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
* T rademark of AMP Incorporated
E
Copyright 1978, 1980, 1985, 1987, 1990 by AMP Incorporated. All International Rights Reserved.
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
AMP INCORPORATED
Harrisburg, PA 17105
5/90
customer
manual
Also available — CM 5388–1 (Spanish translation)
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.
CM 5388, Rev Dii
Prepared by
Technical Publications,
AMP Incorporated
iiiCM 5388, Rev D
Frontispiece. AMP Horizontal Terminating Machine Model 4
NOTE:
Typical Machine Without Wire Stuffer
CM 5388, Rev Div
CUSTOMER HOTLINE
MACHINE/PRODUCT SERVICE
CALL TOLL FREE 1 800 722-1111
(CONTINENTAL UNITED STATES AND PUERTO RICO ONLY)
GENERAL INFORMATION REQUIRED
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MACHINE POLICY
vCM 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. Thoroughly inspect the entire machine for evidence of damage that may have occurred in transit.
If 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.
NOTE
Keep 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 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, and greater efficiency achieved if: (A) the bench is of appropriate height, 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 Dvi
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
Some machines have provisions for being bolted to the bench, and must
be secured in order to remain stationary.
Ċ 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 wedge-
shaped 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.
Å
Å
ÅÅ
ÅÅ
Applied
Product
Supply
GOOD
The Figure shows the physical considerations as
recommended, and the operator in a desirable
position. Note that the chair height and back-
rest 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.
viiCM 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 Dviii
CONTENTS
RECEIVING INSPECTION AND INSTALLATION
v...............................................
A. Receiving Inspection v...............................................................
B. Factors Affecting Machine Placement v.................................................
C. Machine Installation vii...............................................................
D. Electrical Requirements vii............................................................
E. Air Requirements vii.................................................................
1. INTRODUCTION
1.......................................................................
2. DESCRIPTION
1.........................................................................
2.1. Major Groups and Subassemblies 3...................................................
2.2. Switches and Controls 4..............................................................
2.3. Functional Description 6..............................................................
3. 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.......................................................................
5.1. Crimp Height Adjustment 15..........................................................
5.2. Feed Adjustments 17................................................................
5.3. Adjustment of Ram Switches 19.......................................................
6. PREVENTIVE MAINTENANCE
20..........................................................
6.1. Cleaning 20.........................................................................
6.2. Inspection 20.......................................................................
6.3. Lubrication 20.......................................................................
7. REPAIR AND/OR REPLACEMENTS
21.....................................................
7.1. Shear Blade and/or Crimper Replacement 21...........................................
7.2. Anvil, Anvil Holder, or Wire Positioner Replacement 21...................................
7.3. Feed Finger Replacement 24..........................................................
7.4. Pneumatic System Repairs 24.........................................................
7.5. Electrical System Repairs 24..........................................................
8. PARTS LISTS
24.........................................................................
SUPPLEMENT
Wire Stuffer Assembly, CM 5388-2, Rev D
ixCM 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 Dx
CM 5388, Rev D 1
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 high-
volume 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.
2 CM 5388, Rev D
MACHINES WITH BASE NUMBER 469181
MACHINE NUMBER AMPLIVAR SPLICE
(A) (B)
115 VAC
60 HZ 115 VAC
60 HZ
230 VAC
50 HZ TERMINAL NUMBER CRIMP
WIDTH
(IN.)
62000 42777 42778 62157 .110469181-4 469181-5 2-469181-4
-6 -7 -62- 62040 42775 42776 62158 .110
-8 -9 -82- 62001 42779 61849 .140
-01- ĊĊ 62001 42779 61849
-11- 62203 62303 .080
-31- -13- 62304 62305 62200 .110
62000 42777 42778 62157
-51- -61- -33- 62306 62307 62204 .110
62040 42775 42776 62158
-71- -81- -53- 62308 62346 .140
-91- 62308 62346 .180
-02- 62207 62210 .110
-22- 62342 .110
-73- 62201 .140
-04- 62670 .100
-14- 62306 62307 62204 .140
62040 42775 42776 62158
DD
DD
D
D
D
ĊĊ
ĊĊ
ĊĊ
ĊĊ
ĊĊ
ĊĊ
ĊĊ
1-469181-5
D
D
D
ĊĊ
ĊĊ
ĊĊ
ĊĊ
ĊĊ
ĊĊ
ĊĊ
3-469181-0
.180
MACHINES WITH BASE NUMBER 463734
MACHINE NUMBER AMPLIVAR SPLICE
(A) (B)
115 VAC
60 HZ 115 VAC
60 HZ
230 VAC
50 HZ TERMINAL NUMBER CRIMP
WIDTH
(IN.)
62002 61850 42780 .180463734-2 1-463734-4
-4 -61- 62202 .180
-6 -81- 62335 .220
-7 ĊĊ 62295
-8 62309 62451 .180
-01- 62310 62770 .180
62310 62770
-62- 62309 62451 .220
62002 61850 42780
ĊĊ
1-463734-1
.250
-2
-9
1-
2-
D
ĊĊ
ĊĊ
ĊĊ
ĊĊ
ĊĊ
ĊĊ
ĊĊ
ĊĊ
ĊĊ
-91-
-02-
-22-
.220
.220
D
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. Terminals Used with the AMP Horizontal Terminating Machine
3
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.
4 CM 5388, Rev D
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:
Fig. 2-1. Machine Switches and Controls
INDICATOR LAMP
(DS1)
POWER
SWITCH (S1) FUSE HOLDER AND
FUSE (F1)
FEED
SWITCH (S2)
MANUAL RAM
ADVANCE CONTROL
SETUP
SWITCH (S11)
RETRACT
SWITCH (S10)
A. 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.
5
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.
6 CM 5388, Rev D
2.3. Functional Description
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7
CM 5388, Rev D
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8 CM 5388, Rev D
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" without cycling the
machine. This is accomplished by depressing and releasing the FEED pushbutton which closes" switch
(S2) to momentarily energize the terminal feed solenoid valve (L2). This will retract and extend the feed cylinĆ
der ONLY.
3. MACHINE SETUP PROCEDURES
This section contains procedures for setting up the machine and checking it out prior to performing producĆ
tion operation. This will assure that all alignments and adjustments are correct to produce
termination of the proper crimp height for the type of terminal and size wire being used. If procedures are not
carried out in detail, especially following the initial installation of the machine, damage may result to the
tooling. Also included in this section, to prevent duplication, is the manual cycling
procedure which is referred to throughout this manual.
3.1. Manual Cycling Procedure (Figure 2-1)
CAUTION
DO NOT perform this procedure, except when specified within another
procedure, then ONLY in the proper sequence. Otherwise, damage to the
tooling may result due to misalignment and/or adjustments.
1. COMPLETELY close the manual ram advance control by turning CLOCKWISE. DO NOT force the
control after it is closed. Use a 7/16-in. socket wrench or screwdriver to turn control.
2. Connect the electrical plug and air supply.
3. Depress the RUN pushbutton. The indicator lamp will light to indicate power is on."
DANGER
KEEP HANDS CLEAR of feed plate and target area" at all times.
4. Place setup switch (S11) in the OFF position, then depress the foot switch.
5. SLOWLY open the manual ram advance control by turning COUNTERCLOCKWISE. This will
allow the ram to advance slowly. DO NOT open the control more than 1/8 turn.
6. CLOSELY OBSERVE the shear and crimper assembly as it nears the anvil. If misalignment is
observed, IMMEDIATELY close the control by turning CLOCKWISE. Make necessary adjustments as
may be required before proceeding.
7. After ram has become fully extended, fully open manual ram advance control by turning COUNĆ
TERCLOCKWISE. Ram will remain fully extended under pressure.
8. To retract ram, place setup switch (S11) in the ON position. Machine will complete the cycle and
return to the standby condition.
9. Depress the OFF pushbutton, then disconnect the electrical plug and air supply.
9
CM 5388, Rev D
3.2. Preloading Alignment Check (Figure 3-1)
DANGER
BE SURE the electrical and air supply are disconnected before starting
this procedure.
1. Remove anvil guard (2) and ram guard (3) by removing screws (1) securing each to the machine
frame.
2. Remove the four screws (14) securing the anvil holder (17) to the frame.
3. Remove stripper plate (15) from anvil holder (17) and remove the anvil (16); then slide the anvil
holder back over the crimper guide and loosely install four screws (14) to the anvil holder.
Fig. 3-1. Tooling Alignment Check Points
FRAME ANVIL HOLDER
AND ANVIL
SHEAR BLADE
WIRE CRIMPER
CRIMPER GUIDE
RAM
3
1
2
TIGHTEN
SHEAR AND
CRIMPER ASSY
SCREWS IN
NUMERICAL
SEQUENCE
1
3
4
2
STRIPPER PLATE
1
3
4
2
TIGHTEN
ANVIL BODY
SCREWS IN
NUMERICAL
SEQUENCE
4. Slowly advance the ram by performing the manual cycling procedure as described in
Paragraph 3.1.
CAUTION
Be sure the anvil holder is not hitting the feed plate assembly (49). If
it is, loosen the feed plate assembly screws (20) and (21) and move the
feed plate away from the anvil holder.
5. With the ram extended, and while holding the anvil holder against the frame, slide the anvil in the
crimper opening to make sure the crimp height is not too tight. If it is, loosen screws (14) and adjust
screw (10) until clearance is achieved. Remove the anvil after clearance is achieved, place several
thicknesses of paper over the anvil, and center it in the crimper.
6. Tighten the four screws (14) to secure the anvil holder to the frame, and tighten the three screws
(1) in the stripper plate (15) to secure the stripper plate to the anvil holder. Refer to Figure 3-1 for
numerical sequence to tighten the screws.
7. Retract the ram by completing the manual cycling procedure as described in Paragraph 3.1.
8. Replace the anvil guard and ram guard on the machine.
10 CM 5388, Rev D
3.3. Terminal Strip Loading (Figure 3-2)
DANGER
MAKE SURE the electrical plug and air supply are disconnected.
1. 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.
2. 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.
3. Depress and hold feed finger release pin on front of feed plate while feeding terminal strip through
until first terminal has passed tip of feed finger, then release pin to engage feed finger. Pull back slightly
on terminal strip to assure feed finger is indexed against first terminal.
4. Rotate drag lever to allow drag to contact terminal strip.
Fig. 3-2. Feed Plate Elements for Terminal Strip Loading
FEED PLATE
DRAG
DRAG LEVER
FEED FINGER
FEED FINGER
RELEASE PIN
FEED
CYLINDER
11
CM 5388, Rev D
3.4. Machine Checkout
A. Terminal Strip Feed Check
1. With terminal strip loaded into machine, as described in Paragraph 3.3, depress and hold
feed finger release pin while checking drag on terminal strip. Drag must be adjusted so that a
slight pull is required to move the strip. If adjustment is required, refer to Section 5. After checking
the drag, reposition the first terminal ahead of the feed finger as described in
Paragraph 3.3.
2. Connect the electrical plug and air supply, then depress the RUN pushbutton. Red
indicator lamp will light.
3. Depress and release the FEED pushbutton. The terminal strip should advance one
terminal length.
4. Continue to depress and release the FEED pushbutton until the FIRST terminal is
centered on the anvil. If the terminal DOES NOT stop directly centered on the anvil, adjust feed as
described in Section 5.
5. At completion of this check, perform the ram cylinder/ram linkage check as described in
Paragraph 3.4,B.
B. Ram Cylinder/Ram Linkage Check
1. Remove reel support bracket (61, Figure 9-1) by removing four screws (54 and 55).
2. Remove machine cover (65) by removing screws (63) and washers (64).
DANGER
KEEP HANDS CLEAR of machine interior while performing this check.
3. Connect the electrical plug and air supply. Depress the RUN pushbutton, then the OFF pushĆ
button to assure the retraction side of the ram cylinder is pressurized.
4. Check clearance between top of ram bellcrank (26, Figure 8-2) and machine frame (11).
Clearance must be .005 in. or more with ram cylinder fully retracted under pressure. If
necessary, adjust by loosening locknut on cylinder shaft, then turn shaft in bellcrank clevis (27) in
the required direction until clearance is within range. Tighten locknut after making adjustment.
5. 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.
6. Manually cycle machine until ram is fully extended, as described in Paragraph 3.1.
7. Check ram extended switch (S6), on ram return switch bracket (5), to be actuated closed"
by bellcrank. If necessary, adjust switch as described in Section 5.
8. Continue to manually cycle machine to return it to the rest position.
9. Replace machine cover and reel support bracket.
10. Perform manual crimping check as described in Paragraph 3.4,C.
12 CM 5388, Rev D
C. Manual Crimping Check
1. With the electrical plug and air supply connected, depress the RUN pushbutton.
2. With a terminal in the target area," place a combination of stranded wire and magnet wire in
position, as shown in Figure 3-3, with the magnet wire toward the terminal (front).
3. Manually cycle the machine as described in Paragraph 3.1. Observe the ram
advancement and the shearing and crimping of the terminal in the target."
4. After the ram has fully retracted, remove the terminal and inspect it in accordance with ParaĆ
graph 3.4. If necessary, make any adjustments that may be required as described in Section 5.
5. At completion of this check, perform automatic crimping check as described in
Paragraph 3.4,D.
D. Automatic Crimping Check
Fig. 3-3. Wire Placement in Target Area
NOTE:
RIGHT SIDE VIEW
TERMINAL STRIP
LEAD TERMINAL
STRANDED WIRE
MAGNET WIRE
IN BOTTOM
OF TERMINAL
13
CM 5388, Rev D
The automatic crimping check is performed in the same manner as the manual crimping
check described in Paragraph 3.4,C except that the manual ram advance control must be fully open,
the RUN pushbutton depressed, and the foot switch depressed to cycle the machine.
Terminations 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.
If the terminations obtained from the manual cycling check and the automatic crimping check
conform to all requirements, the machine is ready for production operation as described in
Section 4. If machine is not to be operated immediately, depress the OFF pushbutton, then
disconnect the electrical plug and air supply.
3.5. Termination Inspection
All terminations produced by the machine must conform for quality and crimp height as follows:
1. Inspect the termination for conformance to the requirements set forth in Figure 3-4.
Fig. 3-4. Crimped AMPLIVAR Splice
2
1 5
4
3
1. This area must be bellmouth in shape.
2. The sheared end must be cleanly cut off.
3. The wires must extend through the crimped splice.
4. The magnet wire must lie in the bottom of the splice.
5. When two magnet wires are used, they should lie side by side.
14 CM 5388, Rev D
2. Using a crimp height comparator as shown in Figure 3-5, measure the crimp height of
the termination as shown in 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.
Fig. 3-5. Crimp Height Comparator
Fig. 3-6. Crimp Height Measurement
ANVIL BLADE
SPINDLE
ANVIL
BLADE
SPINDLE
FLAT
PORTION
AMPLIVAR
PIGTAIL
SPLICE
SPLICE
CROSS-
SECTION
AMP Incorporated does not sell crimp height comparators. Please send order for part number
RS-1019-5L directly to:
York Machinery & Supply Co. VALCO
20 North Penn Street OR P.O. Box 1413
York, PA 17401 634 Stefko Boulevard
Bethlehem, PA 18017
15
CM 5388, Rev D
4. 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:
1. Connect the machine to the adequate air supply.
2. Plug the electrical plug into the convenient electrical outlet.
DANGER
Be sure all guards and covers are in place. Never operate the machine
without a terminal over the anvil and wires in the target area."
3. Depress the RUN pushbutton. The red indicator lamp will light.
NOTE
Personnel who have not previously operated the machine should
manually cycle it several times, as described in Paragraph 3.1, while
observing the operation and travel of the feed finger and ram before
proceeding.
4. Place wires in the target area" in line with the terminal as shown in Figure 3-3. When using magĆ
net wire with a stranded wire, position them as shown. When splicing two magnet wires, they may be in
any position with respect to each other. The crimp tooling will automatically position them side by side
in the bottom of the terminal as crimping occurs.
5. With the wires in position, depress the foot switch. The machine will cycle only once,
regardless of how long the foot switch is held down.
6. At periodic intervals during production operation, perform termination inspection described in
Paragraph 3.5.
7. At completion of production operation, depress the OFF pushbutton. Disconnect the
electrical plug and air supply.
5. ADJUSTMENTS
The following procedures may be necessary when adjusting the machine, during production operation, or
following the replacement of parts.
5.1. Crimp Height Adjustment
CAUTION
Do not attempt adjustment of crimp height until after performing preloadĆ
ing alignment check described in Section 3.
1. Determine if the crimp height is to be GREATER or SMALLER as described in the termination
inspection in Section 3.
NOTE
If the machine is equipped with an adjustment knob on the right side and
the machine has not been disassembled for the replacement of tooling,
perform Step 2. Otherwise, continue with Step 3.
16 CM 5388, Rev D
2. 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" and continue with Step 3.
Fig. 5-1. Crimp Height Fine Adjustment
MACHINE FRAME
(Right Side)
GREASE
FITTING
CRIMP HEIGHT
ADJUSTMENT KNOB
3. Remove the anvil guard and the ram guard by removing the screws.
4. Remove the terminal strip from the target area" by releasing the drag, using the drag lever.
Depress and hold the feed finger release pin while pulling back on the strip until clear.
5. Place a double thickness of paper over the anvil.
6. SLOWLY extend the ram by manually cycling the machine as described in Section 3.
7. With the ram fully extended, loosen the three screws securing the crimper adjustment block to
the ram and loosen the locking setscrew. Refer to Figure 5-2.
Fig. 5-2. Crimp Height Adjustment Points
ANVIL HOLDER
CRIMPER
ANVIL
RETAINER AND
STRIPPER PLATE AIR BLAST TUBE
CRIMPER
ADJUSTMENT
SCREW
CRIMPER
ADJUSTMENT
BLOCK
LOCKING
SETSCREW
CRIMPER SCREW (Typ 3 Places)
CRIMPER GUIDE
SHEAR BLADE
NOTE:
1. EIGHT FLATS ON CRIMPER ADJUSTMENT
SCREW Ċ FLAT-TO-FLAT (1/8 Turn)
APPROX .004 IN. CHANGE IN CRIMP HEIGHT.
2. TOPSURFACESOFCRIMPER,CRIMPERGUIDE,
SHEAR BLADE, AND CRIMPER ADJUSTMENT
BLOCK MUST BE FLUSH.
17
CM 5388, Rev D
8. To increase crimp height, turn the screw into the crimper adjustment block by turning the wrench
up. To decrease the crimp height, turn the crimper adjustment screw out by turning the wrench down.
A flat-to-flat turn (1/8 turn, or turn to the next consecutive number) will change crimp height approxiĆ
mately .004 in. Turn crimper adjustment screw the necessary turns to
produce a change in crimp height as determined in Step 1.
9. Tighten the three screws securing the crimper adjustment block to the ram and tighten the lockĆ
ing setscrew on the top of the block.
10. Continue to manually cycle the machine to retract the ram to standby position, then remove
paper.
11. Load the terminal strip into the machine as described in Section 3.
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.
13. Replace the anvil guard and the ram guard.
5.2. Feed Adjustments (Figure 5-3)
A. Feed Finger Positioning
1. If necessary, load machine with terminal strip as described in Paragraph 3.3.
2. Connect electrical plug and air supply, then depress the RUN pushbutton.
3. Repeatedly depress and release the FEED pushbutton to advance the lead terminal into the
target area" and centered on the anvil.
4. Determine if terminal strip is being over-fed or under-fed by the feed finger.
5. To adjust, loosen locknut on feed cylinder shaft, then turn feed cylinder adapter IN or OUT as
required to center terminal on anvil. While making adjustment, pull back on terminal strip to hold
feed point against feed finger.
6. At completion of adjustment, tighten locknut to secure cylinder shaft in feed cylinder adapter.
7. Check flow control valve adjustment as described in Paragraph 5.2,B.
B. Flow Control Valve
The flow control valve, located on the retraction side of the feed cylinder, should be adjusted in such a
manner as to slow the feed finger advancement and prevent it from slamming" at the end of stroke.
This also prevents over-feeding.
To adjust the speed, turn the valve adjustment IN to slow the cylinder action, turn it OUT for faster
action.
NOTE
It is not necessary for the speed to be fast. Normally, the operator cannot
remove a completed termination and insert wires for the next termination
before another terminal is in position.
18 CM 5388, Rev D
Fig. 5-3. Feed Adjustment Points
DRAG
DRAG LEVER
FEED FINGER
FEED FINGER
RELEASE PIN
FEED
CYLINDER
DRAG
SETSCREW
SHOULDER
SCREWS
FEED PLATE
FEED
CYLINDER
ADAPTER
LOCKNUT
FLOW CONTROL VALVE
VALVE ADJUSTMENT
C. Terminal 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. If necessary, adjust as follows:
1. Loosen the locknut on the drag setscrew. With the drag lever released, turn the setscrew as
required until the drag rests evenly on the terminal strip.
2. While holding the setscrew in the adjusted position, tighten the locknut.
3. Rotate the drag lever to lift the drag from the terminal strip. The drag should pivot on the setĆ
screw.
19
CM 5388, Rev D
5.3. Adjustment of Ram Switches (Figure 8-2)
The ram rest switch (S5) and the ram extended switch (S6) MUST BE properly adjusted for the
machine to start and/or complete a cycle of operation. To avoid switch breakage, it is necessary for the ram
cylinder to be under pressure in its respective direction in relation to the switch when the switches are
adjusted. Adjust switches as follows after removing the machine cover.
A. Ram Rest Switch (S5)
1. Connect electrical plug and air supply, then depress the RUN pushbutton. Main air (ram) cylĆ
inder (33) must be fully retracted under pressure.
2. Check that switch is actuated open." To perform this check, manually actuate the ram
extended switch (S6) closed." If this energizes the terminal feed solenoid valve (LS), the ram
rest switch must be adjusted.
3. To adjust, loosen nut (12); then turn setscrew (13) IN 1/4 turn at a time while repeating Step 2
until switch is open."
4. Tighten nut to secure setscrew.
5. Check ram extended switch (S6) as described in Paragraph 5.3,B.
B. Ram Extended Switch (S6)
1. Manually cycle machine to extend ram cylinder under pressure, as described in
Paragraph 3.1.
2. With ram cylinder fully extended, the ram extended switch (S6) must be actuated closed."
This will complete the circuit, through the ram rest switch (S5), to energize the feed solenoid valve
(L2). If not, switch must be adjusted.
3. To adjust, slightly loosen screws (3) securing the ram return switch bracket (5); then move
bottom of bracket forward until switch is actuated closed."
4. Tighten screws to secure bracket in the adjusted position.
5. Continue to manually cycle machine to return it to the rest position.
6. Depress the OFF pushbutton, disconnect the electrical plug and air supply; then replace the
machine cover.
20 CM 5388, Rev D
6. PREVENTIVE MAINTENANCE
Preventive maintenance consists of cleaning, inspection, and lubrication. A scheduled program
should be established which will largely depend on the amount of use. It is very important that the target
area" be kept clean at all times to assure proper termination. Remove machine cover while performing the
following procedures.
DANGER
MAKE SURE electrical plug and air supply are disconnected when
performing preventive maintenance on the machine.
6.1. Cleaning
1. Clean the entire machine with a clean, dry cloth.
2. Remove all evidence of metal chips and other contamination using a vacuum cleaner, brush, or
air hose.
DANGER
Compressed air used for cleaning must be reduced to less than
30 psi, and effective chip guarding and personal protective equipment
(including eye protection) must be used.
3. Remove any evidence of grease from unlubricated area and non-moving parts by using a solĆ
vent or similar cleaning fluid.
6.2. Inspection
1. Inspect machine for security of parts. Make any repairs necessary to prevent a malfunction.
2. Inspect the machine for evidence of excessive wear. Replace any unserviceable parts.
3. Inspect all electrical wiring for evidence of broken insulation, chafing, and/or loose
connections. 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.
4. Inspect all air lines for loose connections. Make any necessary repairs by referring to the machine
pneumatic diagram (Figure 2-2).
5. Inspect the filter for excessive condensation. Drain and clean the filter if necessary.
6.3. Lubrication
1. Remove plugs from machine frame.
2. Lubricate grease fittings, through holes in the machine frame, using a grease gun containing a
general purpose grease. Also lubricate grease fitting in crimp height adjustment knob.
3. Lubricate the feed finger pivot points with SAE No. 30 oil.
4. Lubricate the threads of the manual ram advance control SPARINGLY with SAE No. 30 oil.
5. Remove all excess lubrication, then replace plugs in the machine frame.
21
CM 5388, Rev D
7. REPAIR AND/OR REPLACEMENTS
The machine can be disassembled using the item numbers and exploded view drawings in Section 8 (FigĆ
ures 8-1 through 8-4).
Procedures within this section primarily pertain to the replacement of parts (listed in Figures 7-1 and 7-2)
that are considered to be recommended spares and should be stocked by the customer.
DANGER
Be sure the electrical plug and air supply are disconnected when
making repairs or replacements.
7.1. Shear Blade and/or Crimper Replacement (Figure 8-1)
1. Remove the anvil guard (2) and the ram guard (3) by removing screws (1).
2. Remove the two screws (12) securing the crimper (5) and the shear blade (6) to the crimper guide
(7). Note the orientation of parts for replacement purposes.
3. Install new shear blade and crimper using the reversed removal procedure. BE SURE the top of
the crimper and the shear blade are FLUSH with the top of the crimper guide and the crimper adjustĆ
ment block, and that the chamfers are facing UP, before tightening the screws.
4. Before installing the guards, perform the adjustment procedure described in Paragraph 5.1.
7.2. Anvil, Anvil Holder, or Wire Positioner Replacement (Figure 8-1)
1. Remove anvil guard (2) and the ram guard (3) by removing screws (1).
2. Remove the screws (1) securing the stripper plate (15) to the anvil holder (17).
3. Remove the anvil (16) from the anvil holder.
4. If only the anvil is to be replaced, install the new anvil using the reversed removal procedure.
5. 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.
6. If the anvil holder (17) is to be replaced, remove the four screws securing it to the frame. Install the
new anvil holder and mount the wire positioner by using the reversed removal
procedure.
7. Before installing the guards, perform preloading alignment as described in Section 5.
22 CM 5388, Rev D
Fig. 7-1. Tooling Chart for Horizontal Terminating Machine, No. 469181-[ ]
23
CM 5388, Rev D
Fig. 7-2. Tooling Chart for Horizontal Terminating Machine, No. 463734-[ ]
24 CM 5388, Rev D
7.3. Feed Finger Replacement (Figure 8-1)
1. Remove the two screws (27) securing the feed cylinder (33) to the feed plate (49). Pull the cylinder
away from the feed plate to disengage the feed cylinder adapter (28) from the switch actuator (47).
2. Remove the two screws (38) and feed finger holder retainer (39) in back of the feed plate; then
remove the feed finger holder (48) from the front.
3. Loosen the self-locking nut (41) and remove the screw (40) and compression spring (45); then
remove the feed finger (43) from holder.
4. If necessary, install pin (44) in the new feed finger. Install the feed finger using the reversed
removal procedure.
5. Perform the feed adjustments as described in Paragraph 5.2.
7.4. Pneumatic System Repairs
When necessary to make repairs to the pneumatic system, refer to Figure 8-1 through 8-3 for
component replacement and to the pneumatic diagram in Section 2 for making the proper corrections.
7.5. Electrical System Repairs
When necessary to make repairs to the electrical system, refer to Figure 8-4 for component
replacement and to the electrical schematic in Section 2 for making the proper connections. If the ram
switches are replaced, refer to Paragraph 5.3 for making the proper adjustments.
8. PARTS LIST
This section contains parts lists and exploded view drawings covering the entire machine. When
necessary to replace any parts, first locate the parts on the illustration, then refer to the corresponding parts
lists by the item number assigned, to obtain the AMP part number and description. 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.
Items in Figure 8-1 preceded by a bullet (
D
) are considered to be recommended spares and are the cusĆ
tomer's responsibility to stock and replace. Procedures to replace these items are contained in Section 7.
NOTE
Refer to the data plate on the side of the machine for the dash number iniĆ
tially assigned to the machine. The dash number assigned is
determined by the terminal that the machine was initially set up to termiĆ
nate, and by whether the machine operates on 115 Vac, 60 Hz or 230 Vac,
50 Hz current. Part numbers may vary between machines. To replace,
obtain the part number from the old part and refer to the
procedure in Section 7.
25
CM 5388, Rev D
Fig. 8-1. Exploded View, Horizontal Terminating Machine, Model 4 (Sheet 1 of 3)
ITEM
NO. AMP PART
NUMBER DESCRIPTION QTY
HH + , ! %% * :<4D:9>-7 &0<849->492 HH
+ ,
%$) >9 / %6> -; !: B
'$ 9@47
'$ $-8
)$ #"%&"!$
D
$ #$
D
%$
' <48;0<
D
" /5?=>809>
%#$! :8;<0==4:9
%$) <48;0< /5?=>809>
%$) >9 / %6> -; !: B
%$) >9 / %6> -; !: B
%$) >9 / %6> -; !: B
%$) %6> / -; !: B
D
#& %><4;;0<
D
!(
D
!( "$
%$) %6> / -; !: B
)%$ 7-> !:
' %><4;
%$) %6> / -; !: B
%$) %6> / -; !: B
HH %00 42 #& %% * 00/
%$) >9 / %6> -; !: B
D
"")!
%$) %7:>>0/ / %3:?7/0< 4- B
%#$! :8;<0==4:9
D
$
%$) %6> / -; !: B
#&$ 00/ C749/0<
") -70 !#& B &?.0
(( 7:A :9><:7 !#&
!## 7:=0 !#&
") %><00> !#&
*!$ 4<
%$) %7:>>0/ / %3:?7/0< 4- B
($ <-2
!'& 0B !: %71762
%&%$) %6> !: B
%$) %6> / -; !: B
$&!$ 00/ 4920< :7/0<
%$) %6> / -; !: B
!'& %71762 !:
#! %7:>>0/ %;<492 4- B
D
&% & % $ $" ! %#$% ! & '%&" $% $%#"!%&* &" %&" ! $# % '$ &::7492 3-<> "$ & + ,
! ! '$ &::7492 3-<> "$ & + , !
:<
26 CM 5388, Rev D
Fig. 8-1. Exploded View, Horizontal Terminating Machine, Model 4 (Sheet 2 of 3)
ITEM
NO. AMP PART
NUMBER DESCRIPTION QTY
# 00/
" 9@06 4, A
$"# 97:;0<<498
$#( $5= / ,: 9 A
%&%!# $@4=.3
!# 00/ 4820;
"% 00/ 9; ,.3480< 9 * +
"% 00/ 9; ,.3480< 9 * +
$#( $5= / ,: 9 A
$&""!#% 00/ "6,=0
$#( ;4?0
"% /08=414.,=498
"& B698 4, A
$#( $5= $0= A
" ,-60
" 9<0
$$) >-;4.,=9; 9@6
$#( $5= / ,: 9 A
$#( $5= / ,: 9 A
($# 6,=
$) %% !
$#( $5= / ,: 9 A
GG $&$$) 9;4C98=,6 %0;748,=482 '
GG $&$$) 9;4C98=,6 %0;748,=482 '
$#( =8 / $5= ,: A
$#( $5= / ,: A
#% $34::482 96//9@8
%&$#( A
#006
$#( $5= / ,: A
$% #006 $>::9;=
#% #006 $>::9;=
"% "
$#( =8 / $5= ,: 9 A
($# 6,=
!'# ,.3480
$#( =8 / $5= ,: 9 A
($# 6,= 9
"% $@4=.3 9>8=482
&# 9@0;
!'# ;0,<0 960
D
%$ %$ # #! $"#$ % &$%!#$ #$"! $%) %! $%! #" $ &# %996482 3,;= !# % * +
&# %996482 3,;= !# % * +
$&$$) ! % & !
27
CM 5388, Rev D
Fig. 8-1. Exploded View, Horizontal Terminating Machine, Model 4 (Sheet 3 of 3)
A
17
14
16 4
63
57
15
13
(Ref)
AIR BLAST TUBE
SEE DETAIL A"
567 55
54
9
10
8
11
12
14
57
FRAME (Ref)
RAM (Ref)
75
73
74
80
76
78
66 64 56
76 3
1
2
76
21
70
68 67
71
69
65
64 60
61 19
18A
18
59 59
5862
J
K
25
24
33 29
30
27
28
40
41
48
45
42
43
44
20
47
46
36
37
39
38
26
79 76
50 51 34
35
22
23
77
31
32
(Ref)
(Ref)
49
53
52
72
28 CM 5388, Rev D
Fig. 8-2. Exploded View, Machine Subassembly (Sheet 1 of 2)
ITEM
NO. AMP PART
NUMBER DESCRIPTION QTY
EE 76; .975 1/ #%##( 791A76;)4 $-9516);16/ EE
#"' #3; , )8 ?
#"' #3; , )8 ?
#"' #3; , )8 ?
"$ #>1;+0 !4);- 7<6;16/
!$ ")5 "-;)1616/
"$ ")5 "-;)1616/ #>1;+0
#"' #3; , )8 ?
#"' #3; , )8 ?
!% #6)8 74-
$$ 9-):-
( $
" )+016-
%$ #4.43/ -? 7
#"' #3; , )8 7 ?
EE ##( -44+9)63
#$#"' #3; 7 ?
$$ <*-
! !1=7;
! ")5
"
" "-;)1616/
$$ <*-
_
! !1=7;
! !1=7;
")5 -44+9)63
-44+9)63 !1=7;
" ")5
&# -44+9)63
%! 7:- !$
' #;9--;
_
!$
%# !18- !$ ? !$
D
! 7;;-9
D
! @416,-9 7<6;16/
(" )16 19 ")5
"$ 19 @416,-9 7<6;16/
EE #-- 1/ !$ ##( &)4=- 7<6;16/
EE #-- 1/ $" #(#$ )+016-
%$ -?
! !1=7; ,2<:;
#"' ;6 , #3; )8 ?
!$ 6,-?
'#" 4);
! 6,-?
#!" 758
#$#"' ?
6<94-,
D
#%!! '$ $
29
CM 5388, Rev D
Fig. 8-2. Exploded View, Machine Subassembly (Sheet 2 of 2)
Y
X
(See Fig. 8-3)
11
1
6
41
42
44
43
15 36 40 37 38
8
39
35
10 9
7
4
3
2A
2
5
(Typ 4 Places)
(Typ 4
Places)
(Typ 4
Places)
(Ref)
(Ref)
Y
N
P
(See Fig. 8-3)
25
20
24
15
16
14
19
18
12 13
34
33
31
32
30
28
29
30
20
23
15
27
26
22 20 21
30 CM 5388, Rev D
Fig. 8-3. Exploded View, Valve Mounting Plate Subassembly (Sheet 1 of 3)
ITEM
NO. AMP PART
NUMBER DESCRIPTION QTY
BB !$ #%##( &)3;- 5:4914/ &)+ ? BB
BB !$ #%##( &)3;- 5:4914/ &)+ ? BB
# "
#"' #29 , )6 =
#%!! "$ "--3
#"' #29 , )6 =
' #97--9
_
!$
%! 58-
$" =0):89 #6--,
%$ #6-+1)3
! #3599-, #6714/ 1) =
!! 54/ !$ =
!% !16- !$ "-.
' !$ = $:*-
#"' #29 , )6 =
!! 54/ !$ =
!! 54/ !$ =
' !16-
_
!$
$" 17
"$
" $ ":**-7
"$ 5:4914/
"$ #97)14 "-31-.
#"' #29 , )6 =
#'$ !7-88:7- #-48191;-
#"' )+014- !)4 =
$%$ " !1359
$ !$ = $:*-
&& &)+ #53-451, ')> ( #:*88>
&& &)+ #53-451, ')> ( #:*88>
!#% &)3;- (
' )3- !$ = $:*-
%" =0):89
' #97--9
_
!$
!! 358- !$
" ## !16- !$
&& 35< 549753 !$
$ " )3- !$ = $:*-
!! -= !$
&& 549753 ')>
%! 58- !$
! 58-
$%$ " !1359
31
CM 5388, Rev D
Fig. 8-3. Exploded View, Valve Mounting Plate Subassembly (Sheet 2 of 3)
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
52A 5- 21085-4 . . O-RING, Repair 6
53 21086-7 . O-RING, .50" ID x .62" OD Ref
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
32 CM 5388, Rev D
Fig. 8-3. Exploded View, Valve Mounting Plate Subassembly (Sheet 3 of 3)
H
E
E
G
M
D
J
K
G
D
L
H
P
N
M
25
22
26
27
28
24
23
49
37 50
36
34
33
61
34
46
45
35
39 42
31
38
33
40 41
44
48
47
31
32
29
38
43
33
50
5
6
15
21
20
62
18
14
13
16
17
19
63 30
X
347
55
51 52
53
12 11
58
6
18
57 8
9
60
57
56
54
1
5
11
6
18
58
6
4
2
33
CM 5388, Rev D
Fig. 8-4. Electrical System Components (Sheet 1 of 3)
ITEM
NO. AMP PART
NUMBER DESCRIPTION QTY
EE EE $" #(#$ )+015- EE
" 15- 6
#'$ 66:
#'$ "-73)+-4-5: 68 66: #=1:+0
%" 66: #=1:+0
%#
#'$ $=6 ;::65 # )5, #
#'$ 5- ;::65 #
%$$ #=1:+0 A"%
%$$ #=1:+0 A"$"$
%$$ #=1:+0 A
65:)+:
#" % #=1:+0
$ " $ !%
&)+ @ #
$ " $ !% &)+ @ #
" ;9-
%# &)+ @
%# &)+ @
#'$ !8-99;8- #-591:1<-
#"' !)5 , 6 >
#'$ $6//3-
!$ #=1:+0
$-8415)3 !69
!$ $)* 3):
!$ $)*
_
65:)+:
#"' !)5 , >
'#" 6+2 5: $66:0 6
#"' "0, )+0 6 >
$" %3:8))9: 3;-
$" %3:8))9: "-,
$" "15/ ! "-,
$" "15/ ! "-,
$" #$ ! "-,
$" "15/ ! 3;-
$" #$ ! 3;-
$" #$ !1//?*)+2
$" #$ ! 3;-
$" #$
%# #=1:+0
#!"! $-.365
#!"! $-.365
'" 3)+2 6
'" '01:- 6
'" "-, 6
'" (-336= 6
'" 86=5 6
{
$# $
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
34 CM 5388, Rev D
Fig. 8-4. Electrical System Components (Sheet 2 of 3)
35
CM 5388, Rev D
Fig. 8-4. Wire Chart (Sheet 3 of 3)
$:+./6+:4 80 ! 7-8:98:+</.
E
Copyright 1987, 1990 by AMP Incorporated. All International Rights Reserved.
"/>
&" #$%" ##'
! "! "$
+::3;,=:1 !+
" !
"( $ $"$
) * ) *
5;8 +>+35+,5/ @ #9+73;2 <:+7;5+<387
#%!!$
CM 5388-2, Rev DS/ii
Prepared by
Technical Publications,
AMP Incorporated
S/iii/ivCM 5388-2, Rev D
CONTENTS
S1. INTRODUCTION
S/1.....................................................................
S2. DESCRIPTION
S/1.......................................................................
S3. WIRE STUFFER KIT INSTALLATION
S/1...................................................
S4. WIRE STUFFER SETUP PROCEDURE
S/2.................................................
S5. ADJUSTMENTS
S/3......................................................................
S5.1. Wire Gripping Tension Adjustment S/3. ...............................................
S5.2. Flow Control Valves Adjustment S/3. .................................................
S6. REPLACEMENT OF PARTS AND PARTS LIST
S/3..........................................
ILLUSTRATIONS
S5-1. Stuffer Adjustments S/4................................................................
S6-1. Exploded View, Wire Stuffer Assembly No. 469853-1 and -2 S/5...........................
CM 5388-2, Rev D S/1
S1. INTRODUCTION
This supplement covers the wire stuffer assembly (No. 469853-1 or -2) installed on AMP Horizontal TermiĆ
nating Machines, or the kits available for installation on machines that were not originally equipped with the
wire stuffer assembly.
The stuffer inserts wire into the AMPLIVAR* Pigtail Splice prior to crimping. This increases the CMA when
smaller gauge wires under the terminal CMA range are to be crimped.
Information contained in this supplement includes a description of the wire stuffer assembly,
installation instructions for the kit, and procedures for setup, adjustments, and parts replacement. Also inĆ
cluded are a complete parts list and an exploded view drawing.
S2. DESCRIPTION
The wire stuffer assembly includes all items supplied as a kit for converting the machine in the field,
or as installed on a machine when it leaves the factory. Assembly No. 469853-1 is used on machines that
operate on 115 Vac, 60 Hz current; Assembly No. 469853-2 is used on machines that operate on 230 Vac,
50 Hz.
The basic components of the wire stuffer assembly are the air cylinder assembly, the foot switch, the flow
control valves, the solenoid valve, plumbing, and attaching hardware.
The stuffer portion is mounted adjacent to the terminal feed cylinder in place of the standard strip guide. The
wire is fed into the stuffer through a tube in back of the terminal strip guide. From the tube, the wire passes
through a fixed gripper which prevents pull-back of the wire, then passes through the feed
gripper which is actuated by the air cylinder. This advances the wire through another tube into the target
area."
The stuffer air cylinder is controlled by solenoid valve (L4), which receives air pressure from the machine
manifold. The solenoid valve is de-energized and air pressure is directed to the extension side of the air
cylinder until the foot switch is depressed. This energizes the solenoid and air pressure is diverted to the
retraction side of the air cylinder to retract the feed gripper. Release of the foot switch diverts air
pressure back to the extension side of the air cylinder to move the stuffer wire into the target area," placing it
in the U" of the terminal.
After the wires to be spliced have been inserted, the machine is actuated. The stuffer wire is sheared with the
ends of the wires being spliced.
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.
During installation of the kit, some parts must be removed from the machine. These parts will either be re-
installed or retained in the event the wire stuffer is removed and the machine is to be restored to its original
configuration.
Refer to Figure S6-1 during installation of the kit in accordance with the following procedure:
1. Disconnect electrical power and air supply to the machine.
2. Remove the terminal strip from the machine.
3. Remove cover from machine and retain parts for re-installation.
4. Remove the existing strip guide from the feed plate by removing two screws. Store the guide and
screws if they are serviceable.
5. Install the wire stuffer assembly on the feed plate with two screws (19); then install the terminal
strip guide (21) with two screws (20).
S/2 CM 5388-2, Rev D
6. Remove and retain two screws securing feed solenoid (L2) to frame base. Leave the feed soleĆ
noid in place and install two valve spacer posts (11).
7. Place the solenoid valve (L4), with installed parts, on the valve posts with the exhaust
muffler (2) to the RIGHT. Secure the solenoid valve to the posts, using the two screws removed in Step
6.
8. Loosen the left screw securing the feed plate holddown to the feed plate (as viewed from the front
of the machine). Install the front tube guide (32) behind the screw; then tighten screw to secure in
position.
9. Install the rear wire guide (31) with two screws (30) on back of the feed plate using the two existing
holes to the left of the terminal strip drag.
10. Insert one end of a 6-in. piece of tubing (22) into the hole in the left end of the drag
hitch mounting bracket (28). The other end should hang down between the wire stuffer and the termiĆ
nal strip drag.
11. Insert one end of another 6-in. piece of tubing (22) through the rear wire guide and front tube
guide. Cut the right end of the tube at an angle; then insert it in the opening in the feed plate holddown.
Tubing must not be inserted so far that it will interfere with the terminal strip passing through the stuffer.
Cut off the other end (left end) just short of the feed gripper when extended so the stuffer wire travels
smoothly from the feed gripper into the tube.
CAUTION
When installing tubing, DO NOT permit sharp bends or allow it to rub on
moving parts of the machine.
12. Cut tubing (1) into two equal lengths and attach the tubing to solenoid.
NOTE
When placing tubing in Steps 13 and 14, AVOID sharp bends or kinks in
tubing that may restrict air flow.
13. After placing tubing in the approximate location, cut each piece to length. The tubing is
to be connected to the flow control valve (17) on the extension port of the air cylinder (26). Remove nuts
and ferrules from connectors (16) and install on the ends of the tubing. Connect tubing to connectors
with nuts; then tighten.
14. Thread the wire from the foot switch (12) through the remaining hole in the strain relief bracket on
the back of the frame base; then secure ring terminal (13) on green wire to ground screw on the frame
base. Connect terminal (9) on black wire to terminal block tab at position 1. Connect terminal on reĆ
maining wire to terminal block at position 14. Refer to machine electrical schematic in machine manual
when making connections.
15. Connect terminal on one wire from solenoid valve to terminal block tab at position 12.
Connect terminal on remaining wire to terminal block tab at position 13.
16. Perform setup procedure of the wire stuffer as described in Section S4.
S4. WIRE STUFFER SETUP PROCEDURE
The following procedure is required to set up the wire stuffer for operation following its initial installation on
the machine and when changing to a different size of wire to be spliced. See Figure S6-1.
1. Select a wire of the proper size to increase the combined CMA (circular mil area) as
required. Wire size is limited to 18-22 AWG copper and 18 AWG aluminum.
2. Insert stuffer wire through tube (22), fixed and feed grippers (24) and into the target area."
3. Perform the set up procedure of the machine as described in the Horizontal Terminating
Machine Manual (CM 5388).
S/3
CM 5388-2, Rev D
S5. ADJUSTMENTS
Several adjustments may be necessary prior to production operation of the wire stuffer following the initial
installation or when changing to another stuffer wire size. These adjustments include the wire length into the
crimping area, gripping tension on the wire by the grippers, and the flow control valves. Once the flow conĆ
trol valves are set, they should not require further adjustment. Wire length into the crimping area should be
to the customer's discretion. The gripping tension may require adjustment each time the stuffer wire size
changes.
S5.1. Wire Gripping Tension Adjustment (see Figure S5-1)
NOTE
The fixed and feed grippers must be adjusted by trial and error. The fixed
gripper must allow the stuffer to advance smoothly, yet prevent backward
movement during retraction of the air cylinder. The feed
gripper must grip the stuffer wire firmly enough to pull it through the fixed
gripper, but release sufficiently on the retraction stroke to avoid kinking of
the wire between the grippers.
1. To INCREASE or DECREASE the gripping tension of the blades, turn the self-locking nut IN or
OUT as required to obtain correct tension on the spring.
2. If necessary to increase or decrease the gripper blade angle, loosen the jam nut on top of the
gripper. To INCREASE the angle, turn the screw IN. To DECREASE the angle, turn the screw OUT.
Tighten the jam nut after the proper angle is obtained.
S5.2. Flow Control Valves Adjustment (see Figure S5-1)
NOTE
The flow control valves in the extension and retraction ports of the air cylinĆ
der provide control of the cylinder action. If the cylinder action is too fast, it
will cause bending of the stuffer wire, slipping of the
grippers, or variation in the wire length.
1. Loosen the jam nut securing the adjustment screw in the side of the valve.
2. To SLOW the cylinder action, turn the adjustment screw IN. To SPEED UP the cylinder action, turn
the adjustment screw OUT. The adjustment screw should not be turned more than 1/8 turn between
test cycles of the cylinder.
3. At completion of adjustment, tighten jam nut to secure a screw.
S6. REPLACEMENT OF PARTS AND PARTS LIST
Due to the simplicity of the wire stuffer, no special instructions are required for the replacement of parts. If
replacement of any parts should be required, refer to the exploded view (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 assemĆ
bly, except for tubing which is indicated by total inches required.
S/4 CM 5388-2, Rev D
S5-1. Stuffer Adjustments
FIXED GRIPPER
WIRE FEED
BLOCK SCREW-FEED
GRIPPER
JAM NUT
FEED HITCH
MOUNTING
BRACKET
SELF-LOCKING
NUT
STUFFER
WIRE
SPRING
GRIPPER
BLADE
CYLINDER SHAFT
FLOW CONTROL VALVE
(Typ 2 Places)
JAM NUT
TO CYLINDER RETRACTION PORT
ADJUSTMENT
SCREW
TO CYLINDER
EXTENSION PORT
AIR CYLINDER
TUBING
(Entrance)
STUFFER
WIRE
DRAG HITCH
MOUNTING
BRACKET
FRONT 3/4 VIEW
S/5
CM 5388-2, Rev D
S6-1. Exploded View, Wire Stuffer Assembly No. 469853-1 and -2 (Sheet 1 of 2)
ITEM
NO. AMP PART
NUMBER DESCRIPTION QTY
- - 469853-1 STUFFER ASSY, Wire (115 V) - -
- - 469853-2 STUFFER ASSY, Wire (230 V) - -
1 27319-4 . TUBING, 1/4" OD 40"
2 26524-1 . MUFFLER, Exhaust, 1/8" NPT 2
3 27319-3 . TUBING, 3/8" OD 3"
4 22304-1 . NIPPLE, 1/8" NPT 1
5 22293-3 . ELBOW, Female, 1/8" NPT x 1/4" Tube 1
6 16732-1 . VALVE, Solenoid, 110 Vac, 4-Way (-1 Assy) 1
7 16732-2 . VALVE, Solenoid, 220 Vac, 4-Way (-2 Assy) 1
8 26668-2 . NIPPLE, Chase 1
9 640903-1 . TERMINAL, FASTON*, PIDG*, .250, Red 4
10 500023-2 . SPIRAP*, .125, Teflon 14"
11 463631-1 . POST, Valve Spacer 2
12 811099-1 . FOOT SWITCH ASSY 1
810749-1 . . SWITCH, Replacement (For Foot Switch) 1
13 36154 . TERMINAL, Ring No. 10, Red 1
14 1- 22301-1 . TEE, 3/8" Tubing x 1/8" NPT 1
15 22294-6 . ELBOW, Male, 1/8" NPT x 1/4" Tube 1
16 22295-7 . CONNECTOR, Male, 1/8" NPT x 1/4" Tube 2
17 23054-1 . VALVE, Flow Control 2
18 22311-1 . NIPPLE, Close, 1/8" NPT 2
19 3- 21000-2 . SCREW, Skt Hd Cap, No. 8-32 x 1.250" L 4
20 1- 21002-7 . SCREW, Btn Hd Cap, No. 6-32 x .375" L 2
21 691730-2 . GUIDE, Terminal Strip 1
22 24028-1 . TUBING, Nylon, 1/8" OD (Note 2) 12"
23 2- 21000-5 . SCREW, Skt Hd Cap, No. 6-32 x .250" L 4
24A 389572 . GRIPPER ASSY
D
2
24B 389599 . SPRING
D
2
24C 21022-2 . NUT, Hex, Slfkg, No. 8-32
D
2
25 453282-1 . BRACKET, Feed Hitch Mounting 1
26 23851-1 . CYLINDER, Double Acting Air 1
27 2- 21000-6 . SCREW, Skt Hd Cap, No. 8-32 x .375" L 2
28 453283-1 . BRACKET, Drag Hitch Mounting 1
29 453284-1 . BLOCK, Wire Feed 1
30 2- 21000-8 . SCREW, Skt Hd Cap, No. 8-32 x .62" L 2
31 453285-1 . GUIDE, Rear Wire 1
32 457301-1 . GUIDE, Front Tube 1
D
Remove existing spring in Item 24A and replace with items 24B and 24C.
S/6 CM 5388-2, Rev D
S6-1. Exploded View Wire Stuffer Assembly No. 469853-1 and -2 (Sheet 2 of 2)
A
B
A
B
10 9
3
2
14
8
11
15
5
4
6 7
9
13
12
20
21
19
28
22
23
18
17
16
19
26
27
25
23
24 29
22
31
30
32
1
16
15
2
1
BLACK
WHITE
GREEN
