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E
2007 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.
AMP-TAPETRONIC*
Machine 69875 and 69875-1
SAFETY PRECAUTIONS
READ THIS FIRST !
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1.1.
1.2.
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2.1.
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2.2.
3.1.
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3.2.
3.3.
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4.1.
4.2.
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4.4.
5.1.
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5.2.
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6.1.
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6.2.
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7.1.
7.2.
7.3.
7.4.
7.5.
8.1.
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8.2.
8.3.
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8.4.
8.5.
8.6.
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TOOLING ASSISTANCE CENTER 1-800-722-1111
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This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.tycoelectronics.com
Customer Manual
409-1993
12 NOV 07 Rev J
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LOC B
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Summary of Contents for Tyco Electronics AMP-TAPETRONIC 69875
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Page 1: Table Of Contents
For latest revision and Regional Customer Service, All International Rights Reserved visit our website at www.tycoelectronics.com TE logo and Tyco Electronics are trademarks. LOC B *Trademark. Other products, logos, and company names used are the property of their respective owners. - Page 2 05. Equipment number (and serial number if applicable) 06. Product part number (and serial number if applicable) 07. Urgency of request 08. Nature of problem 09. Description of inoperative component(s) 10. Additional information/comments that may be helpful 2 of 46 Rev J Tyco Electronics Corporation...
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Page 3: Introduction
When reading this manual, pay particular attention to DANGER, CAUTION, and NOTE statements. DANGER Denotes an imminent hazard which may result in moderate or severe injury. CAUTION Denotes a condition which may result in product or equipment damage. Rev J 3 of 46 Tyco Electronics Corporation... -
Page 4: Dimensions And Specifications
Refer to Section 8 for die replacement procedures for terminal and butt splice dies, and for machine conversion procedure when converting to run closed end splices and spare wire caps. Refer to Section 7 for any adjustments that may be necessary. of 46 Tyco Electronics Corporation... -
Page 5: Description
2. DESCRIPTION Machines 69875 and 69875-1 are identical except for the electrical systems required to power the machines. Machine NOTE 69875 operates on 115 Vac, 60 Hz; Machine 69875-1 operates on 230 Vac, 50 Hz power. of 46 Tyco Electronics Corporation... -
Page 6: Physical Description
At the beginning of a machine cycle, the flywheel is rotating, the ram is in the neutral or holding position, and a product is in the crimping position. When the foot switch is depressed, the machine solenoid is of 46 Tyco Electronics Corporation... - Page 7 The machine is operated by a foot switch. The foot switch must be depressed and released to perform each cycle of operation. For further information, refer to the wiring diagram in Figure 6 and the electrical schematic in Figure 7. Rev J 7 of 46 Tyco Electronics Corporation...
- Page 8 AMP-TAPETRONIC Machine 69875 and 69875-1 409-1993 Figure 6 8 of 46 Rev J Tyco Electronics Corporation...
- Page 9 AMP-TAPETRONIC Machines 69875 and 69875-1 409-1993 Figure 7 Rev J 9 of 46 Tyco Electronics Corporation...
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Page 10: Receiving Inspection And Installation
2. 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 Tyco Electronics immediately. 3. Check all components and parts to be certain they are secure. -
Page 11: Machine Installation
Tooling alignment should be checked and adjusted by your local field service engineer. of 46 Tyco Electronics Corporation... - Page 12 The clutch will release at the end of the cycle. CAUTION Turning the flywheel in the direction opposite of the arrow may cause damage to the machine. 4. Repeat Step 3 as necessary to complete the operation being performed. of 46 Tyco Electronics Corporation...
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Page 13: Product Loading And Unloading
5. Position first product in tape a few positions to the left of the crimping area. MAKE SURE feed notches in tape engage with teeth on feed belt. 6. Adjust terminal guide to feed product straight into the crimping dies as shown in Figure 12. of 46 Tyco Electronics Corporation... - Page 14 1. Remove front guard and raise tape release lever. 2. Remove tape from indexing mechanism. 3. Cut excess lead from tape and discard. 4. Secure end of tape to reel with masking tape. 5. Remove reel from reel support. of 46 Tyco Electronics Corporation...
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Page 15: Production Operation
Product may also jam or pile up in the moving die if vertical movement of the wire stop is out of adjustment. Refer to Section 7 for any adjustments that may be necessary. Rev J 15 of 46 Tyco Electronics Corporation... -
Page 16: Preventive Maintenance
To avoid personal injury, always turn off main power switch and disconnect machine from power source when DANGER performing lubrication, cleaning, or parts replacement. 5.1. Cleaning Clean the dies daily. Do not allow deposits of dirt to build up on bottoming surfaces and die closure surfaces. 16 of 46 Rev J Tyco Electronics Corporation... -
Page 17: Visual Inspection (Monthly)
C [250 1 Part SAE 20 Motor Oil and 1 Part STP VALVOLINE X-5 Light National Lubrication Grease Institute STP Lubricant, STP Corporation VALVOLINE Oil Company, Division of Ashland Oil and Refining Company Figure 15 of 46 Tyco Electronics Corporation... - Page 18 Open flywheel guard and Monthly remove flywheel. 4. Oil Points (Indexing Mechanism) Ball joint Feed linkage on right Monthly assembly side of machine fittings and (Figure 16,A). pivot points Slide bar Indexing mechanism Monthly Figure 16 (cont’d) of 46 Tyco Electronics Corporation...
- Page 19 4 (a) 1 (b) 1 (f) 3 (a) 1 (a) 3 (f) 3 (b) 1 (c) & (e) 3 (d) 1 (d) Connecting Rod 3 (c) Retainer Nuts 3 (e) 1 (g) Figure 16 (end) of 46 Tyco Electronics Corporation...
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Page 20: Troubleshooting
4. Inspect the machine for worn or damaged mechanical components. 5. Inspect all lubrication points for excessive build–up of lubricants or dirt. 6. Inspect for insufficient lubrication. 6.2. Troubleshooting Table A troubleshooting table can be found in Figure 17. 20 of 46 Rev J Tyco Electronics Corporation... - Page 21 Gain access through either of the lift holes will produce a clicking" noise. of machine and push down on top of ball joint assembly until assembly bottoms. Connect power cord, place power switch in the ON"position and operate machine. Figure 17 (cont’d) of 46 Tyco Electronics Corporation...
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Page 22: Adjustments
The machine contains a four–position insulation crimp adjustment, located on the front of the ram, that ranges from No. 1 (tight) to No. 4 (loose). 1. Remove the front guard to gain access to the tooling. of 46 Tyco Electronics Corporation... - Page 23 (be in contact with) wire insulation. If not, raise release lever and turn the insulation adjustment knob to the next lower number; then repeat Steps 4 through 7 and Step 9. 10. After obtaining the proper crimp, replace the front guard. of 46 Tyco Electronics Corporation...
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Page 24: Wire Stop Vertical Lift Adjustment
3. Loosen the locknut on the adjustment screw, then turn adjustment screw until the screw head touches the machine frame and wire stop lift plate touches the ram lift pin. Tighten the locknut to secure the adjustment screw. of 46 Tyco Electronics Corporation... - Page 25 Die Centered Over Splice or Wire Barrel of Splice or Cap Cap In Splice Or Cap Out Too Far Too Far Turn Adjustment Turn Adjustment Screw Wire Barrel Screw Clockwise Counterclockwise Figure 20 Rev J 25 of 46 Tyco Electronics Corporation...
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Page 26: Crimp Location Adjustment
Product must be indexed into the CENTER of the die closure. In the event of machine wear or variations in the feed holes within the tape, it may be necessary to advance or retract the tape feed (belt travel) or feed ratchet as follows: of 46 Tyco Electronics Corporation... -
Page 27: Repair And Replacement
8.1. Die Replacement If converting the machine to run closed end splices or spare wire caps or converting back to run terminals or butt NOTE splices, refer to the conversion procedures in Paragraph 8.3. Rev J 27 of 46 Tyco Electronics Corporation... - Page 28 6. Tighten the holding screws on both dies. Applicator Guard Removed for Clarity. Always Keep Guards In Place When Operating the Machine. Moving Die Holder Stationary Die Holder Holding Screw Moving Die Holding Screw Wire Funnel Stationary Die Figure 22 of 46 Tyco Electronics Corporation...
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Page 29: Wire Funnel Replacement
NOTE: Three screws and three spacers shown with guard are packaged and installed with wire funnel 68306-1 only. Use existing mounting screws and washers with guard when installing wire funnel Part No. 68299-1. Figure 23 of 46 Tyco Electronics Corporation... -
Page 30: Machine Conversion
4. Remove the screw and metal guard from the front of the indexing mechanism. Refer to Figure 25,B. Moving Screw (8-32) Wire Stop Stationary Lower Tooling Holder 307250-1 See Instructions Packaged With Dies for Specific Extractor 308163-1 Wire Stop Configuration. (For Closed End Splices) Figure 24 of 46 Tyco Electronics Corporation... - Page 31 (The chamfer is necessary so that the offset of the upper die will seat tightly in the mount.) 15. Swing mount back to vertical position and re–install ram retaining plate with four screws. Rev J 31 of 46 Tyco Electronics Corporation...
- Page 32 18. Lower the tape release lever. 19. Hand–cycle the machine, as described in Section 4, until the dies begin to mate, then shift the lower tooling holder as needed to align dies as shown in Figure 28. of 46 Tyco Electronics Corporation...
- Page 33 Against Bottom Edge of Mount, Then Tighten Die Screw Moving Die Figure 27 When Dies are Aligned, Push Indexing Mechanism Tape Release T oward Rear of Machine: Lever Lowered Then Tighten Screws in Holder Dies Must Align Figure 28 of 46 Tyco Electronics Corporation...
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Page 34: Shear Pin Replacement
Undercut Portion of Pin Should Be Flush With Moving Die Holder Shear Pin Part No. 251465-1 Tape Release Lever Figure 29 of 46 Tyco Electronics Corporation... -
Page 35: Trip Control Replacement
Adjustment Link Assembly End Bearing Remove Base Mount Base Mount Holding and Lower Tooling as a Screws and Washers Unit Lower Tooling Holding Screws (Do Not Disturb) Base Mount Adjustment Screw (Do Not Disturb) Figure 30 of 46 Tyco Electronics Corporation... - Page 36 27. Re–install stop tube as described in Paragraph 8.5. 28. Install dies as described in Paragraph 8.1. 29. Load product into machine as described in Section 4, then check tape feed belt adjustments as described in Section 7. 36 of 46 Rev J Tyco Electronics Corporation...
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Page 37: Parts Lists And Drawings
Prior to this release, the following changes were made: S Reel Support Assembly in Figure 33 was revised S Wiring Diagram and Schematic were redrawn S Updated format to current corporate requirements Rev J 37 of 46 Tyco Electronics Corporation... - Page 38 251477-1 PLATE, Lift 237003-1 RAM, Cover (See Figure 32, Detail A) 251440-1 251465-1 PIN, Shear 251438-1 MOUNT, Ram Tool 251493-1 RETAINER, Tape 251443-1 HOLDER, Tooling 251451-1 GUIDE, Terminal Figure 32 (Sheet 1 of 6) cont’d of 46 Tyco Electronics Corporation...
- Page 39 SCREW, Slflkg Shldr, .248" Dia x .250" L 21046-7 RING, External Retaining 21023-7 WASHER, Flat, No. 10 22170-3 PIN, Cotter 3-21000-1 SCREW, Skt Hd Cap, No. 8-32 x 1.00" L Figure 32 (Sheet 2 of 6) cont’d of 46 Tyco Electronics Corporation...
- Page 40 22140-4 SCREW, Slflkg Skt Hd Cap, 1/4-20 x .75" L 28772-2 BEARING, Rod End, LH, 1/4-28 23044-1 NUT, Hex, LH, 1/4-28 387911-1 ROD, Connecting 1-22202-5 NUT, Hex, 1/4-28 Figure 32 (Sheet 3 of 6) cont’d of 46 Tyco Electronics Corporation...
- Page 41 22287-4 SPRING, Extension 308161-1 GUARD, Left Side 5-21028-3 PIN, Spring, .125" Dia x .625" L 21899-3 WASHER, Flat, 1/4" 21001-4 SCREW, Btn Hd Cap, 1/4-20 x .750" L Figure 32 (Sheet 4 of 6) cont’d of 46 Tyco Electronics Corporation...
- Page 42 AMP-TAPETRONIC Machine 69875 and 69875-1 409-1993 Figure 32 (Sheet 5 of 6) cont’d of 46 Tyco Electronics Corporation...
- Page 43 Tape Applicator To Item 71 On Page 36 Item 111 Page 41 The slot in the probe head assembly (Item 35) must be centrally aligned with the stationary die. If alignment of probe head assembly is necessary, relocate shims between surfaces of Item 39 bracket (Item 11H) and arms (Item 11B) as required.
- Page 44 STUD, Feed Pivot 22547-4 GROMMET 251537-2 BRACKET, Switch 24134-1 ACTUATOR, Switch 24132-2 SWITCH 22538-7 BUSHING, Snap 21001-4 SCREW, Skt Hd Cap, 1/4-20 x .750" L 21024-6 WASHER, Lock, 1/4" Figure 33 (Sheet 1 of 3) cont’d of 46 Tyco Electronics Corporation...
- Page 45 SCREW, Skt Hd Cap, No. 10-32 x .625" L 21024-5 WASHER, Lock, No. 10 856670-1 CAM, Pull 251433-1 ARM, Eccentric 251512-1 BOLT, Special Shoulder 551336-2 SHAFT, Main (Stop Position 70) Figure 33 (Sheet 2 of 3) cont’d of 46 Tyco Electronics Corporation...
- Page 46 AMP-TAPETRONIC Machine 69875 and 69875-1 409-1993 Figure 33 (Sheet 3 of 3) end of 46 Tyco Electronics Corporation...
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