TE Connectivity 1804150-1 Customer'S Manual Download Page 3

Page: 3 / 26

Gripper Pressure



Regulator

SL Starlite Crimp

Quality Monitor

1976085-1

Hinged Door Release

Main Guard

Terminator Control Panel



(Shown with Cycle Counter)

Terminator Control Panel



(Shown with Cycle Counter)

Reel Support Bracket

Hinged Door

DCC Terminator



Control Box

DCC Terminator



Control Box

Crimp Quality Monitor

1320420-2

Gripper Pressure



Regulator

TERMINATOR

PART NUMBER

DESCRIPTION

CRIMP

CAPACITY

CRIMP QUALITY MONITOR

PART NUMBER

PRECISION

ADJUST

WORK

LIGHT

1804150-1

AMP 3K DCC Terminator

3000 lb / 13.3 KN

1320420-2

Standard

1804150-2

AMP 3K DCC Terminator

Customer Supplied Monitor

1804150-3

AMP 5K DCC Terminator

5000 lb / 22.2 KN

1320420-2

1804150-4

AMP 5K DCC Terminator

Customer Supplied Monitor

1804150-5

AMP-3K DCC Terminator

3000 lb / 22.2 KN

1976085-1

1804150-6

AMP 5K DCC Terminator

5000 lb / 22.2 KN

1976085-1

409-10064

3 of 26

Rev B

Figure 1

Summary of Contents for 1804150-1

Page 1: ...iption 6 2 3 Electrical Description 7 2 4 Machine Guards 8 2 5 Description of Operation 8 3 RECEIVING INSPECTION AND INSTALLATION 9 3 1 Receiving Inspection 9 3 2 Installation 9 3 3 Considerations Aff...

Page 2: ...ds 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 Th...

Page 3: ...tor 1320420 2 Gripper Pressure Regulator TERMINATOR PART NUMBER DESCRIPTION CRIMP CAPACITY CRIMP QUALITY MONITOR PART NUMBER PRECISION ADJUST WORK LIGHT 1804150 1 AMP 3K DCC Terminator 3000 lb 13 3 KN...

Page 4: ...NS TE PART NUMBER DESCRIPTION 1424266 1 Air Feed Valve Assembly 40 mm 1 5 8 Inch Stroke Figure 2 Most side feed and end feed heavy duty mini applicators with the exception of those listed below can be...

Page 5: ...require the optional Air Feed Valve Assembly1424266 1 Refer to applicator instruction sheets for set up of applicators DCC Terminator Control Box Crimp Quality Monitor 1320420 2 Main Air Shut off Valv...

Page 6: ...scrap cut CSC assembly The grip transfer assembly performs the function of holding onto the wire after the footswitch is pressed until the crimp is analyzed as either good or bad If the crimp is analy...

Page 7: ...ator The AMP 3K and AMP 5K DCC terminators operate on 100 240 Vac 50 60Hz single phase current with ground see Figure 4 Power for the DCC terminator control box comes from the terminator s electrical...

Page 8: ...opened the DCC terminator will turn off indicated by a red light above the red Main Air Off button This will also turn off the main air and cause a guard open error light to flash The error must be re...

Page 9: ...wire from the machine 11 The grip jaws transfer back to the left 3 RECEIVING INSPECTION AND INSTALLATION 3 1 Receiving Inspection These machines are thoroughly inspected during and after assembly A f...

Page 10: ...he tonk is completed rotate the carrier strip cut assembly up to the operating position and secure the latch bar with the T handle DANGER STOP After completing the manual terminator cycle be sure to r...

Page 11: ...talled Crimp Quality Monitor NOTE i When installing a crimp quality monitor it is the customer s responsibility to ensure that the monitor is installed correctly and functioning properly The AMP 3K an...

Page 12: ...ity while preventing it from sliding unintentionally Figure 8 illustrates proper machine location and operator position and the following A Bench The bench to be used should be of sturdy construction...

Page 13: ...hat 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 f...

Page 14: ...Rev B 4 OPERATOR INTERFACE PANEL Refer to Figure 9 and Figure 10 Step Button Crimp Inspect Button Chop Mode Select Button Chop Delay Button Error Reset Button Error Field Main Air Off Button Main Air...

Page 15: ...409 10064 15 of 26 Rev B Figure 10 Cont d...

Page 16: ...have to be cycled to continue in step mode 3 The chop blade will close This opens the wire cut blade 4 The grip jaws will transfer to the right to place the wire into the wire cut blades 5 The chop b...

Page 17: ...itch is faulty 14 Footswitch is bad or is stuck in the on position 15 DCC controller failed to detect Power up of terminator 16 Bad footswitch input detected 17 Bad keypad detected 18 Bad spare input...

Page 18: ...ade 7 DIAGNOSTICS 7 1 Software Version Identification 1 Turn off the main terminator power 2 Turn the main terminator power on 3 When the LEDs on the DCC terminator control panel come on press and hol...

Page 19: ...to prevent damage to weaker wire insulation NOTE i The gripper pressure should be as high as possible to prevent the operator from pulling a bad termination out of the machine before it is cut off by...

Page 20: ...interfere with the guard If it is too far toward the terminator it could hit the wire blades 1 Manually cycle the terminator to bring the tonk foot Figure 12 down to meet the grip jaw NOTE i When manu...

Page 21: ...jaw on the wire 6 Hand cycle the terminator 7 Observe the wire during the terminator cycle The wire should remain level during the termination process 8 If the wire end is lower than the wire passing...

Page 22: ...e DCC terminator controller in input monitoring mode 2 Move the gripper mechanism completely to the left 3 Loosen the band securing the transfer cylinder retract switch Figure 12 4 Start at the left a...

Page 23: ...D on the switch is not lit adjust the switch 5 Loosen the screw on the switch 6 Slide the switch to the bottom of the cylinder 7 Slide the switch up until the LED on the switch lights 8 Slide the swit...

Page 24: ...ve the two screws securing the fixed wire blade See Figure 15 2 Remove the fixed wire blade 3 Install a new blade by first placing the blade guide hole on the blade pin 4 Lightly tighten the two screw...

Page 25: ...blade Be sure the cutting edge is back toward the movable carrier shop blade 4 Place the scrap guide in place and install the two screws 5 Make sure the side of the fixed blade is aligned with the ho...

Page 26: ...k on the assembly 13 Hand tighten the four M4 screws Be sure to install the scrap guide that one of the M4 screws secures 14 Install and fully tighten the two M6 air cylinder screws 15 Fully tighten t...

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