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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 

to the valves located on the back of the machine. 

NOTE 

Quick Disconnect Coupling PN 23238-1 is required to run air-feed applicators. 

6.  Adjust the reel support for side-feed or end-feed product, depending on the applicator being used. 

7.  Mount the terminal strip guide on the left sheet metal guard for side-feed product, or on the right sheet 

metal guard for end-feed product, depending on the applicator being used. 

8.  Mount the terminal reel on the reel support. Thread the terminal strip through the guard and into the 

applicator according to the instruction sheet included with the applicator. If necessary, adjust the 
lubricator bowl. 

9.  Align the product reel to the applicator by adjusting the reel flanges. 

10. Close the guard. 

NOTE 

The guard door must be closed in order to operate the machine. See paragraph 4.4.C. 

 

Speed Indication 

Guard Status 

Machine Status/ 
Error Code 

Error Reset 

Batch Count 

Count Reset 

Speed 
Decrease 

Jog 

Speed 
Increase 

Main Power Switch 

Decrease Speed -- 

Decrease the motor speed for normal cycle operation and for jogging. 

Increase Speed -- 

Increase the motor speed for normal cycle operation and for jogging. 

Error Reset -- 

Clears the displayed error code. 

Count Reset 

-- Clears the batch count to 0. 

Jog -- 

Causes the DC motor to rotate at the jog speed set by the Increase / Decrease Speed. 

Speed Indication -

- Each 

“>”

 represents a portion of the full operation or jog speed setting. Minimum speed is denoted 

with a single 

>.  Maximum speed is denoted by 

“>>

>>

>>.”

 

 

Machine Status / Error Code Display -- 

Displays 

“O

K

 if there is no error code being displayed or 

“ERRxxx”

 when an 

error has occurred. The 

“xxx”

 represents a number corresponding to an error described in the error code table (Figure 17). 

 

Guard Status Indication 

-- A solid 

" indicates that the guard interlock is closed. An open icon in this display indicates 

that the guard interlock is open. The DC motor will not run when the guard interlock is open. 

Summary of Contents for AMP 3K/40

Page 1: ...ns Affecting Placement of Bench Machines Figure 8 10 4 OPERATION 11 4 1 Control Panel Operation 11 4 2 Applicator Installation 11 4 3 Setup 13 4 4 Mode Selection and Operation 13 4 5 Adjusting the Mot...

Page 2: ...nt Never wear loose clothing or jewelry that may catch in moving parts of the equipment Never alter modify or misuse the equipment SUPPORT CENTER CALL TOLL FREE 1 800 522 6752 CONTINENTAL UNITED STATE...

Page 3: ...and adjustment The specifications and requirements for the AMP 3K 40 and AMP 5K 40 CE Terminating Machines are as listed below Deflection 0 13 mm 0046 in Maximum per 4 448 Newtons 1 000 lb Crimp Forc...

Page 4: ...ights special or important information Always wear approved eye protection while operating the equipment Always wear approved hearing protection while operating the equipment Use caution working with...

Page 5: ...es 30 mm 1 1 8 in Stroke Machines 1 1 8 in Stroke Applicator for Model K Terminating Machine Pre Feed 690602 6 Post Feed 690501 4 1 5 8 in Stroke Applicator for Model T and Model G Terminating Machine...

Page 6: ...nstallation and removal of the applicator See Figure 5 4 The crimp height adjustment group uses an eccentric located in the ram linkage along with detented stops in the mechanism to adjust the crimp h...

Page 7: ...409 10204 Rev G 7 of 23 Figure 5...

Page 8: ...h circuit breaker connects ac power to the control system The CPU motor controller and safety circuit are located in the electrical control box 2 3 Machine Guard A guard is installed to provide protec...

Page 9: ...ating location Insert the reel support post into the appropriate hole on top of the machine until the roll pin engages a groove in the machine frame Figure 7 Attach the terminal strip guide included w...

Page 10: ...comfort and convenience This height allows the operator to rest both feet on the floor thereby providing for the shifting of weight and leg position Machine Mounting and Location on Bench The machine...

Page 11: ...in Figure 9 The control panel will be used to set up and operate the machine see paragraph 4 3 and paragraph 4 4 4 2 Applicator Installation Install the proper applicator in the quick change mounting...

Page 12: ...eel flanges 10 Close the guard NOTE The guard door must be closed in order to operate the machine See paragraph 4 4 C Speed Indication Guard Status Machine Status Error Code Error Reset Batch Count Co...

Page 13: ...until the Jog button is released or the crankshaft completes the cycle If the Jog button is released in mid cycle and pressed again the crankshaft will continue to rotate in the forward direction at...

Page 14: ...reel removed lift and rotate the reel support bar to the opposite side of the machine Mount the terminal reel on the reel support and load the terminal strip into the applicator Remove the metal term...

Page 15: ...igure 10 the left side of the ram assembly the right side of the ram assembly the left side of the frame just behind the ram assembly at two places and NOTE Give one pump of grease while the ram is ne...

Page 16: ...the end of the motor SHUT HEIGHT GAGE PN MACHINE PART NUMBERS SHUT HEIGHT DIMENSIONS APPLICATOR TYPE 679655 2 2161400 2161500 135 79 mm 0 025 5 346 0010 in TE Type Figure 11 6 2 Shut Height Adjustment...

Page 17: ...e the ram post adaptor Re tighten the screws 3 Repeat Steps 1 and 2 as necessary until the proper shut height is attained NOTE The miniature applicator is an integrated assembly consisting of upper to...

Page 18: ...ment lever in either direction will change the crimp height by approximately 0 013 mm 0005 in per step 5 Repeat Steps 3 and 4 until the appropriate crimp height is obtained CAUTION To avoid damaging t...

Page 19: ...ed to align slot with crimp area of the applicator 3 Tighten the screws 7 MACHINE OPTIONS AND INSTALLATION OF THE AIR FEED VALVE ASSEMBLY The following machine options are available for the AMP 3K and...

Page 20: ...ble ports see Figure 15 13 Make sure slide valve is off pulled away from filter 14 Attach air supply hose to air valve assembly 15 To turn air on slide valve towards filter to turn air off slide valve...

Page 21: ...The guard interlock is open E003 The insert interlock is open E004 The safety circuit is not operational E005 Control panel is not communicating with the CPU board E020 Movement of the TDC switch was...

Page 22: ...re listed in Figure 18 along with corresponding input description A solid dot indicates the input is on A hollow dot indicates the input is off Press Error Reset to exit the diagnostic mode Input Iden...

Page 23: ...rvice 12 RoHS INFORMATION Information on the presence and location of any substances subject to RoHS Restriction on Hazardous Substances can be found at the following website http www tycoelectronics...

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