AMP 4 Reference guide

onlinecomponents.com
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

onlinecomponents.com
* Trademark 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.

onlinecomponents.com
CM 5388, Rev Dii
Prepared by
Technical Publications,
AMP Incorporated

onlinecomponents.com
iiiCM 5388, Rev D
Frontis iece. AMP Horizontal Terminating Machine Model 4
NOTE: Typical Machine Without Wire Stuffer

onlinecomponents.com
CM 5388, Rev Div
C STOMER HOTLINE
MACHINE/PROD CT SERVICE
CALL TOLL FREE 1 800 722-1111
(CONTINENTAL NITED STATES AND P ERTO RICO ONLY)
GENERAL INFORMATION REQ IRED
,, -!#().%3 2%-!). 4(% 02/0%249 /& 
.#/20/2!4%$ (% #534/-%2 3(!,, (!6% ./ 4)4,% 4/
4(% -!#().%3 !.$ ()3 ).4%2%34 3(!,, "% ,)-)4%$ 4/
4(% 53% /& 3!)$ -!#().%3 &/2 4(% 0520/3% ).$)>
#!4%$ $52).' 4(% 34!4%$ 4%2- !4 4(%
30%#)&)%$ 0,!.4
/ -!*/2 #(!.'% /2 -/$)&)#!4)/. 3(!,, "% -!$%
7)4(/54 72)44%. #/.3%.4 /&  .#/20/2!4%$
0!2% !.$ #/-0/.%.4 0!243 !2% !6!),!",% !4 ./-)>
.!, 02)#%3
 ,)34 /& #/-0/.%.4 0!243 )3 ).#,5$%$ ). 4(%
).3425#4)/.!, -!4%2)!, /2 $2!7).'3 3500,)%$ 7)4(
%!#( -!#().%
(% #534/-%2 3(!,, "% &5,,9 2%30/.3)",% &/2
4(% -!).4%.!.#% /& 4(% -!#().%3 ).#,5$).' 3%26>
)#).' 2%0!)2 !.$ 2%0,!#%-%.4 /& $!-!'%$ /2 "2/>
+%. 0!243 !#( -!#().% 3(!,, "% 2%452.%$ ). 53>
!",% #/.$)4)/. ? 2%!3/.!",% 7%!2 !.$ 4%!2 %8>
#%04%$ %&/2% 2%452.).' 4(% -!#().% #/.4!#4
 .#/20/2!4%$ !22)3"52' %..39,6!.)!
2%15%34).' ).3425#4)/.3 &/2 3()00).' !.$
$)30/3)4)/.
 )%,$ .').%%23 !2% !6!),!",% 4/ 02/6)$%
!33)34!.#% ). 4(% !$*534-%.4 /2 2%0!)2 /&
4(% -!#().% 7(%. 02/",%-3 !2)3% 7()#( 9/52
-!).4%.!.#% 0%23/..%, !2% 5.!",% 4/ #/22%#4 /.>
4!#4  .#/20/2!4%$ )%,$ .').%%2).' %26)#%3
&/2 !00,)#!",% &%%3
WHEN CONTACTING
FIELD ENGINEERING SERVICES
 534/-%2 .!-%
 534/-%2 !$$2%33
 %23/. 4/ #/.4!#4 .!-% 4)4,%
4%,%0(/.% .5-"%2 !.$ %84%.3)/.
 %23/. #!,,).'
 !#().% /2 4//, .5-"%2 !.$ 3%2)!,
.5-"%2 )& !00,)#!",%
 2/$5#4 0!24 .5-"%2 !.$ 3%2)!, .5-"%2
)& !00,)#!",%
 2'%.#9 /& 2%15%34
 !452% /& 02/",%-
 %3#2)04)/. /& )./0%2!4)6% #/-0/.%.43
 )%,$ .').%%2).' %26)#%3 /&&%23 4(%
Customer Hotline !3 ! -%!.3 /& 02/6)$).' 4%#(>
.)#!, !33)34!.#% 7(%. 2%15)2%$
(%. #/.4!#4).'  )%,$ .').%%2).'
%26)#%3 "9 4%,%0(/.% 2%'!2$).' 3%26)#% 4/ ! -!>
#().% /2 4//, )4 )3 35''%34%$ 4(!4 ! 0%23/. &!-),)!2
7)4( 4(% $%6)#% "% 02%3%.4 7)4( ! #/09 /& 4(%
-!.5!, !.$ $2!7).'3 4/ 2%#%)6%
).3425#4)/.3 !.9 $)&&)#5,4)%3 #!. "% #/22%#4%$ ).
4()3 -!..%2
(%. #!,,).' 4(% 534/-%2 /4,).% "% 2%!$9 7)4(
4(% &/,,/7).' ).&/2-!4)/.
 $$)4)/.!, ).&/2-!4)/.#/--%.43
4(!4 -!9 "% (%,0&5,
DANGER
SAFETY PRECA TIONS PREVENT INJ RY
!&%'5!2$3!2%$%3)'.%$).4/-!#().%34/02/4%#4/0%2!4).'0%23/..%,&2/--/34(!:!2$3$52).'./2-!,-!#().%
/0%2!4)/. /7%6%2 !3 7)4( -/34 -!#().%29 #%24!). 02%#!54)/.3 -534 "% 4!+%. "9 4(% /0%2!4/2 !.$ 2%0!)2-!.
%6%2 ).3%24 (!.$3 ).4/ !. ).34!,,%$ -!#().%!00,)#!4/2 /2 !.9 0!24 /& ! -!#().% 4(!4 )3 /0%2!4%$ "9 %,%#42)#)49 /2 #/->
02%33%$ !)2 7)4(/54 &)234 05,,).' 4(% -!#().% 0/7%2 #!",% 0,5' &2/- 4(% /54,%4 2%#%04!#,% !.$/2 3(544).' /&& 4(% #/->
02%33%$ !)2 !4 4(% ,).% 6!,6% !.$ $)3#/..%#4).' 4(% !)2 (/3% ()3 7),, 02%6%.4 ).*529 ). 4(% %6%.4 4(!4 37)4#(%3 /2 /4(%2
#/.42/,3 !2% !##)$%.4!,,9 !#4)6!4%$
 '2/5.$%$ %,%#42)#!, /54,%4 3(/5,$ !,7!93 "% 53%$ 4/ 2%#%)6% 4(% 0,5' /. 4(% -!#().% 0/7%2 #!",%
/)-02/6%#,!2)490(/4/'2!0(3!.$$2!7).'3-!9./43(/7-!#().%!00,)#!4/2'5!2$3.3/-%#!3%3)4)3)-02!#4)#!,
4/ 3(/7 4(% 6!2)%49 /& '5!2$3 $%3)'.%$ 4/ -%%4 30%#)&)# 3!&%49 2%15)2%-%.43 !3 3%4 &/24( ). #/$%3 !.$ 34!.$!2$3
!$/04%$ "9 #534/-%23 !.$/2 %.&/2#%$ ). ! ')6%. ,/#!,%
(/5'(! '5!2$ -!9 ./4 "% 3(/7. !.$ 02/#%$52%3 -!9 ./4 2%&,%#44(%.%%$&/2)432%-/6!, 4(% '5!2$ must "%). 0,!#%
$52).' ./2-!, /0%2!4)/. /& 4(% -!#().%!00,)#!4/2
MACHINE POLICY

onlinecomponents.com
vCM 5388, Rev D
RECEIVING INSPECTION AND INSTALLATION
A. Receiving Inspection
The machines are thoroughly inspected during and a ter assembly. Prior to packaging and shipping, a inal
series o tests and inspections is made to ensure proper unctioning. While the machine should require no
adjustments be ore placing it in operation, the ollowing inspection should be per ormed as a sa eguard
against potential problems generated in transit.
1. Care ully uncrate the machine, and place it on a sturdy bench or table where both
illumination and height will permit a care ul examination.
2. Thoroughly inspect the entire machine or evidence o damage that may have occurred in transit.
I the machine is damaged in any way, ile a claim against the carrier and noti y AMP
Incorporated immediately.
3. Check all components and parts to be certain they are secure.
4. Check all wiring (i applicable) or loose connections, cuts, or other possible causes o
electrical short circuits.
5. Inspect all pneumatic lines (i applicable) or evidence o 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 Place ent
The location o the machine in relation to the operator's position is extremely important in terms
o both sa ety and maximum e iciency. Studies have repeatedly shown that operator atigue will
be reduced, and greater e iciency achieved i : (A) the bench is o appropriate height, pre erably
with sound-deadening rubber mounts; (B) the machine is properly located on the bench with ample work
areas on both sides to acilitate work low; (C) the operator uses a swivel chair with padded seat and back
rest which are independently adjustable; and (D) the oot switch (or oot valve), on machines so equipped, is
placed on a rubber mat to maintain its movability, while preventing it rom sliding
unintentionally.
Ċ Bench
A sturdy bench 28 to 30 in. high aids com ort by allowing the operator's eet to rest on the loor and the
weight and leg position to be easily shi ted. The bench should have rubber mounts to reduce noise. An open
area under the bench should allow the chair to slide ar enough in or the operator's back to be straight and
supported by the chair's back rest.

onlinecomponents.com
CM 5388, Re Di
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 bac strain and fatigue. The target area should face
the front of the bench and be parallel to the edge. (Access to the bac 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 bac rest
adjustments. The seat and bac rest should be padded, and the bac 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 bac is straight and
supported by the bac 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
eeps it movable while preventing unintentional sliding.
The preferred foot switch location varies to some extent among operators. Some operators li e 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 bloc 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 bac -
rest are properly adjusted, and that the chair is
properly located in respect to the bench. Thus, the
operator's bac 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.

onlinecomponents.com
viiCM 5388, Rev D
C. Machine Installation
With the considerations outlined in Paragraph B, locate the achine in a well-lighted area with adequate
electrical power and air supply.
After positioning the achine on a sturdy bench, it is advisable to secure it with bolts or screws to prevent
ove ent. If ore convenient for the operator, and beneficial to production, the achine can be tilted at a
30 _ angle by ounting it on an inclined plane.
D. Electrical Requirements
The achine 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
fra e of the achine to a suitable etallic ground point.
E. Air Requirements
The operating air pressure ust be 90 to 110 psi. The supply should have a ini u volu e of 3 cf with
sufficient reserve and quick recovery so that the pressure does not fall below 90 psi when
additional equip ent is operated.

onlinecomponents.com
CM 5388, Rev Dv
CONTENTS
RECEIVING INSPECTION AND INSTALLATION v...............................................
A. Receiving Inspection v...............................................................
B. F ctors Affecting M chine Pl cement v.................................................
C. M chine Inst ll tion vii...............................................................
D. Electric l Requirements vii............................................................
E. Air Requirements vii.................................................................
1. INTRODUCTION 1.......................................................................
2. DESCRIPTION 1.........................................................................
2.1. M jor Groups nd Sub ssemblies 3...................................................
2.2. Switches nd Controls 4..............................................................
2.3. Function l Description 6..............................................................
3. MACHINE SETUP PROCEDURES 8.......................................................
3.1. M nu l Cycling Procedure 8..........................................................
3.2. Prelo ding Alignment Check 9........................................................
3.3. Termin l Strip Lo ding 10.............................................................
3.4. M chine Checkout 11................................................................
3.5. Termin tion 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 R m Switches 19.......................................................
6. PREVENTIVE MAINTENANCE 20..........................................................
6.1. Cle ning 20.........................................................................
6.2. Inspection 20.......................................................................
6.3. Lubric tion 20.......................................................................
7. REPAIR AND/OR REPLACEMENTS 21.....................................................
7.1. She r Bl de nd/or Crimper Repl cement 21...........................................
7.2. Anvil, Anvil Holder, or Wire Positioner Repl cement 21...................................
7.3. Feed Finger Repl cement 24..........................................................
7.4. Pneum tic System Rep irs 24.........................................................
7.5. Electric l System Rep irs 24..........................................................
8. PARTS LISTS 24.........................................................................
SUPPLEMENT Wire Stuffer Assembly, CM 5388-2, Rev D

onlinecomponents.com
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 ire 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.......................................................