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409-5861

3 of 26

Rev B

Figure 1

1. INTRODUCTION

This manual contains information on the installation, operation, and maintenance of the AMP-O-LECTRIC Model “G" 
Terminating Machines 122754-1 through -5. See Figure 1. Terminating Machines 122754-1 and -2 are designed 
to be used with Komax Model 40 machine, Terminating Machines 122754-3 and -4 are designed to be used with 
Komax Model 43 machine, and Terminating Machine 122754-5 is a generic unit designed to be used on other 
lead-making machines to crimp terminals to wire. To set up and operate the Komax machines, refer to the 
customer manual supplied with the machine.

When reading this manual, pay particular attention to DANGER, CAUTION, NOTE statements.

DANGER

STOP

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

i

Highlights special or important information.

Reasons for reissue of this customer manual are provided in Section 9, REVISION SUMMARY.

NOTE

i

Measurements are in metric units [followed by U.S. customary units in brackets]. 

Summary of Contents for 122754-1

Page 1: ...EIVING INSPECTION AND INSTALLATION 7 3 1 Receiving Inspection 7 3 2 General Installation 7 3 3 Installing Terminating Machines 122754 1 and 2 into Komax Model 40 Machine 8 3 4 Installing Terminating M...

Page 2: ...s into installed application equipment NEVER alter modify or misuse the application equipment TOOLING ASSISTANCE CENTER CALL TOLL FREE 1 800 722 1111 CONTINENTAL UNITED STATES AND PUERTO RICO ONLY The...

Page 3: ...signed to be used on other lead making machines to crimp terminals to wire To set up and operate the Komax machines refer to the customer manual supplied with the machine When reading this manual pay...

Page 4: ...s the same function as the manual precision adjustment lever 2 2 Electrical The electrical components of each terminating machine consists of an operator control panel a motor and a CPU motor controll...

Page 5: ...ugh the four choices indicated AIR FEED Manually activates the optional air feed valve ERR RESET LIGHT SWITCH Resets the control unit after an error was encountered COUNTER RESET Resets the batch coun...

Page 6: ...nd the air feed solenoid are connections for the terminating machine interface J2 the parent machine interface J3 the manual cycle button J4 the main drive motor connector J5 the main ac power connect...

Page 7: ...e of this accessory See Figure 5 If using the optional lift eye install the lift eye carefully A 19 05 mm 75 in thread length is required for the lift eye to support the machine Make sure the locking...

Page 8: ...post 3 3 Installing Terminating Machines 122754 1 and 2 into Komax Model 40 Machine 1 Install the interface cable part number 189274 1 and power cable part number 189276 2 2 Attach the remote display...

Page 9: ...he wire b Install the short plates for outside gripping jaws grip the wire behind the transfer jaws of the wire 7 Verify the rotation of the stacker jaw and adjust the stop positions if necessary Figu...

Page 10: ...part number 189425 1 located on the top of the controller to the 9 pin D connector located on the side of the remote display 4 Install the tonk assembly supplied with the installation kit onto the ram...

Page 11: ...on when the terminating machine is in the split cycle position This output turns off 130 m sec after the terminating machine starts If the terminating machine is in error READY output is off the line...

Page 12: ...bypass optical isolator The software turns on the bypass whenever the motor is not in motion Also the motor relay is software bypassed when the operator sets the bypass mode before jogging the termin...

Page 13: ...umbscrew at the front of the ram post adaptor 3 Place the applicator onto the base plate of the terminating machine Slide the applicator back until the two notches in the applicator base plate engage...

Page 14: ...lamp and the removable rear stop located on the right side of the base plate Re install the rear stop at the alternate mounting position on the base plate Refer to Figure 9 5 Set the crimp height and...

Page 15: ...3 Manual Cycling The terminating machine is provided with a manual cycle button located on the left side of the machine next to the power connection for the dereeler assembly Pressing the manual cycl...

Page 16: ...the fully retracted position JOG MODE Forward When the manual cycle button is pressed in this mode the crankshaft moves in the forward direction at a reduced speed The motor is activated only while t...

Page 17: ...the power supply to the machine Turn OFF power to the terminating machine with the main power switch circuit breaker If applicator is an air feed type DISCONNECT air lines to valve located on the righ...

Page 18: ...o the fully retracted position 7 ADJUSTMENTS The following adjustments are necessary to maintain the operating condition of the terminating machine and to set up the machine after replacing parts DANG...

Page 19: ...s positioned just above the locator plate of the shut height gage Align the locator plate so that the cutout areas are aligned with the lobes on the ram post adaptor See Figure 14 5 After shut height...

Page 20: ...T NOT BE CHANGED NOTE i The shut height is set to 135 8 0 025 mm 5 348 001 in so that mini applicators do not require re shimming When measuring the shut height with the shut height gage it will be ne...

Page 21: ...hine as described in Section 3 RECEIVING AND INSPECTION 3 Secure the applicator ram to the ram post adaptor by turning the thumbscrew located at the front of the ram assembly clockwise until tight See...

Page 22: ...ad Half Step 0 064 mm 0025 in Adjustment Lever Reading Below 0 00 mm 000 in Setting Read Half Step 0 064 mm 0025 in Manual Precision Adjustment Lever Positioned on 0 00 mm 000 in Dial Indicator Plate...

Page 23: ...e tension for 6 477 mm 255 in deflection with applied force of 66 7 N 15 lb force at a point of 93 mm 3 66 in from the bottom of the belt as it clears the bottom of the motor pulley See Figure 18 CAUT...

Page 24: ...ine detects a CQM that is connected but not powered up error appears only on initial power up This warning appears if the CQM is not powered If the machine cycles the terminating machine the warning i...

Page 25: ...that contacts are fully seated Check for overheating of the motor Check and clean the filter screen and motor ventilation slots Verify proper operation of the motor temperature switch normally closed...

Page 26: ...EST CYCLE MODE The terminating machine is in a special testing mode used during the manufacturing of the machine Running the machine in this mode is not recommended To exit this mode power down the te...

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