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Tyco Electronics DT-3000 Customer's Manual

Direct drive terminator
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2008 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.
Direct Drive Terminator (DT)-3000
Machines 1725100-[ ] and
DT-5000 Machines 1725800-[ ]
SAFETY PRECAUTIONS
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TOOLING ASSISTANCE CENTER 1-800-722-1111
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READ THIS FIRST !
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This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at
Customer Manual
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Summary of Contents for Tyco Electronics DT-3000

  • Page 1: Table Of Contents

    For latest revision and Regional Customer Service, All International Rights Reserved visit our website at TE logo and Tyco Electronics are trademarks. www.tycoelectronics.com LOC B *Trademark. Other products, logos, and company names used are the property of their respective owners.
  • Page 2 409-10042 DT-3000 Machines 1725100-[ ] and DT-5000 Machines 1725800-[ ] DANGER 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.

  • Page 3: Introduction

    . The machines are intended for use with (AMP) Tyco Electronics applicators, JAM (Toyojamco Ltd.) applicators, and JST (JST Manufacturing Company Ltd.) applicators as indicated in Figure 1. All of these machines are restricted to China.
  • Page 4 409-10042 DT-3000 Machines 1725100-[ ] and DT-5000 Machines 1725800-[ ] Denotes an imminent hazard which may result in moderate or severe injury. DANGER Denotes a condition which may result in product or equipment damage. CAUTION Highlights special or important information.

  • Page 5: Description

    409-10042 DT-3000 Machines 1725100-[ ] and DT-5000 Machines 1725800-[ ] 2. DESCRIPTION These machines were designed to be used as a stand–alone semi–automatic bench unit. It is assembled with metric hardware. A precision adjustment feature on the machine provides quick and accurate crimp height adjustments. The batch counter provides a count of the terminations.
  • Page 6 409-10042 DT-3000 Machines 1725100-[ ] and DT-5000 Machines 1725800-[ ] DC Motor Crankshaft Motor Access Cover Figure 4 Precision Crimp Height Adjustment Mechanism Base Plate for Machines Quick-Release -1 and -5 T-Handle Alternate Rear Stop Base Plate for Machines Mounting Position -2, -3, -6, and -7 Figure 5 (Cont’d)

  • Page 7: Electrical Description

    409-10042 DT-3000 Machines 1725100-[ ] and DT-5000 Machines 1725800-[ ] Base Plate for Machines -4 Swing Handle Figure 5 (End) 2.2. Electrical Description The electrical components of these machines consist of the operator control panel, the motor, and the CPU/motor controller package. The machine operates on 100/240 Vac, 50/60 Hz, single–phase current with ground.

  • Page 8: Receiving Inspection And Installation

    409-10042 DT-3000 Machines 1725100-[ ] and DT-5000 Machines 1725800-[ ] Reel Support Hole Hole for Customer Supplied Lift Ring DC Motor Motor Access Cover Back Cover Terminal Strip Guide CPU/Motor Controller (Behind Back Cover) Power Switch/Circuit Breaker Figure 7 3. RECEIVING INSPECTION AND INSTALLATION 3.1.

  • Page 9: Considerations Affecting The Placement Of Bench Machines

    409-10042 DT-3000 Machines 1725100-[ ] and DT-5000 Machines 1725800-[ ] Insert the reel support post into the appropriate hole on top of the machine (Figure 7) until the roll pin engages a groove in the machine frame. 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.

  • Page 10: Operation

    409-10042 DT-3000 Machines 1725100-[ ] and DT-5000 Machines 1725800-[ ] The preferred foot switch location varies to some extent among operators. Some operators prefer the switch located so that their foot rests on the switch when their feet are in the natural sitting position (calf of leg perpendicular to the foot).

  • Page 11: Setup

    409-10042 DT-3000 Machines 1725100-[ ] and DT-5000 Machines 1725800-[ ] 2. Place the applicator on the quick–change base plate, then slide it back until the two notches in the applicator base engage the stops at the back of the quick–change base plate. At the same time, guide the ram post into the ram post adapter.
  • Page 12 409-10042 DT-3000 Machines 1725100-[ ] and DT-5000 Machines 1725800-[ ] released in mid–cycle and pressed again, the crankshaft will continue to rotate in the forward direction at the default reduced speed. If the machine does not complete the cycle, either adjust the speed control knob (as described below), or complete the cycle using the footswitch (at a speed determined by the speed control knob) after the Jog button has been pressed and released.
  • Page 13 409-10042 DT-3000 Machines 1725100-[ ] and DT-5000 Machines 1725800-[ ] Jog Button Icon Jog Button Speed Control Knob Green Indicator Machine Ready Icon Fault Icon Speed Control Icon Batch Counter The yellow and green indicators on the top of the control panel indicate the machine status.

  • Page 14: End-Feed/Side-Feed Applicator Conversion

    409-10042 DT-3000 Machines 1725100-[ ] and DT-5000 Machines 1725800-[ ] Adjusting the Speed Control Knob The default speed of the crankshaft in the Jog Mode is set to a minimum initial value which is not defined by the initial position of the speed control knob. Adjusting the speed upwards enables jogging at speeds greater than the default in case greater speeds are required to complete a cycle.

  • Page 15: Preventive Maintenance

    409-10042 DT-3000 Machines 1725100-[ ] and DT-5000 Machines 1725800-[ ] 5. PREVENTIVE MAINTENANCE Preventive maintenance will keep the machine in good working order and ensure maximum reliability and service from all of its components. DANGER To avoid personal injury, electrical and pneumatic power must be DISCONNECTED at the source prior to maintenance.

  • Page 16: Adjustments

    409-10042 DT-3000 Machines 1725100-[ ] and DT-5000 Machines 1725800-[ ] Precision Crimp Height Adjustment Mechanism Lubrication Points Lubrication Points Figure 11 6. ADJUSTMENTS The following adjustments are necessary to maintain the machine in operating condition, and to set up the machine after replacing parts.

  • Page 17: Crimp Height Adjustment Using Precision Adjustment Mechanism

    409-10042 DT-3000 Machines 1725100-[ ] and DT-5000 Machines 1725800-[ ] NOTE The miniature applicator is an integrated assembly consisting of upper tooling, lower tooling, and adjustment capability. The applicator requires a fixed shut height; that is, the distance between the bottom of the ram and the base mount when the ram is FULLY bottomed.

  • Page 18: Conversion Adapter Kits 1725156-[ ]

    409-10042 DT-3000 Machines 1725100-[ ] and DT-5000 Machines 1725800-[ ] Adjustment Lever Reading (+" above 0.00 mm [.000 in.] setting) Read Full Step Read Half Step Read Full Step 0.051 mm 0.064 mm .051mm [.002 in.] [.0025 in.] [.002 in.]...

  • Page 19: Lubricator Bowl Assembly 354550-3

    409-10042 DT-3000 Machines 1725100-[ ] and DT-5000 Machines 1725800-[ ] 7.2. Lubricator Bowl Assembly 354550-3 (Figure 13) The lubricator bowl is used to apply a small amount of lubricant to terminals to prevent them from jamming in the machine after the crimping process.
  • Page 20 409-10042 DT-3000 Machines 1725100-[ ] and DT-5000 Machines 1725800-[ ] Bolt Securing Sheet Metal Guard Rear Controller Panel Mounting Bolts Air Feed Cable Assembly Detail See Detail Insert Small End of Air Feed Cable Assembly Into J7 Socket Figure 14...
  • Page 21 409-10042 DT-3000 Machines 1725100-[ ] and DT-5000 Machines 1725800-[ ] 7. Prepare the base plate for Air Feed Kit 1424266–1 (for Machines –2 and –3) as follows: install the socket head screw and rear stop to the base plate, then remove the back left base plate clamp. Refer to Figure 15.

  • Page 22: Troubleshooting

    409-10042 DT-3000 Machines 1725100-[ ] and DT-5000 Machines 1725800-[ ] 10. Turn the air “on” by moving the slide valve toward the filter. See Figure 16. away NOTE The air can be turned off "by moving the slide valve from the filter.

This manual is also suitable for:

Dt-5000

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