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409-10064

9 of 26

Rev B

5. The crimp quality monitor analyzes the crimp and determines that it is good.

6. The grip jaws open to release the wire.

7. The operator removes the wire and terminal from the machine.

8. The carrier chop blades close to cut off the carrier strip. (If the DCC terminator controller is set to carrier 
chop mode.)

9. The carrier chop blades open. (If the blades closed in the previous step.)

B. Machine Cycle With a Bad Crimp as Determined by the Crimp Quality Monitor:

1. The operator places stripped wire through the opening in the guard insert, through the open grip jaws and 
against the wire stop of the applicator.

2. The operator presses the foot switch.

3. The grip jaws close on the wire.

4. The terminator cycles to apply a terminal to the wire.

5. The crimp quality monitor analyzes the crimp and determines that it is bad or defective.

6. The carrier chop blades close to cut off the carrier strip and open the wire cut jaws. 

7. The grip jaws transfer to the right pulling the wire and terminal along with it.

8. The carrier chop blades open and the wire cut jaws close cutting off the terminal.

9. The grip jaws open to release the wire.

10. The operator removes the 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 final series of inspections is made to 
insure the proper machine functioning before packaging and shipping.

To protect against damage that may have occurred during shipment, remove the machine from the crate 
(Paragraph 3.2) and carefully inspect the machine for damage. If damage is evident, file a claim against the 
carrier and notify Tyco Electronics immediately.

3.2. Installation

A. General Machine Installation

Remove all mounting bolts securing the machine to the shipping pallet. Install lift ring on top of the machine.

NOTE

i

Lift ring (M1220 eye bolt) is customer supplied.

CAUTION

!

Install the lift ring carefully. A 19.05-mm [.75-in.] thread length engagement is required for the lift ring to support the 

machine.

Attach a suitable hoist to the lift ring, lift the machine, and place it in the selected operating location.

Insert the reel support post into the appropriate hole on top of the machine (Figure 6) until the roll pin engages 
a groove in the machine frame.

Attach the terminal strip guide included with the machine with the two thumbscrews supplied. Mount the guide 
on the left guard for side-feed applicators. Mount the guide on the right guard for end-feed applicators.

Содержание 1804150-1

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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