AMP Field Engineer. If a common crimp height is used for several different terminal combinations, the crimp height must be +/-.001 in.

  • Page 26: Machine Production Operation

    MACHINE PRODUCTION OPERATION Before placing the machine in production operation, be sure it has been properly setup and checked out according to procedures in Section 3. Perform production operation as follows: Connect the machine to the adequate air supply. Plug the electrical plug into the convenient electrical outlet. Be sure all guards and covers are in place.

  • Page 27: Crimp Height Fine Adjustment

    Increase or decrease the crimp height by turning the adjustment knob on the right side. The letter A" produces the minimum crimp height (tightest) and the letter F" the maximum crimp height (largest), or approximately .005 in. between letters. Refer to Figure 5-1. If, after performing several crimping test cycles manually and under power, the desired crimp height cannot be obtained, set the adjustment knob on the letter A"...

  • Page 28: Feed Adjustments

    12. Perform manual and power crimping procedures, and then the termination inspection as described in Section 3 to be sure the crimp height is correct. If not, repeat Steps 4 through 12 until correct crimp height is obtained. Perform Step 2 for fine adjustment.

  • Page 29: Feed Adjustment Points

    DRAG FEED FINGER DRAG LEVER DRAG SETSCREW FEED FINGER RELEASE PIN SHOULDER SCREWS FEED CYLINDER LOCKNUT FEED PLATE FEED CYLINDER ADAPTER VALVE ADJUSTMENT FLOW CONTROL VALVE Fig. 5-3. Feed Adjustment Points T erminal Strip Drag The drag must apply sufficient pressure to the terminal strip to prevent pullback of the strip by the feed finger when it is retracted to pick up the next feed point.

  • Page 30: Adjustment Of Ram Switches

    (S6) closed." If this energizes the terminal feed solenoid valve (LS), the ram rest switch must be adjusted. To adjust, loosen nut (12); then turn setscrew (13) IN 1/4 turn at a time while repeating Step 2 until switch is open."...

  • Page 31: Preventive Maintenance

    Make any repairs that may be necessary by referring to the electrical schematic in Figure 2-3 and the wiring diagram in Figure 8-4. Inspect all air lines for loose connections. Make any necessary repairs by referring to the machine pneumatic diagram (Figure 2-2).

  • Page 32: Repair And/Or Replacements

    If only the anvil is to be replaced, install the new anvil using the reversed removal procedure. If the wire positioner (4) is to be replaced, loosen screw (1) and remove the wire positioner. Install the new wire positioner by using the reversed removal procedure.
  • Page 33 Fig. 7-1. T ooling Chart for Horizontal T erminating Machine, No. 469181-[ ] CM 5388, Rev D...
  • Page 34 Fig. 7-2. T ooling Chart for Horizontal T erminating Machine, No. 463734-[ ] CM 5388, Rev D...

  • Page 35: Feed Finger Replacement

    When ordering parts DO NOT order by the item number. Order parts by the AMP part number AND the description. The quantity (QTY) column on the parts list indicates the number of parts required per machine and/or location.
  • Page 36 THESE ITEMS ARE RECOMMENDED SPARES AND THE CUSTOMER'S RESPONSIBILITY TO STOCK AND REPLACE. SEE FIGURE 7-1 (Tooling Chart) FOR THE 469181-[ ] MACHINE, AND FIGURE 7-2 (Tooling Chart) FOR THE 463734-[ ] MACHINE. Fig. 8-1. Exploded View, Horizontal Terminating Machine, Model 4 (Sheet 1 of 3) CM 5388, Rev D...
  • Page 37 THESE ITEMS ARE RECOMMENDED SPARES AND THE CUSTOMER'S RESPONSIBILITY TO STOCK AND REPLACE. SEE FIGURE 7-1 (Tooling Chart) FOR THE 469181-[ ] MACHINE, AND FIGURE 7-2 (Tooling Chart) FOR THE 463734-[ ] MACHINE. Fig. 8-1. Exploded View, Horizontal Terminating Machine, Model 4 (Sheet 2 of 3) CM 5388, Rev D...
  • Page 38 RAM (Ref) (Ref) AIR BLAST TUBE FRAME (Ref) SEE DETAIL A" (Ref) (Ref) Fig. 8-1. Exploded View, Horizontal Terminating Machine, Model 4 (Sheet 3 of 3) CM 5388, Rev D...

  • Page 39: Exploded View, Machine Subassembly

    PLATE ASSY , Valve Mounting See Fig. 8-4 ELECTRICAL SYSTEM, Machine 21019-3 NUT, Hex, 3/8-16 815922-1 PIN, Pivot Adjust 3- 21002-4 SCREW, Btn Hd Skt Cap, 1/4-20 x .625" L 815921-1 PLATE, Index 21899-3 WASHER, Flat, 1/4" 815924-1 LABEL 817210-1...
  • Page 40 (Typ 4 Places) (Typ 4 Places) (Typ 4 Places) (Ref) (See Fig. 8-3) (Ref) (See Fig. 8-3) Fig. 8-2. Exploded View, Machine Subassembly (Sheet 2 of 2) CM 5388, Rev D...

  • Page 41: Exploded View, Valve Mounting Plate Subassembly

    PLATE SUBASSY , Valve Mounting (115 Vac, 60 Hz) 469756-2 PLATE SUBASSY , Valve Mounting (230 Vac, 50 Hz) 460114-1 BASE FRAME 21001-1 SCREW, Skt Hd Cap, 1/4-20 x .38" L 460131-1 SUPPORT, Reel 21001-3 SCREW, Skt Hd Cap, 1/4-20 x .62" L 22306-6 ELBOW, Street, 90 , 3/8"...
  • Page 42 ITEM AMP PART DESCRIPTION NUMBER 22293-3 ELBOW, Female, 1/8" NPT x 1/4" Tube 3- 21000-0 SCREW, Skt Hd Cap, 8-32 x .88" L 24892-1 ELBOW, Street, 45 , 1/8" NPT 22295-7 CONNECTOR, Male, 1/8" NPT x 1/4" Tube 26668-2 NIPPLE, Chase 24146-1 HOSE, Buna-N, 1/4"...
  • Page 43 51 52 Fig. 8-3. Exploded View, Valve Mounting Plate Subassembly (Sheet 3 of 3) CM 5388, Rev D...

  • Page 44: Electrical System Components

    FUSE, 115 Vac, 60 Hz (ABC3) 24517-3 FUSE, 230 Vac, 50 Hz (ABC2) 18126-1 SWITCH, Pressure Sensitive 4- 23715-5 SCREW, Pan Hd, No. 4-40 x .50" L 23485-1 SWITCH, Toggle 23426-1 PLATE, Switch, ON-OFF 601716-8 BLOCK, Terminal, 8 Pos., 6-32 601989-1 PLATE, Tab, .250, Flat...
  • Page 45 Fig. 8-4. Electrical System Components (Sheet 2 of 3) CM 5388, Rev D...
  • Page 46 Fig. 8-4. Wire Chart (Sheet 3 of 3) CM 5388, Rev D...
  • Page 47 NO. 469181-[ ] AND NO. 463734-[ ] 5/90 S U P P L E M E N T Also available CM 5388-3 (Spanish translation) AMP INCORPORATED Harrisburg, Pa. 17105 * Trademark of AMP Incorporated Copyright 1987, 1990 by AMP Incorporated. All International Rights Reserved.
  • Page 48 Prepared by T echnical Publications, AMP Incorporated S/ii CM 5388-2, Rev D...
  • Page 49 CONTENTS INTRODUCTION ..............DESCRIPTION .

  • Page 50: S1. Introduction

    S3. WIRE STUFFER KIT INSTALLATION The wire stuffer kit can be installed on any AMP Model IV Horizontal Terminating Machine, regardless of the terminals the machine is equipped to apply. When the kit is received, items listed under the two assemblies will be pre-assembled as completely as possible for ease of installation.

  • Page 51: S4. Wire Stuffer Setup Procedure

    Remove and retain two screws securing feed solenoid (L2) to frame base. Leave the feed sole noid in place and install two valve spacer posts (11). Place the solenoid valve (L4), with installed parts, on the valve posts with the exhaust muffler (2) to the RIGHT.

  • Page 52: S5. Adjustments

    (Figure S6-1) to identify the part by item number; then to the parts list for the AMP Part Number and description. Detail parts are indented under the assembly on which they are used. The QTY (quantity) column indicates the number required per assem bly, except for tubing which is indicated by total inches required.

  • Page 53: Stuffer Adjustments

    TUBING SELF-LOCKING (Entrance) STUFFER WIRE AIR CYLINDER SPRING GRIPPER BLADE CYLINDER SHAFT FLOW CONTROL VALVE (Typ 2 Places) JAM NUT TO CYLINDER EXTENSION PORT ADJUSTMENT TO CYLINDER RETRACTION PORT SCREW FRONT 3/4 VIEW S5-1. Stuffer Adjustments CM 5388-2, Rev D...
  • Page 54 MUFFLER, Exhaust, 1/8" NPT 27319-3 TUBING, 3/8" OD 3" 22304-1 NIPPLE, 1/8" NPT 22293-3 ELBOW, Female, 1/8" NPT x 1/4" Tube 16732-1 VALVE, Solenoid, 110 Vac, 4-Way (-1 Assy) 16732-2 VALVE, Solenoid, 220 Vac, 4-Way (-2 Assy) 26668-2 NIPPLE, Chase 640903-1 TERMINAL, FASTON*, PIDG*, .250, Red...

  • Page 55: Exploded View, Wire Stuffer Assembly No. 469853-1 And -2

    BLACK WHITE GREEN 24 29 S6-1. Exploded View Wire Stuffer Assembly No. 469853-1 and -2 (Sheet 2 of 2) CM 5388-2, Rev D...

This manual is also suitable for:

469181463734Cm 5388-2469853-1469853-2