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TE AMP 3K/40 Customer's Manual

Manual is about: up 2268 kg crimp force

Summary of AMP 3K/40

  • Page 1

    Customer manual 1 of 23 © 2016 te connectivity ltd. Family of companies. 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. Product information 1-800-522-6752 ...

  • Page 2

    409-10204 rev g 2 of 23 safety precautions — avoid injury — read this first! 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 repa...

  • Page 3

    409-10204 rev g 3 of 23 figure 1 1. Introduction this manual contains information on operation, preventive maintenance, and adjustments of the amp 3k/40 and amp 5k/40 ce terminating machines pn 2161400-[ ] and pn 2161500-[ ] respectively. See figure 1. Descriptions in this manual pertain to the cont...

  • Page 4

    409-10204 rev g 4 of 23 when reading this manual, pay particular attention to danger, caution, 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. Note highlights special or imp...

  • Page 5

    409-10204 rev g 5 of 23 2. Description the amp 3k/40 and amp 5k/40 ce terminating machines were designed to be used as stand-alone semi- automatic bench units. They are assembled with metric hardware. Note measurements are in metric units [followed by u.S. Customary units in brackets] unless otherwi...

  • Page 6

    409-10204 rev g 6 of 23 figure 4 2. The crankshaft-ram group conveys the motor rotational force to the up-and-down action of the ram for driving the applicator during the crimping cycle. 3. The base plate provides the mounting surface on which the applicator is installed. The quick-release latching ...

  • Page 7

    409-10204 rev g 7 of 23 figure 5.

  • Page 8

    409-10204 rev g 8 of 23 2.2. Electrical description the pn 2161400-[ ] and pn 2161500-[ ] machine electrical components consist of the operator control panel, the motor, and the cpu/motor controller and safety circuit package. The machine operates on 100/240 vac, 50/60 hz, single-phase current with ...

  • Page 9

    409-10204 rev g 9 of 23 3.2. Installation remove all mounting bolts securing the machine to the shipping pallet. Install lift ring (see figure 7) on top of the machine. Note lift ring (m1220 eye bolt) is customer supplied. Caution install the lift ring carefully. A 19.05-mm [.75-in.] thread length e...

  • Page 10

    409-10204 rev g 10 of 23 3.3. Considerations affecting placement of bench machines (figure 8) the location of the machine in relation to the operator's position is extremely important in terms of both safety and maximum efficiency. Studies have repeatedly shown that operator fatigue will be reduced,...

  • Page 11

    409-10204 rev g 11 of 23 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. The foot switch should be movable, so that its location can be readily changed when the operator shifts position to minimi...

  • Page 12

    409-10204 rev g 12 of 23 figure 9 4. Set the crimp height and insulation crimp discs so that the letters and numbers on the applicator pad align with the front pad on the ram post adapter. 5. If the applicator is an air-feed type, make sure the front door cover is closed, then connect the airlines t...

  • Page 13

    409-10204 rev g 13 of 23 4.3. Setup install a miniature applicator and terminals according to paragraph 4.2. 1. Turn on the main power using the switch located on the front of the control panel. 2. Be sure the guard is closed. 3. Jog the machine (as described in paragraph 4.3.B.) through a complete ...

  • Page 14

    409-10204 rev g 14 of 23 4.5. Adjusting the motor speed the speed of the motor is adjusted using the decrease speed and increase speed buttons on the membrane keypad (see figure 9). The decrease and increase buttons are used to adjust the motor speed for full-cycle mode and for jog mode. The speed s...

  • Page 15

    409-10204 rev g 15 of 23 5.2. Lubrication the moving parts of the machine require regular lubrication to ensure reliable service and long life. The preferred greases are chevron ultra-duty ep nlgi 2, chevron ulti-plex ep nlgi 2, and caltex ultra-duty ep nlgi 2. Note contact te engineering for 2 nd c...

  • Page 16

    409-10204 rev g 16 of 23 6.1. Measuring the shut height the shut height is the distance between the bottom surface of the ram post adaptor and the top surface of the machine base plate as shown in figure 11. Note shut height gage pn 679655-2 (see the table in figure 11) is recommended for measuring ...

  • Page 17

    409-10204 rev g 17 of 23 2. If the shut height is incorrect, proceed as follows: a. Remove the two socket head cap screws which secure the ram post adaptor. Remove the ram post adaptor and shims. Change the shim thickness as required to adjust the shut height. Shims contain .051- mm [.002-in.] peel-...

  • Page 18

    409-10204 rev g 18 of 23 1. Adjust the manual precision adjustment lever to “0" by pulling the lever away from the pivot pin. Lock the lever in place by releasing it. 2. Install the applicator into the machine as described in paragraph 4.2. 3. Cycle the machine to crimp three sample terminations. Ch...

  • Page 19

    409-10204 rev g 19 of 23 the guard contains two slots into which the inserts can be placed: the rear slot places the insert close to the applicator; the front slot places the insert farther away from the applicator. The type of insert used determines which slot is to be used. An insert placed into t...

  • Page 20

    409-10204 rev g 20 of 23 8. Tighten gland nut "snugly" around wire. 9. Secure cover to the electrical control box with six m4 bolts. 10. For metric air line fittings, remove item 1. For english air line fittings, item 1 remains. 11. If the air feed applicator requires the optional base plate clamp: ...

  • Page 21

    409-10204 rev g 21 of 23 figure 16 8. Troubleshooting contact the support center at 1-800-522-6752. 8.1. Error codes see the table in figure 17 for a listing of error codes. Error code error description e001 the host is inhibiting operation. E002 the guard interlock is open. E003 the insert interloc...

  • Page 22

    409-10204 rev g 22 of 23 8.2. Diagnostics the control panel can be placed in a diagnostics mode to check operation of the machine inputs and to check the detected ac line voltage. To place the control panel in the diagnostics mode. 1. Press and release error reset to clear any error. 2. Press and ho...

  • Page 23

    409-10204 rev g 23 of 23 11. Replacement and repair replacement parts and recommended spares are identified and listed in drawings and documentation packages. To order replacement parts, call 1-800-522-6752, send a facsimile of your purchase order to 717-986-7605, or write to: customer service (038-...