C. Davis Systems CDS-LC User manual

C. Davis Systems CDS-LC
M O D E L C D S - L C
OPERATIONS MANUAL
TABLE OF CONTENTS
INTRODUCTION
.............................................................................................................................................
1
SECTION 1
1.0 SAFETY.................................................................................................1-1
1.1 EMERGENCY........................................................................................1-1
1.2 Know your machine................................................................................1-1
1.3 Power Supply.........................................................................................1-1
1.4 Keep uards in place.............................................................................1-1
1.5 Wear safety o les..............................................................................1-1
1.6 Keep Work Area clean...........................................................................1-1
1.7 Avoid Dan erous Environment..............................................................1-1
1.8 Keep Visitors away from work area.......................................................1-1
1.9 Do Not Abuse Cords..............................................................................1-1
1.10 Disconnect Machine...............................................................................1-1
1.11 Remove Tools........................................................................................1-1
1.12 Sharp Objects........................................................................................1-1
SECTION 2
2.0 SYSTEM DESCRIPTION.......................................................................2-1
2.1 Feeder ...................................................................................................2-1
2.2 Crimper...................................................................................................2-2
2.3 Funnel....................................................................................................2-2
2.4 Contact Positioner..................................................................................2-2
SECTION 3
3.0 INSTALLATION.....................................................................................3-1
3.1 Set-Up....................................................................................................3-1
SECTION 4
4.0 SYSTEM OPERATION..........................................................................4-1
4.1 Pre-Start Check List...............................................................................4-1
4.2 Start-Up Procedures..............................................................................4-1
4.3 Operation Description............................................................................4-2
4.4 Operation...............................................................................................4-2
4.5 Shut-Down Procedure............................................................................4-2
4.6 Emer ency.............................................................................................4-2
Model #CDS-LC C. Davis Systems Inc., Operations Manual

C. Davis Systems CDS-LC
SECTION 5
5.0 TROUBLESHOOTING...........................................................................5-1
SECTION 6
6.0 MAINTENANCE.....................................................................................6-1
6.1 Maintenance Procedures.......................................................................6-1
6.2 Crimper Disassembly............................................................................6-1
6.3 Contact Sensor Adjustment (not typical on LC models)........................6-2
6.4 Sensor Amplifier Adjustment
6-2
SECTION 7
7.0 SPARE PARTS
7-1
Model #CDS-LC C. Davis Systems Inc., Operations Manual

C. Davis Systems CDS-LC
INTRODUCTION
This manual provides the information required for operation and maintenance of
C. DAVIS SYSTEMS wire terminator station CDS-LC. Information includes:
description, receivin inspection and installation, machine operation, preventive
maintenance, adjustments, and repair and replacement parts lists. When it is
necessary to replace parts within the Crimper, always refer to the parts list
supplied with the Crimper bein used.
The 35 LB (approx.) machine is compact in desi n and is intended for bench-top
operation. The size is approximately 12 in. wide x 18 in. deep x 12 in. hi h. For
operation, the machine requires a constant air supply of 100 to 120 psi with
adequate volume (3.5 cfm).
When readin this manual pay particular attention to DANGER, CAUTION, and
NOTE statements. A DANGER is to inform you of possible hazards that could
cause bodily injury, a CAUTION is to advise you of precautions to take to avoid
dama e to the machine, and a NOTE hi hli hts special or important information.
NOTE: Each machine is shipped with a documentation packa e that
should be retained for customer reference. The packa e
includes drawin s of the machine alon with this manual.
For information beyond the scope of the documentation
packa e, contact:
C. Davis Systems
725 SE LINCOLN ST.
Portland, OR 97214
[phone]
Model #CDS-LC C. Davis Systems Inc., Operations Manual

C. Davis Systems CDS-LC
1.0 SAFETY
1.1 EMERGENCY
Unplu Machine at Source and Disconnect Air.
1.2 now your machine
Read the manual carefully and learn the applications,
limitations and hazards.
1.3 Power Supply
ONLY plu the Crimper Station power cord into a 110-120
VAC power source and an air supply with a ran e of 100-
120 PSI.
1.4 eep guards in place.
1.5 Wear safety goggles durin the operation of the machine.
1.6 eep Work Area clean.
1.7 Avoid Dangerous Environment
Do not operate machine in damp or wet locations and keep
work area well lit.
1.8 eep Visitors away from work area.
1.9 Do Not Abuse Cords
Never pull machine by power cord and air lines. Keep them
away from heat, oil and sharp ed es.
1.10 Disconnect Machine when not in use, before servicin and before
troubleshootin .
1.11 Remove Tools
After maintenance or servicin , check the area for tools left
in or on the machine.
1.12 Sharp Objects should not be used in the bowls as they can
scratch the bowls' surface and restrict proper contact movement.
Model #CDS-LC C. Davis Systems Inc. Operations Manual

C. Davis Systems CDS-LC
2.0 SYSTEM DESCRIPTION
Dual Contact Feeder Crimper:
Model # LC-2208-12GA
Serial #
Contact #
From the front and top of the machine you can reach:
A. The Feeder Bowl.
B. The Crimper Assembly, in the center.
C. The ON button on the top far ri ht
D. The POWER ON Li ht on the upper left corner of the
electrical box.
The rear side of the machine houses the male air supply quick disconnect ,the
electrical power cord, and the foot switch.
2.1 Feeder
Vibratory feeder bowl (confi ured to feed contact listed in the
system description) is mounted to an aluminum base plate with
rubber isolation feet. The contacts are oriented and fed onto an
Escapement mechanism that sin ulates them and blows them to
the Crimp Head. The Escapement mechanisms have sensors
mounted in them to keep a steady supply of contacts in Que.
When the sensor detects the Escapement is full the feeder bowl
will shut off.
Model #CDS-LC C. Davis Systems Inc. Operations Manual

C. Davis Systems CDS-LC
2.2 Crimper
The Crimper is a modified DEUTSCH, DANIELS, or ASTRO
Crimper that is fitted with a funnel assembly to stop, position the
contact, and uide the stripped wire into the contact prior to
crimpin .
2.3 Funnel
The FUNNEL assembly consists of 2 pivotin split jaws mounted
on a base with removable hyperbolic steel funnels that uide the
wire into the contact. After the wire is crimped the jaws are opened
with a small air cylinder. The jaw uide retains the jaws to the
base.
2.4 Contact Positioner
A contact positioner extends throu h the funnel base and into the
indenter housin of the crimper. The positioner ensures that the
contact will be centered in the indenters prior to rippin .
Model #CDS-LC C. Davis Systems Inc. Operations Manual

C. Davis Systems CDS-LC
3.0 INSTALLATION
3.1 Set-Up
3.1.1 Place the machine on a solid table or work bench. Soft
tables’ can dampen the vibratory feeders.
3.1.2 The Contact Feeder Crimper requires one 110-120 VAC
power source and an air supply with a ran e of 100-120 PSI.
Hoses should be a minimum of 1/4" ID with 1/4" fittin s.
3.1.3 Set all sensors accordin to the sensor adjustments in
section 6.3.
3.1.4 Set the ap between the Slide Escapements and the feeder
bowls. The ap should not be bi enou h for the contact to
fall into.
On Vertical Escapements, the Orienter unit should be lined
up with the Escapement below.
3.1.5 Connect feed tube line into upper hole of reject “y” on the
back of the crimp head. Connect tank and tube to lower hole
reject “y”. Note: Reject tank will need to be emptied
periodically as jammin will result.
Model #CDS-LC C. Davis Systems Inc. Operations Manual

C. Davis Systems CDS-LC
4.0 SYSTEM OPERATION
4.1 Pre-Start Check List
4.1.1 Verify there is a 110-120 VAC power source and an air
supply with a ran e of 100-120 PSI
4.1.2 The Contact Feeder Crimper is desi ned to accommodate
only the contacts, as noted in section 2.0. Any attempt to
use another type of contact will jam the Feeder mechanism.
4.2 Start-Up Procedures Refer to drawing Below
4.2.1 Load specified contacts in the bowl (factory determined), by
openin the hin ed access cover (item #1). Feed in the
contacts no hi her than the lower lip near the bowl exit
(approximately 3/4" from top). Overfillin will jam the bowl.
4.2.2 Connect the Air Supply (100 - 120 PSI) at the back of the
machine (item #5).
4.2.6 Check air pressure to the machine to make sure it is correct.
Model #CDS-LC C. Davis Systems Inc. Operations Manual

C. Davis Systems CDS-LC
4.3 Operation Description
4.3.1 Make sure all safety uards are in place durin operation. (main
cover #1 above)
4.3.2 Durin operation DO NOT insert anythin other than wire into the
crimper.
4.3.3 Switch on the "Power" switch (#10 above) located on top of the
electrical box by pressin once (once more to turn off). The
Feeder Bowl will turn on and contacts will feed to the Crimper.
The Crimper will rip the part.
4.4 Manual Operation
4.4.1 The operator now inserts a wire into the Split Funnel until it stops.
4.4.2 The operator must keep a sli ht down pressure on the crimper
while activatin the pedal to ensure insulation is butted up a ainst
the contact. Depressin the pedal causes the Funnel to open
allowin for full insertion. The crimper then crimps the contact
onto the wire.
4.4.3 The operator now releases the pedal and removes the
wire/contact assembly from the funnel. The machine will reload
automatically.
4.4.4 Note: Optimum performance is achieved by depressin and
releasin the pedal in one quick motion and removin the wire
immediately after bein crimped.
4.5 Shut-Down Procedure
Turn off the machine by pressin the start / stop button located on
top of the electrical box. If the machine is to be dormant for an
extended period of time, unplu the power cord and remove the air
supply to prevent condensation in air lines.
Model #CDS-LC C. Davis Systems Inc. Operations Manual

C. Davis Systems CDS-LC
5.0 TROUBLESHOOTING
DO NOT open or clear the crimper without first shuttin down electrical power
and air.
SYMPTOM PROBABLE CAUSE SOLUTION
Contacts not Crimper in rip position cycle power by
feedin pressin button
twice
Bowl is overfilled Turn OFF machine,
remove excess
contacts and clear
exit for proper
shuttlin .
Contact stuck in the Turn OFF machine,
feed tube shake feed tube
to loosen contact.
Feed tube obstruction Remove & clean
tube, and inspect
shuttle at tube
connection.
Escapement jam Refer to Maintenance
Section 6.5.
Model #CDS-LC C. Davis Systems Inc. Operations Manual

C. Davis Systems CDS-LC
SYMPTOM PROBABLE CAUSE SOLUTION
Loss of air Check air supply,
hoses, air filter
element, and air
valve. Replace
if needed.
Contact jammed Wire pushed in crimper power cycle machine,
in Crimper before crimper was ready clear by hand if needed
followin all safety
precautions pertainin
to power and air.
Loss of air pressure Check Air pressure and
lines
Funnel does not Loss of air Check air supply hoses
open and air valve.
Replace, if needed.
Machine rattles Feeder bowl is set to Reset bowl ap
real loud when close to Escapement accordin to section
contact is selected 3.1
Contact stuck between Remove contact from
bowl and Escapement between bowl and
Escapement. Check
Settin accordin to
section 3.1
Bowl does not Bowl vibration is low Amplitude
move contacts adjustment may
up to escapement need to be
adjusted to
factory settin .
Bowl mountin
bolt not ti ht.
Bowl vibration does Check power check power supply
not come on and Bowl driver
fuse. Fuse is
located in electrical
box on the bowl
controller, #6005.1.
Model #CDS-LC C. Davis Systems Inc. Operations Manual

C. Davis Systems CDS-LC
6.0 MAINTENANCE
6.1 Maintenance Procedures
USE EXTREME CAUTION WHEN TESTING AND CALIBRATING
ELECTRICAL AND PNEUMATIC DEVICES WHILE POWER IS
ON. HIGH VOLTAGE IS PRESENT WHEN COVER IS
REMOVED.
6.1.1 The air filter should be inspected re ularly. The re ularity of
inspections is dependent upon the accumulation of water
and debris in the air-lines. Replace filter, as necessary.
6.1.2 The Crimper should be inspected periodically to determine
wear. Lubricate with KRYTOX hi h performance lubricant,
as required.
Model #CDS-LC C. Davis Systems Inc. Operations Manual

C. Davis Systems CDS-LC
6.1.3 Clean the bowl with a water dampened cloth, as needed.
Never use sharp objects or cleanin solution .
6.2 Crimper Disassembly (see drawing below)
The funnel base is bolted to the crimper. The funnel jaws (item #9)
are mounted on top of it. To remove the jaws remove the 2 socket
head cap screws that hold the funnel jaw uide in place (item #11).
Gently slide the jaws as one unit off the 2 dowel pins. The jaws are
held to ether with a tension sprin . Now the crimp tool may be
accessed. Do not remove the screws from the crimper body. To
remove crimper, Remove main screws (#8 & 16) and ently
remove crimp tool.
Model #CDS-LC C. Davis Systems Inc. Operations Manual

C. Davis Systems CDS-LC
6.4 Adjusting Amplifier
Locate the contact sensor amplifiers inside the electrical box. It
has a small red and reen LED on it with a white set button. With
no contact in the head, push and hold the white set button. A small
white LED should start blinkin (after about 3 sec.). Then release.
The sensor should now be properly adjusted. With the contact
removed the red LED should be off.
There may also be other amplifiers located in the electrical box.
They are to be set in the same manor above. The CDS-LC model
machine may not use a fiber optic sensor at all depending on
the contact.
NOTE: On some vertical escapements, the red and reen LEDs
alternate when a part passes in front of them. All sensor amplifiers
should be adjusted with no part in front of them and completely
assembled
Model #CDS-LC C. Davis Systems Inc. Operations Manual

C. Davis Systems CDS-LC
6.5 Escapements
The Escapement is the component of the machine that sin ulates
and feeds the contact to the crimp head. It is mounted at or on the
end of the feeder bowl. The feeder bowl will feed the parts into the
escapement. There is a sensor on the Escapements to tell the
machine when it is full. Which type of Escapement you have can
be observed by its style.
With Slide type Escapements the contacts drop into it from the
feeder bowl and slide down to the Shuttle. They stack up until they
are in front of the sensor. At that point the bowl will shut off or that
bowls Air ate will come on. The ap between the feeder bowl and
the Escapement should be less then half the size of the contact to
prevent the contact from droppin down into the ap. If the bowl
rattles a ainst the Escapement, it is to close. If a wron contact
ets in the bowl it will feed into the escapement and drop to the
bottom and slide down into the shuttle causin it to jam. By
removin all the contacts out of the Escapement you can retrieve
the wron contact without takin the Escapement apart.
With Vertical Escapements The contacts feed into the Orientation
devise that puts the contact into position before droppin it into the
Escapement. The Orientation devise is mounted directly to the
feeder bowl. It must be ali ned with the Escapement to feed the
contact into the Escapement. Half way down the Escapement is a
device we call the Pickle Fork. It is the devise that holds the stack
up and lets one part at a time drop into the Shuttle at the bottom. In
the event of a wron or bent contact ettin into the Escapement,
the front cover can be removed by unscrewin the two thumb
screws in the front to access all of the mechanism within. Just
remove the contacts (includin the one in the Shuttle) and
reassemble. The fiber optic sensor should never stick into the
vertical track. To set the fiber optic sensor, refer to section 6.4.
With Zig-Zag Escapements The contacts are fed ri ht into the
Escapement and are stacked in the Zi -Za track. The contacts are
oriented just before sendin them to the Crimp head. A sensin
device or sometimes a mechanical orientatin device is used. The
front cover can be removed to access bad or bent contacts. If you
open the front and turn on the feeder bowl, it will feed all the
contacts out of the Escapement. The fiber optic sensor should
never stick into the track. To set the fiber optic sensor, refer to
section 6.4.
Model #CDS-LC C. Davis Systems Inc. Operations Manual

C. Davis Systems CDS-LC
7.0 SPARE PARTS
RECOMMENDED SPARE PARTS LIST FOR THE CDS-LC
ITEM
NUMBER
PART NUMBER ITEM (not all items are used on
every machine. List covers all
machines.
APROX.
LEAD
TIME
1 CDS-P107 PLC 2 weeks
2 0275-701303 Omron Que & Puff Sensor 2 weeks
3 0275-790243 Sensor Amplifier (VS21R) 2 weeks
4 0275-790244 Fiber Optic Sensor 2 weeks
5 Misc. Parts 1-1/2” Cylinder Sprin Extend 3 weeks
6 CDS-M050 Cylinder Mount 3 weeks
7 0750-700174 Funnel Cylinder 2 weeks
8 CDS-P048-B Duetsch crimper 4 weeks
9 CDS-P063 Funnel Jaw Assembly 4 weeks
10 CDS-M041 Funnel Jaw Guide 4 weeks
11 CDS-P059 Funnels 4 weeks
12 CDS-P037 Feeder Controller Cube 2 weeks
13 CDS-P108 Air Valve 3 weeks
14 CDS-M064 Positioner Body 4 weeks
15 CDS-M065 Positioner Insert 4 weeks
16 CDS-P106 Fabco Cylinder 2 weeks
17 CDS-P050 Indenter Sprin 1 week
18 0765-771250 Spare Crimp Head 4 weeks
19 0765-790049 ¼’ Reject “y” 2 weeks
20 CDS-P012 ¼” Feeder Tube (per ft.) 2 weeks
21 CDS-P027 Quick Exhaust Valve 3 weeks
22 CDS-P115 Booster 2 weeks
*Please call for pricin
*Lead times may vary dependin on quantity
Model #CDS-LC C. Davis Systems Inc. Operations Manual

C. Davis Systems CDS-LC
Model #CDS-LC C. Davis Systems Inc., Project #3524 Operations Manual April, 20 Pa e 1 of 1