AMP* Horizontal Terminating Machine
Model 4, No. 469181–[ ] and No. 463734–[ ]
Including CM 5388–2, Rev D, Optional Wire
Stuffer Assembly No. 469853–1 & –2
CM 5388
01 MAY 90 Rev O
CM 5388
Rev D
AMP* HORIZONTAL TERMINATING
MACHINE MODEL 4, NO. 469181–[ ]
and NO. 463734–[ ] INCLUDING
CM 5388–2, Rev D
OPTIONAL WIRE STUFFER
ASSEMBLY NO. 469853–1 & –2
5/90
Also available — CM 5388–1 (Spanish translation)
customer
manual
AMP INCORPORATED
Harrisburg, PA 17105
This AMP controlled document is subject to change. For latest revision, contact
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.
E
Prepared by
Technical Publications,
AMP Incorporated
ii
CM 5388, Rev D
NOTE:
Typical Machine Without Wire Stuffer
Frontispiece.
CM 5388, Rev D
AMP Horizontal Terminating Machine Model 4
iii
DANGER
SAFETY PRECAUTIONS PREVENT INJURY
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CUSTOMER HOTLINE
MACHINE/PRODUCT SERVICE
CALL TOLL FREE 1 800 722-1111
(CONTINENTAL UNITED STATES AND PUERTO RICO ONLY)
INFORMATION REQUIRED
GENERAL
MACHINE POLICY
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CM 5388, Rev D
RECEIVING INSPECTION AND INSTALLATION
A.
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.
1.
Carefully
uncrate
the
machine,
and
place
it
on
a
sturdy
bench
or
table
where
both
illumination and height will permit a careful examination.
2.
If
Thoroughly inspect the entire machine for evidence of damage that may have occurred in transit.
the
machine
is
damaged
in
any
way,
file
a
claim
against
the
carrier
and
notify
AMP
Incorporated immediately.
3. Check all components and parts to be certain they are secure.
4.
Check
all
wiring
(if
applicable)
for
loose
connections,
cuts,
or
other
possible
causes
of
electrical short circuits.
5.
Inspect all pneumatic lines (if applicable) for evidence of loose connections and cuts that may
cause leakage.
Keep
NOTE
this
manual
with
the
machine
for
the
benefit
of
personnel
responsible for installation, operation, and maintenance. In addition, be
sure to keep any other documents or samples with the machine.
B.
Factors Affecting Machine Placement
The
of
be
location
both
of
safety
reduced,
the
and
and
machine
maximum
greater
in
relation
efficiency.
efficiency
to
the
operator's
Studies
achieved
if:
have
(A)
position
repeatedly
the
bench
is
is
extremely
shown
of
that
important
operator
appropriate
height,
in
terms
fatigue
will
preferably
with sound-deadening rubber mounts; (B) the machine is properly located on the bench with ample work
areas on both sides to facilitate work flow; (C) the operator uses a swivel chair with padded seat and back
rest which are independently adjustable; and (D) the foot switch (or foot valve), on machines so equipped, is
placed
on
a
rubber
mat
to
maintain
its
movability,
while
preventing
it
from
sliding
unintentionally.
Ċ
Bench
A sturdy bench 28 to 30 in. high aids comfort by allowing the operator's feet to rest on the floor and the
weight and leg position to be easily shifted. The bench should have rubber mounts to reduce noise. An open
area under the bench should allow the chair to slide far enough in for the operator's back to be straight and
supported by the chair's back rest.
CM 5388, Rev D
v
Ċ
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 elimiĆ
nates unnecessary operator motion and helps prevent back strain and fatigue. The target area should face
the front of the bench and be parallel to the edge. (Access to the back of the machine must also be proĆ
vided.)
NOTE
Ċ
Some machines have provisions for being bolted to the bench, and must
be secured in order to remain stationary.
Operator's Chair
The operator's chair should swivel, and should have independent seat height and back rest
adjustments. The seat and back rest should be padded, and the back rest should be large enough to proĆ
vide support both above and below the waist line.
In use, the chair should be far enough under the bench so the operator's back is straight and
supported by the back rest.
Ċ
Foot Switch
When the operator is correctly positioned in front of a machine equipped with a foot switch, the foot should
rest on the switch comfortably, and with ease. The foot switch should be movable, so that its location can be
readily changed when the operator shifts position to minimize fatigue. Placing the switch on a rubber mat
keeps it movable while preventing unintentional sliding.
The preferred foot switch location varies to some extent among operators. Some operators like 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 floor). Others prefer that it be slightly in front of the natural position. The important thing
to remember is that the foot should be at approximately 90_ (right angle) to the calf when resting on the
switch. Those who prefer the foot switch slightly in front of the natural position may require a wedgeshaped block placed in under it.
DANGER
DO NOT connect electrical or pneumatic power to the machine until
called for in the setup procedure, Section 3.
GOOD
ÅÅ
Å
ÅÅ
Å
Applied
Product
The Figure shows the physical considerations as
recommended, and the operator in a desirable
position. Note that the chair height and backrest are properly adjusted, and that the chair is
properly located in respect to the bench. Thus, the
operator's back is straight, and supported by the
chair. Note also that the operator's upper arms are
in a direct line with the torso.
The plan view identifies typical locations for
supply" and applied product", and serves as an
aid in visualizing the convenience in materials hanĆ
dling afforded by proper setup and correct operator
position.
Supply
vi
CM 5388, Rev D
C.
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. If more convenient for the operator, and beneficial to production, the machine can be tilted at a
30
_ angle by mounting it on an inclined plane.
D.
Electrical Requirements
The machine requires a 115 Vac, 60 Hz, single-phase, 5 A power source. Machines are also available for
230 Vac, 50 Hz current. The line should be well-regulated so the voltage does not drop excessively under
additional line loads. If the electrical receptacle being used does not have a ground connector, connect the
frame of the machine to a suitable metallic ground point.
E.
Air Requirements
The operating air pressure must be 90 to 110 psi. The supply should have a minimum volume of 3 cfm with
sufficient
reserve
and
quick
recovery
so
that
the
pressure
does
not
fall
below
90
psi
when
additional equipment is operated.
CM 5388, Rev D
vii
CONTENTS
RECEIVING INSPECTION AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
v
A.
Receiving Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B.
Factors Affecting Machine Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C.
Machine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
vii
D.
Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
vii
E.
Air Requirements
vii
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
v
v
1.
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2.
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
3.
2.1.
Major Groups and Subassemblies
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
2.2.
Switches and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
2.3.
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
MACHINE SETUP PROCEDURES
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
3.1.
Manual Cycling Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
3.2.
Preloading Alignment Check
9
3.3.
Terminal Strip Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.4.
Machine Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.5.
Termination Inspection
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.
MACHINE PRODUCTION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.
7.
8.
5.1.
Crimp Height Adjustment
5.2.
Feed Adjustments
5.3.
Adjustment of Ram Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.1.
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.2.
Inspection
6.3.
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REPAIR AND/OR REPLACEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.1.
Shear Blade and/or Crimper Replacement
7.2.
Anvil, Anvil Holder, or Wire Positioner Replacement
7.3.
Feed Finger Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.4.
Pneumatic System Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.5.
Electrical System Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
21
PARTS LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SUPPLEMENT
viii
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Wire Stuffer Assembly, CM 5388-2, Rev D
CM 5388, Rev D
ILLUSTRATIONS
Frontispiece
AMP Horizontal Terminating Machine Model 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
1-1
Terminals Used with the AMP Horizontal Terminating Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2-1
Machine Switches and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-2
Machine Pneumatic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2-3
Machine Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-1
Tooling Alignment Check Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-2
Feed Plate elements for Terminal Strip Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-3
Wire Placement in Target Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-4
Crimped AMPLIVAR* Splice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-5
Crimp Height Comparator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3-6
Crimp Height Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5-1
Crimp Height Fine Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-2
Crimp Height Adjustment Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-3
Feed Adjustment Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7-1
Tooling Chart for the Horizontal Terminating Machine, No. 469181-[ ] . . . . . . . . . . . . . . . . . . . . . 22
7-2
Tooling Chart for the Horizontal Terminating Machine, No. 463734-[ ] . . . . . . . . . . . . . . . . . . . . . 23
8-1
Exploded View, Horizontal Terminating Machine Model 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8-2
Exploded View, Machine Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8-3
Exploded View, Valve Mounting Plate Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8-4
Electrical System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
CM 5388, Rev D
ix
x
CM 5388, Rev D
1.
INTRODUCTION
This manual provides information concerning the setup, operation, and maintenance of the AMP
Horizontal Terminating Machine (see Frontispiece). This machine applies AMPLIVAR pigtail splices to
unstripped magnet wire and prestripped wires of other types. Serrations in the splices cut through the magĆ
net wire insulation to make electrical contact. This eliminates a time-consuming stripping
operation. Splices are applied with uniformly high mechanical strength and electrical conductivity, at highvolume production rates.
The Horizontal Terminating Machine weighs approximately 146 lbs, and requires a power source of 115
Vac, 3 A, 60 Hz, or 230 Vac, 1.5 A, 50 Hz, depending on the model of the machine. A minimum of 90 to 100
psi air pressure is also required for the machine.
A wire stuffer assembly can be used with this machine to eliminate the need to change the crimp height
adjustment if there is a change in the combined CMA (circular mil area) of the wires to be crimped. A suppleĆ
ment in the back of this manual gives detailed information for the wire stuffer assembly.
Figure 1-1 is a table which provides a listing of machines, the AMPLIVAR splice, and its crimp width.
The eight sections of this manual are arranged in an order convenient for setup and maintenance
personnel. Setup personnel should follow carefully the procedures in Section 3, as any attempt to
operate the machine without proper setup and checkout could result in damage and unnecessary
downtime.
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 diagnosĆ
ing cycling problems, and in Section 5 for making adjustments. For information beyond the scope of this
manual contact your local AMP Field Engineer, or
AMP Incorporated
Field Engineering
P.O. Box 3608
Harrisburg, PA 17105-3608
Phone: (717) 564-0100
When reading this manual, pay particular attention to DANGER, CAUTION, and NOTE statements. A DANĆ
GER denotes an imminent hazard which may result in moderate or severe injury, a CAUTION denotes a
condition which may result in product or equipment damage, and a NOTE highlights special or
important information.
2.
DESCRIPTION
The AMP Horizontal Terminating Machine is basically rectangular in appearance Ċ approximately 23 in.
long, 27 in. wide, and 11 in. deep. The machine performs three functions: automatic feeding of
terminals; application (crimping) of terminals; and trimming of scrap wire. The appearance of the
machine differs greatly from the standard bench-type machine, mainly because its primary (crimping)
motion occurs on a horizontal plane, and not vertically as in other machines.
The crimp tooling is nearly flush with the front surface of the machine, allowing the wire to be held close to
the tooling for splicing ease when using very short leads.
The operator places the wires in the target area" with the magnet wire in the barrel of the terminal, then
depresses the foot switch. the machine automatically shears the splice (terminal) from the strip, crimps the
splice onto the wires, shears off the excess wire and advances the next terminal into the crimping position.
The machine's electrical circuit design prevents double tripping. This means that the foot switch cannot be
actuated while the cycle is in progress, and that the amount of time the foot switch is depressed is not critiĆ
cal. For a detailed functional description of the machine, refer to Paragraph 2.3.
CM 5388, Rev D
1
MACHINES WITH BASE NUMBER 469181
MACHINE NUMBER
(A)
(B)
115 VAC
115 VAC
60 HZ
60 HZ
DD 469181-4
DD
-6
-8
D
D
D
469181-5
230 VAC
50 HZ
62000
42777
42778
62157
2-
-6
62040
42775
42776
62158
-9
2-
-8
62001
42779
61849
.140
62001
42779
61849
.180
62203
62303
62304
62305
62200
.110
62000
42777
42778
62306
62307
62204
62040
42775
42776
-0
ĊĊ
1-
-1
ĊĊ
1-
-3
D1-469181-5
1-
-5
D 1-
2-469181-4
CRIMP
WIDTH
(IN.)
TERMINAL NUMBER
-7
1-
ĊĊ
-6
D 1-
AMPLIVAR SPLICE
-8
3-469181-0
3-
-1
3-
-3
3-
-5
.110
.110
.080
62157
.110
62158
1-
-7
62308
62346
.140
1-
-9
ĊĊ
ĊĊ
62308
62346
.180
2-
-0
ĊĊ
ĊĊ
62207
62210
.110
2-
-2
ĊĊ
ĊĊ
62342
.110
3-
-7
ĊĊ
ĊĊ
62201
.140
4-
-0
ĊĊ
ĊĊ
62670
4-
-1
ĊĊ
ĊĊ
62306
62307
62204
62040
42775
42776
.100
.140
62158
MACHINES WITH BASE NUMBER 463734
MACHINE NUMBER
(A)
(B)
115 VAC
115 VAC
60 HZ
60 HZ
230 VAC
50 HZ
CRIMP
WIDTH
(IN.)
TERMINAL NUMBER
ĊĊ
1-463734-4
62002
-4
ĊĊ
1-
-6
62202
.180
-6
ĊĊ
1-
-8
62335
.220
-7
ĊĊ
1-
-9
62295
-8
ĊĊ
2-
-0
62309
62451
.180
2-
-2
62310
62770
.180
.220
463734-2
D
AMPLIVAR SPLICE
D1-463734-1
61850
42780
.180
.250
1-
-0
1-
-2
ĊĊ
ĊĊ
62310
62770
2-
-6
ĊĊ
ĊĊ
62309
62451
2-
-9
ĊĊ
ĊĊ
62002
61850
.220
.220
42780
THE MACHINE NUMBERS IN COLUMN (B) HAVE BEEN SUPERSEDED BY THE RESPECTIVE MACHINE
NUMBERS IN COLUMN (A).
DD
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.
Fig. 1-1.
2
Terminals Used with the AMP Horizontal Terminating Machine
CM 5388, Rev D
The very large number of wire combinations that can be joined with AMPLIVAR splices makes some tooling
changes necessary. Design features, however, do minimize the number of required changes, and only two
different feed plates are needed for the entire range of splices. Two or three wires may be joined in one
splice.
The wire stuffer assembly is covered separately in the supplement at the back of this manual. The stuffer
assembly is also available in kit form for field installation.
2.1. Major Groups and Subassemblies
The four major groups or subassemblies of the machine are the feed plate group, the crimp tooling group,
the ram group, and the valve mounting plate subassembly. These groups are shown in the
exploded views (Figure 8-1 through 8-3), and are described in subsequent paragraphs.
A.
Feed Plate Group (Figure 8-1)
The feed plate (49) contains a groove that guides the terminal strip to the target area." Two feed plates
are available to accommodate the full range of terminals. The feed finger (43), driven by the air feed
cylinder (33), advances the terminal strip one position with each cycle of the machine. The terminal
strip drag (26) prevents the strip from being pulled back as the feed finger retracts to pick up the next
feed point in the strip.
B.
Crimp Tooling Group (Figure 8-1)
The crimper adjustment block (8) is attached to the machine ram with three screws (11) through elonĆ
gated holes, allowing for adjustment by means of the crimper adjustment screw (10). Two
compression springs (9), placed in the grooves of the crimper adjustment block, apply pressure
toward the ram when the three screws are loosened, to keep the crimper adjustment screw against the
ram during adjustment.
The crimper guide (7), shear blade (6), and crimper (5) form the shear and crimp assembly. The
crimper guide is attached to the crimper adjustment block with four screws. The crimper and shear
blade are attached to the adjustment block with two screws.
The top of the crimper and the top of the shear blade should be FLUSH with the top of the crimper
guide and against the adjustment block to assure proper alignment with the anvil (16) and the anvil
holder (17).
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. The crimper guide is engaged with the anvil holder at all times and
eliminates crimper-anvil adjustment in ONE DIRECTION.
The crimper adjustment screw (10) provides a full range of crimp height adjustment for each
terminal. Turning the crimper adjustment screw in either direction from flat-to-flat (1/8 turn) changes
the crimp height approximately .004 in. For the convenience of the operator, the flats are numerically
identified from one to eight.
When the ram advances, the shear blade trims the scrap wire and at the same time shears the terminal
from the strip. As the ram retracts, the stripper plate strips the crimped terminal from the crimper. An air
blast tube is attached to the stripper plate, and as the ram reaches the fully
retracted position, a preset blast of air is directed at the anvil to clear scrap wire and tab chips from the
target area." When the ram is fully retracted, the cycle is complete.
C.
Ram Group (Figure 8-2)
The ram group provides the force to the crimper for crimping the terminals. The main
components of this group are the machine frame (11), main air cylinder (33), link (24), ram bellcrank
(26), and the ram (19). When the main air cylinder is fully retracted, the ram is
also fully retracted by the linkage which connects the two components. Refer to Paragraph 3.3C for
further details on checking the ram stroke.
CM 5388, Rev D
3
D.
Valve Mounting Plate Subassembly (Figure 8-3)
The main components of this subassembly are the base frame (1), main solenoid valve (51), manifold
(13), air filter (19), pilot actuators (27), pressure sensitive switches (25), and the
feed solenoid valve (29). Refer to Paragraph 2.3 for a functional description of the valve
operation in relation to the air cylinders. 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.
Each is described in the following paragraphs:
POWER
SWITCH (S1)
FUSE HOLDER AND
FUSE (F1)
INDICATOR LAMP
(DS1)
FEED
SWITCH (S2)
RETRACT
SWITCH (S10)
SETUP
SWITCH (S11)
MANUAL RAM
ADVANCE CONTROL
Fig. 2-1.
A.
Machine Switches and Controls
Power Switch (S1)
The power switch controls the electrical power to the machine. It is operated by two pushbuttons, the
RUN pushbutton turns the machine on," the OFF pushbutton turns it off."
B.
Indicator Lamp (DS1)
The red indicator lamp is connected in series with the power switch and lights when the RUN
pushbutton is depressed and latched to indicate power is on" to the machine.
4
CM 5388, Rev D
C.
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.
D.
Feed Switch (S2)
The feed switch is operated by depressing the FEED pushbutton. The purpose of the switch is to
advance the terminal strip during setup as described in Section 3 and when making adjustments as
described in Section 5. When the pushbutton is depressed and released, with the power to the
machine on," it momentarily energizes the terminal feed solenoid valve (L2) to advance the
terminal strip one terminal length, and de-energizes the ram retract solenoid valve (L1).
E.
Retract Switch (S10)
The retract switch is operated by depressing the RETRACT pushbutton. This switch retracts the ram in
the event a jam should occur that prevents the ram from fully extending, or if pilot
actuated switch (S8) fails to close when the ram is fully extended.
F.
Setup Switch (S10)
The ON-OFF setup switch is used in conjunction with the manual ram advance control during setup
of the machine. During normal operation, the switch MUST be in the ON position. When placed in the
OFF position, it prevents the ram from retracting after becoming fully extended, by breaking the circuit
to the ram extended switch (S6).
G.
Manual Ram Advance Control
The manual ram advance control is located below the switch mounting plate. The purpose of
the control is to stop the ram operation at any point during extension stroke as may be
required during setup, described in Section 3, or when making adjustments as described in
Section 5. Using a screwdriver or 7/16-in. socket wrench, and completely closing the control
(CLOCKWISE), prevents the ram from extending when the foot switch (S3) is depressed. To
advance the ram with the setup switch (S11) in the OFF position, SLOWLY turn the control
COUNTERCLOCKWISE. The ram can be stopped at any point during the extension stroke by
completely closing the control (CLOCKWISE). With the ram fully extended, placing the setup switch in
the ON position will retract the ram to the rest position.
H.
Foot Switch (S3)
The foot switch may be placed at any location that is most convenient for the operator.
Depressing the foot switch enables the machine to complete one cycle of operation. The machine
cannot be cycled again until the foot switch is released. A cycle in progress must be completed before
another cycle can occur.
CM 5388, Rev D
5
2.3. Functional Description
-* )*6(5.47.32 .6 /*(036*6 6:.7(- 73 &440< 43:*5 73 7-* (327530
(.5(8.75< &2) 0.,-7 .2).(&735 0&14 2 7-* 67&2)'< (32).7.32 &.5 45*6685* .6 68440.*) 7-538,- 7-* +.07*5
1&2.+30) 7*51.2&0 +**) 630*23.) 9&09*
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7-538,- 7-* 5&1 5*75&(7 630*23.) 9&09* )**2*5,.=*) 73 7-* 5*75&(7.32 6.)* 3+ 7-* 5&1 (34*2 5&1 5*67 436.7.32
28480-1
# ! # !
!
$!
!
$
28494-1
$
%
17249-1
""
%
%
23054-1
#
!
16732-1
#
!
%
23851-1
!
""
# !
%
23054-1
#
23054-1
!
460838-1
#
16732-1
28496-1
#
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%
23134-1
!
25283-1
""
17357-1
23054-1
#
461439-1
!
26863-1
! %
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Fig. 2-2.
Machine Pneumatic Diagram
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*2*5,.=* 7-* 5&1 *;7*2) 630*23.) 9&09* -.6 ).9*576 &.5 45*6685* 7-538,- 7-* 9&09* 73 7-*
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-70
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Fig. 8-3.
30
Exploded View, Valve Mounting Plate Subassembly (Sheet 1 of 3)
CM 5388, Rev D
ITEM
NO.
AMP PART
NUMBER
DESCRIPTION
QTY
43
22293-3
.
ELBOW, Female, 1/8" NPT x 1/4" Tube
1
44
3- 21000-0
.
SCREW, Skt Hd Cap, 8-32 x .88" L
2
45
24892-1
.
ELBOW, Street, 45_, 1/8" NPT
1
46
22295-7
.
CONNECTOR, Male, 1/8" NPT x 1/4" Tube
1
47
26668-2
.
NIPPLE, Chase
3
48
24146-1
.
HOSE, Buna-N, 1/4" OD
24"
49
22620-1
.
TUBING, 1/4" OD
76"
50
22620-2
.
TUBING, 3/8" OD
35"
51
17249-1
.
VALVE, 115 Vac, AAA Double Solenoid
1
52
17249-2
.
VALVE, 230 Vac, AAA Double Solenoid
1
5- 21085-4
.
.
6
21086-7
.
O-RING, .50" ID x .62" OD
Ref
52A
53
O-RING, Repair
54
17250-1
.
SUBPLATE
1
55
5- 21000-6
.
SCREW, Skt Hd Cap, 10-24 x .88" L
4
56
21899-3
.
WASHER, Flat, 1/4" ID
5
57
3- 21002-0
.
SCREW, Btn Hd Cap, 10-32 x .88" L
4
58
27090-2
.
HOSE, 3/8" ID
39"
60
24892-3
.
ELBOW, Street, 45_, 3/8" NPT
1
61
22302-1
.
COUPLING, Female, 3/8" NPT
1
62
22304-6
.
NIPPLE, Hex, 3/8" x 1/4" NPT
2
63
23134-1
.
LUBRICATOR, Air Line
1
Fig. 8-3.
CM 5388, Rev D
Exploded View, Valve Mounting Plate Subassembly (Sheet 2 of 3)
31
E
50
37
22
26
25
36
27
H
G
28
46
34
24
H
49
23
35
33
61
15
21
62
45
42
39
E
34
38
20
M
19
31
33
6
48
40
18
K
63
5
J
D
17
30
50
G
47
L
41
D
44
38 29
31
43
16
13
33
14
32
55
51 52
3
47
M
58
53
6
12
58
6
N
P
18
6
11
18
11
5
54
5
56
57
60
7
8
9
1
2
X
4
Fig. 8-3.
32
Exploded View, Valve Mounting Plate Subassembly (Sheet 3 of 3)
CM 5388, Rev D
ITEM
NO.
AMP PART
NUMBER
EE
DESCRIPTION
EE
$" #(#$ )+015-
QTY
EE
" 15- 6
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