TE Connectivity AMP 3K/40 CE 2161600-1 User manual

©2012 Tyco Electronics Corporation, a TE Connectivity Ltd. Company
All Rights Reserved
*Trademark
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners.
Customer Manual
TOOLING ASSISTANCE CENTER 
1-800-722-1111
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.te.com
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LOC B
customer manual
409-32021
READ THIS FIRST ! . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
AMP 3K/40 CE Terminators (with Stripping Module)
2161600-[ ] and AMP 5K/40 CE Terminators (with
Stripping Module ) 2161700-[ ] 08 FEB 12 Rev A
A.
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1. Functional Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2. Electrical Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3. Machine Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4. Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3. RECEIVING INSPECTION AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1. Receiving Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 9
3.2. Installation of Terminator and Stripping Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3. Considerations Affecting Placement of the Machine. . . . . . . . . . . . . . . . . . . . . . . . . .12
4. OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
4.1. Host Module Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
4.2. Applicator Setup and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
4.3. Stripping Module Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
5. PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
5.1. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
5.2. Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
5.3. Terminator Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
6. DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
7. MECHANICAL ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.1. Strip Blade Closure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
7.2. Strip Length Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
7.3. Wire Brush Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
7.4. Gripper Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
7.5. Tonk Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
7.6. Strip Cam Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
7.7. Start Sensor Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
8. ELECTRICAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
9. PARTS REPLACEMENT AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
10. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
11. DISPOSAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
12. ROHS INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
13. REVISION SUMMARY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SAFETY PRECAUTIONS
ORIGINAL INSTRUCTIONS

409-32021
SAFETY PRECAUTIONS AVOID INJURY
Safeguards are designed into this application equipment to protect operators and maintenance personnel from most hazards
during equipment operation. However, certain safety precautions must be taken by the operator and repair personnel to
avoid personal injury, as well as damage to the equipment. For best results, application equipment must be operated in a dry,
dust-free environment. Do not operate equipment in a gaseous or hazardous environment.
•Carefully observe the following safety precautions before and during operation of the equipment:
•ALWAYS wear appropriate ear protection.
•ALWAYS wear approved eye protection when operating powered equipment.
•ALWAYS keep guard(s) in place during normal operation.
•ALWAYS insert power plug into a properly grounded receptacle to avoid electrical shock.
•ALWAYS turn off the main power switch and disconnect electrical cord from the power source when performing
maintenance on the equipment.
•NEVER wear loose clothing or jewelry that may catch in moving parts of the application equipment.
•NEVER insert hands into installed application equipment.
•NEVER alter, modify, or misuse the application equipment.
•NEVER enter the electrical enclosure immediately after turning off the machine power switch and disconnecting the
electrical cord from the power source. High residual voltages may be present in the electrical enclosure. Read the
warning label on the electrical enclosure lid before entering the enclosure.,
TOOLING ASSISTANCE CENTER
CALL TOLL FREE 1-800-722-1111 (CONTINENTAL UNITED STATES AND PUERTO RICO ONLY)
The Tooling Assistance Center offers a means of providing technical assistance when required.
In addition, Field Service Specialists are available to provide assistance in the adjustment or repair of the
application equipment when problems arise which your maintenance personnel are unable to correct.
INFORMATION REQUIRED WHEN CONTACTING THE TOOLING ASSISTANCE CENTER
When calling the Tooling Assistance Center regarding service to equipment, it is suggested that a person familiar
with the device be present with a copy of the manual (and drawings) to receive instructions. Many difficulties can
be avoided in this manner.
When calling the Tooling Assistance Center, be ready with the following information:
1. Customer name
2. Customer address
3. Person to contact (name, title, telephone number, and extension)
4. Person calling
5. Equipment number (and serial number if applicable)
6. Product part number (and serial number if applicable)
7. Urgency of request
8. Nature of problem
9. Description of inoperative component(s)
10. Additional information/comments that may be helpful
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DANGER
STOP

Main Guard
Gripper Pressure
Regulator
Reel Support Bracket
Terminator Control Panel
Terminal Strip Guide
Work Light
Stripping Module
Optional CQM II
DAQ Module
Host Module
TERMINATOR TE PART NUMBER
AMP 3K/40 CE Terminator with Stripping Module 2161600-1
AMP 3K/40 CE Terminator with Stripping Module and CQM II 2161600-2
AMP 5K/40 CE Terminator with Stripping Module 2161700-1
AMP 5K/40 CE Terminator with Stripping Module and CQM II 2161700-2
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Figure 1
1. INTRODUCTION
This manual contains information on the operation, adjustments and preventive maintenance of stripping
modules used on AMP 3K/40 CE terminators 2161600-[ ] and on the AMP 5K/40 CE terminators 2161700-[ ].
Refer to Figure 1.
For information concerning the AMP 3K/40 CE terminators and AMP 5K/40 CE terminators , refer to 409-10204
and any documentation included with the terminator.
Most side-feed and end-feed heavy-duty mini applicators and light-duty mini applicators can be run with the
stripping module. Slight modifications may be required to run these applicators; most modifications involve
removing the wire stop. Refer to Paragraph 4.2, Applicator Setup and Installation.
Refer to the applicator instruction sheet and documentation included with the applicators for operation,
adjustment, and preventive maintenance of the applicators.
NOTE
i
The “start sensor” is also referred to as the “wire sensor.”

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Always wear approved eye protection while operating the equipment.
Always wear approved hearing protection while using the equipment.
Use caution working with this equipment..
Main electric ON/OFF switch.
Do NOT operate the equipmentt if the guard is removed.
Lift point for the equipment.
Read and understand the entire manual before using the equipment.
Moving parts can crush and cut. Do not operate the equipment without guards in place.
When reading this manual, pay particular attention to DANGER, CAUTION, NOTE statements.
Denotes an imminent hazard which may result in moderate or severe injury.




Denotes a condition which may result in product or equipment damage. 



Highlights special or important information. 


DANGER
STOP
CAUTION
!
NOTE
i

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2. DESCRIPTION
The Stripping Module is a pneumatically driven, microprocessor controlled, in-line stripping module designed to
be used to provide wire stripping capability to the AMP 3K/40 CE terminator and AMP 5K/40 CE terminator
Machines. The stripping modules accept a wide range of wire insulation types.
It is assembled with metric hardware.
NOTE
i
Measurements are in metric units [followed by U.S. customary units in brackets]. Some commercial items may contain
non-metric hardware.
Figure 2 contains specifications and requirements for the stripping module.
Wire Range Base Module: 0.03mm - 2.0mm (32-14 AWG)
Maximum Insulation 5.08mm (.200 In.)
Cable Breakout: Greater than 29mm (1.14 In.)
Strip Length: 2.54mm - 10.16mm (.100 In. - .400 In.)
Gripping Jaw Pressure: Variable air pressure
Noise: Less than 82dBa Typical at Operator Position
with Standard Mechanical Feed Applicator
Weight: 4.55 Kilograms [10 lb.]
Height: 127mm [5 In.]
Electrical: +24VDC (Supplied by the Terminator)
Air: 620-760 KPA [90-100 psi], 2.83 liters/sec (6
scfm)
Physical Environment (Temperature): 4.45 C to 605 C [405 F to 1045 F]
Altitude: Not Applicable
Relative Humidity: Less than 95% (non-condensing)
Transportation and Storage: Storeinaclean,dryenvironmentafter coating all
surfaces lightly with a rust preventing oil.
Figure 2
2.1. Functional Description
The stripping module is a mechanism which will prepare discrete wire by stripping the insulation from the
conductor for preparation of a crimp onto a terminal.
The machine consist of three functional areas.
The transfer sub-assembly consists of the side transfer block, applicator latches, and the transfer air
cylinder. This sub-assembly provides a means of sliding the mechanism to the side so that the terminal
may be applied to the wire. See Figure 3.
The gripper sub-assembly consists of the upper and lower grip jaws, the gripper mounting block, the
left and right gibs, the jaw drive block, and the gripper air cylinder. The gripper sub-assembly provides a
means of holding the wire during the wire stripping and terminal application process. The gripper
mechanism is "tonked" during the machine cycle to place the stripped wire in the terminal wire barrel.
See Figure 3.
The stripping sub-assembly consists of the U-block, the main block, the gibs, the blade drive block, the
blade adjust block, the inner and outer strip blades, the start sensor block, start sensor arm, the start
sensor, the start sensor air cylinder, the strip cam, and the strip air cylinder. This sub-assembly drives the
inner strip blade to cut through the wire insulation. It also moves part of the mechanism away from the
operator to pull the insulation slug off the wire. The mechanism also contains the wire start sensor to
begin the cycle. See Figure 3.

Transfer Subassembly
Stripping Subassembly
T-Handle Location
Precision Adjust
Tonk Block
Gripper 
Subassembly
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Figure 3 (Cont’d)

Strip Cylinder
Strip Cam
Main Block
Start Sensor Assembly
Outer Strip Blade
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Figure 3 (End)
2.2. Electrical Description
The stripping module components consist of the host module, electrically controlled pneumatic valves, and
various switches and sensors. The host module operates on +24VDC power which is supplied by the terminator.
The terminator main power switch applies power to the terminator and to the host module. The main power
switch / circuit breaker is located on the front of the terminator operator control panel.
The host module is mounted to a bracket on the right side of the machine. See Figure 1. The host module has
an LCD touch screen and provides operating screens for setup and operation of the stripping module. Refer to
Section 4 for a description of stripping module screens and controls.
2.3. Machine Guard
A combination of guards is installed to provide protection for the operator while maintaining proper visibility of
the work area. The main guard (Figure 1) swings open to the left and the hinged guard (Figure 1 and Figure 4)
swings open to the right to allow easy access for applicator installation and setup. Safety interlocks on the
guards prevent the machine from cycling if the guard doors are open during production operation.

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2.4. Description of Operation
The strip and crimp cycle of operation is as follows:
1. The cycle may be started automatically (with "Wire Sensor" selected as the starting means), or with the foot
switch. In automatic operation ("Wire Sensor" selected as the starting means), the operator places a wire
through the grip jaws and strip blades to depress the wire sensor, which automatically starts the cycle. If the
foot switch was selected as the starting means, the operator depresses the foot switch to activate the cycle.
2. The gripper jaws then close on the wire while the strip blades close to cut through the insulation. The
stripping mechanism pulls the blades away from the operator to remove the insulation slug.
3. The stripping unit shifts to the "right side position" to remove the stripping blades from the applicator.
4. The terminator cycles to crimp a terminal onto the wire.
5. After completing the crimp, the grippers open to release the crimped wire and the stripping blades retract.
6. The wire sensor arm then retracts so that the air blast can blow the insulation slug into the scrap bin.
7. The stripping unit then transfers back to the start position.
Host Module
(Stripping Module Display)
Optional CQM II
DAQ Module
Hinged Guard Right Guard Pneumatic Assembly
ElectricalControlBox
Figure 4

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3. RECEIVING INSPECTION AND INSTALLATION
3.1. Receiving Inspection
The Stripping Module is 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 packaging
and carefully inspect the machine for damage. If damage is evident, file a claim against the carrier and
immediately notify TE.
DANGER
STOP
To avoid personal injury, be sure to turn "off" and disconnect power to the machine.
3.2. Installation of Terminator and Stripping Module
Remove all mounting bolts securing the terminator to the shipping pallet. Install lift ring on top of the machine.
Lift point for the equipment. Place the lift ring in the supplied hole. Lift ring (M12 X 20 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 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, then
proceed as follows:
1. Connect the power cord to a suitable electrical supply.
NOTE
i
The machine will automatically detect the supply voltage and adjust the controller accordingly.
NOTE
i
Models exported to Europe will be installed by TE Service Representatives. These representatives will verify that the
electrical and pneumatic connections are correct. Both pneumatic and electrical connections must be installed in a way
that provides a lockable isolation switch for hard-wired or direct piped machines. This is necessary to interrupt power to
the machine for setup or maintenance.
2. Connect the pneumatic assembly to a suitable air supply.
3. Apply AC power to the machine by turning on the main power switch. The host module will proceed through
a start-up process.
4. The host module is used on a variety of different pieces of equipment. It is necessary to configure the host
module for the equipment being used.

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a. Press the tools icon at the top of the screen.
Tools Icon
b. Scroll down and touch the System Settings icon.
System Settings Icon
c. Select the terminator marked “AMP 3K/5K CE” from the host machine pull-down menu.
Appropriate
Terminator Pull-Down Menu

d. Then select the Stripper Module button as shown below.
NOTE
i
Currently, the stripper module can only be used with this version of the machine.

Pull-Down Menu
Stripper Module 
Installed
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This completes configuration of the host module for the AMP 3K/40 CE terminator or AMP 5K/40 CE
terminator stripping module.
After configuring the host module, proceed as follows:
1. Remove the applicator.
2. Manually return the terminator ram to the top of its travel (TDC).
3. If it hasn’t been done already, connect air and turn "on" the main air shut-off valve.
4. Close all guards.
5. Reset the stripping module. Resetting the stripping module brings up the air to the stripping module and
causes the mechanisms to move to their home position.
NOTE
i
The stripping module is not reset if a red “X” is displayed as shown in the bottom left corner of the screen or if there is an
exclamation point displayed there indicating the system is in “Error mode”.
Red “X” Indicates NOT 
Reset.
To reset the stripping module touch the red “X” or exclamation point and press the reset button when displayed.

Reset Button
NOTE
i
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This screen will only be displayed for a few seconds if the user does not press one of the buttons shown. 
A green check will indicate that the stripping module has been reset.
Green Check
IndicatesStripping
Module Has Been
Reset.
NOTE
i
The user can go back into the Reset Screen at anytime by touching the icon in the lower left corner. If the system is
already reset an “Off” button will be active and can be used to remove air from the stripping module.

6. Check for proper functioning of the machine by operating the stripping module in step mode. Refer to
Paragraph 4.1.
3.3. Considerations Affecting Placement of Bench Machines
The location of the machine in relation to the operator's position is extremely important in terms of both safety
and maximum efficiency. Studies have repeatedly shown that operator fatigue will be reduced, and greater
efficiency achieved, if: (1) the bench is of appropriate height, preferably with sound-deadening rubber mounts;
(2) the machine is properly located on the bench with ample work areas on both sides to facilitate work flow; (3)
the operator uses a swivel chair with padded seat and back rest which are independently adjustable; and (4) the
foot switch, on machines so equipped, is placed on a rubber mat to maintain its movability, while preventing it
from sliding unintentionally. Figure 6 illustrates proper machine location and operator position.

Mounting Hole
Mounting Hole
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Figure 5
Figure 7illustrates:
A. Bench
The bench to be used should be of sturdy construction, preferably with rubber mounts to minimize noise. A
height of 762.0mm to 812.8mm [30 in. to 32 in.] is the most suitable for operator 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.
B. Machine Mounting and Location on Bench
The machine should be located near the front of the bench with the "target area" (tooling area where the
product is applied) not more than 152.4mm to 203.2mm [6 in. to 8 in.] from the front edge, or a minimum of
50.8mm [2 inches} from the front edge, as shown in Figure 5. This location will eliminate unnecessary
operator motion and help to avoid back strain and fatigue.
Orientation of the machine should be such that the "target area" is facing the front of the bench and is parallel
to the front edge. (Access to the back of the machine MUST also be provided.)
Machines should be securely bolted to the bench. Machines should not extend beyond the front of the bench.
Figure 6

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Figure 7
C. Operator's Chair
The operator's chair should swivel, and should have independent seat height and back rest adjustments. The
seat and back rest should be padded, and the back rest should be large enough to provide support both
above and below the waist line.
In use, the chair should be far enough under the bench so that the operator's back is straight and is supported
by the back rest.
4. OPERATION
4.1. Host Module Controls
To operate with the stripping module, the options screen must have Use Stripper Module selected. To operate
without the stripping module (crimp only operation), deselect the radio button marked Use Stripper Module.,
Select or Deselect
Use Stripper Module
On the stripper screen (Figure 8) the operator can select how the stripping operation is to be performed.

DEFINITION ACTION
Mode Selection: Allows the user to select the strip option or strip and crimp option
Enable Via: Allows the user to select whether the wire sensor or footswitch is used to
cycle the system.
Air Blast Duration: Allows the user to increase or decrease the duration that the air blast is applied. Longer air blast durations may be necessary to remove stripped
debris from the tooling. The default value is .4.
Transfer Return Delay: Allows the user to increase or decrease the delay time to allow for easier removal of the completed crimps from the tooling after each cycle. The
default is .2.
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Figure 8
The Production screen is where the user is able to cycle the system in full cycle or step mode. See Figure 9.
Figure 9

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To operate the machine in step mode the radio button "Single Step Mode" must be selected. Once in single step
mode each touch of the step button will perform a single step until the cycle has been completed. See Figure 10.
Single Step Mode Icon StepButton(ForOperating in
Step Mode)
Figure 10
NOTE
i
In this mode, neither the “wire sensor” nor the footswitch are used.
NOTE
i
The “Calculate Head Room” Button, Force vs Time Graph, Nominal Crimp Height, and the Part Number display are only
displayed on this screen if the stripping module is used in conjunction with the CQM II option.
In addition, several icons may be displayed on the right-hand side of the screen to indicate the current
operational status of the machine. These icons are (Figure 11):
The “jog” icon indicates that the terminators Jog buttons are operational and jogging of the terminator is allowed.
The footswitch icon indicates that footswitch was selected to be used to cycle the system.
This icon indicates that the machine was set up for strip and crimp mode.
Figure 11
4.2. Applicator Setup and Installation
A. Side-Feed/End-Feed Applicator Preparation
Prepare side-feed applicators for use with the stripping module by removing the applicator wire stop. Prepare
end-feed applicators for use by removing the applicator wire stop and moving the track-mounted "hold down"
back as far as possible.
Install the applicator onto the terminator (Paragraph 4.2,C). Adjust the wire brush and strip length and check
for any interferences. If interference with the track-mounted "hold down" exists, remove the track-mounted
"hold down."
B. Terminal Sticking Elimination/Prevention
Certain types of terminals are more likely to stick in the crimpers than other types. In many types of
application equipment, the wire stop acts as a terminal stripper. When using the stripping module, however,
the wire stops must be removed.
Besides removing the applicator wire stop, the following methods may be used to eliminate/prevent terminal
sticking:
•Use a terminal lubricator.
•Use a spring-loaded, ram-mounted wire depressor mounted between the crimper and the wire barrel
crimper.
•Use a ram-mounted terminal "hold-down" commonly found on end-feed applicators.

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C. Applicator Installation/Removal
It may be necessary to install the applicator from either the left side or the right side of the gripper mechanism,
depending on the applicator and type of product being run. Instructions for installing the applicator from the
left side and the right side are listed below.
To remove the applicator, disconnect power to the machine and remove in reverse order of installation.
Left-Side Installation
DANGER
STOP
To avoid personal injury, be sure to disconnect power to the module and the terminator before installing or removing the
applicator
1. Slide the stripping module and movable part of the transfer assembly to the right side position.
2. Remove the tonk from the ram post adapter.
3. Loosen the screw holding the scrap deflector and rotate the scrap deflector toward the front of the machine.
4. Loosen the applicator latch on the machine base plate and push it out of the way.
5. From the left side of the gripper assembly, tilt the applicator and place it in position on the base plate.
6. Slide the applicator ram into the ram post of the terminator.
7. Place the left (applicator) latch on the terminator into the slots on the applicator base plate.
8. Lift the right (applicator) latch and tighten against the applicator base plate.
9. Rotate the scrap deflector back against the applicator base plate and tighten the hold down screws
10. Install the tonk into the ram post adapter.
11. Manually cycle the terminator and stripping module to verify fit, clearance, and proper operation.
Right-Side Installation
DANGER
STOP
To avoid personal injury, be sure to disconnect power to the module and the terminator before installing or removing the
applicator.
1. Remove the upper portion of the strip assembly by loosening the locking latch on the right side of the
transfer assembly.
2. Lift the strip assembly off the transfer assembly and set it on a work bench.
3. Remove the tonk from the ram post adapter.
4. Loosen the screw holding the scrap deflector and rotate the scrap deflector toward the front of the machine.
5. Loosen the (applicator) latch on the machine base plate and push it down out of the way.
6. From the right side, place theapplicator on the base plate.
7. Slide the applicator ram into the ram post of the terminator.
8. Place the left (applicator) latch on the terminator base plate into the slots on the (applicator) base plate.
9. Lift the right (applicator) latch and tighten it against the applicator base plate.
10. Rotate the scrap deflector back against the applicator base and tighten the hold down screws.
11. Place the upper portion of strip assembly back on the transfer assembly.
12. Partially tighten the locking latch.
13. Push the upper portion of the strip assembly toward the rear of the machine until the wire brush
adjustment screw bottoms on the rear stop.
14. Install the tonk into the ram post adapter.
15. Manually cycle the terminator and stripping module to verify fit, clearance, and proper operation.

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4.3. Stripping Module Removal
The stripping module may need to be removed when changing applicators (refer to Paragraph 4.2,C for
applicator installation procedures).
DANGER
STOP
To avoid personal injury, be sure to disconnect power to the module and the terminator before installing or removing the
stripping module.
1. Loosen the cap screw located at the right side of the module.
2. "Back off" the clamp on the right side of the module.
3. Slide the module to the right and lift "up," to removing the module from the mounting base.
5. PREVENTIVE MAINTENANCE
Preventive maintenance will keep the stripping module in good working order and ensure maximum reliability
and service from all of its components.
DANGER
STOP
To avoid personal injury, electrical and pneumatic power must be DISCONNECTED at the source prior to maintenance.
5.1. Cleaning
Clean any debris from the stripping module daily.
DANGER
STOP
Compressedair used for cleaningmust be reducedto less than 207kPa[30 psi], and effectivechip guardingand personal
protective equipment (including eye protection) must be used.
If an air-feed assembly is installed, check and replace the air filter element if necessary.
Wipe off the guards with a clean soft cloth.
CAUTION
!
DO NOT USE ANY SOLVENT TO CLEAN THE GUARDS. Solvent could damage the guards.
Remove the stripping assembly and proceed as follows:
a. Thoroughly clean both the stripping assembly and the area in and around the base plate.
b. Inspect the stripping assembly for damaged parts, clean the assembly and remove all insulation scrap
and wire strands.
c. Remove all insulation scrap and wire strands from the gripper assembly.
d. Re-install the stripping assembly.
5.2. Lubrication
Lubricate all sliding surfaces with a general purpose grease at least every 250,000 cycles.
NOTE
i
Apply grease to groove in the bottom of the strip cam.
Apply light weight oil to the surfaces of the strip blades.
CAUTION
!
Do NOT get oil on the cutting surfaces of the blades, or sticking of the insulation slug may occur.

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Use a grease gun to apply grease to the transfer assembly through the grease fitting at least every million
cycles.
NOTE
i
It is necessary to remove the Tooling-In Position Switch to gain access to the grease fitting.
5.3. Terminator Preventive Maintenance
For preventive maintenance procedures for the terminator, refer to customer manual 409-10204.
When performing the monthly mandatory safety checks in the terminator manual, be sure the stripper module is
disabled during the tests. For example, when the guards are opened, or the magnetically operated switch
actuator is removed, power to the stripper module main air valve is removed, disabling it's operation.
6. DIAGNOSTICS
The easiest way to verify correct operation of the stripping module is by manually operating the unit in “Single
Step Mode” as described in Paragraph 4.1.
If further diagnostic troubleshooting is necessary the user can go to “Diagnostics Mode”.
CAUTION
!
Diagnostics mode should only be attempted by someone thoroughly knowledgeable with the equipment. In “Diagnostics
Mode” outputs can be turned on or off directly by the user. It is possible for the user to damage tooling by directly turning
on outputs that cause tooling to collide.
To enter the Diagnostics Mode, proceed as follows:
1. Touch the “Tools” icon on the menu bar. (it may be necessary to touch the upside-down triangle (back
arrow) in the upper right corner of the screen to bring up the menu bar). See below.
Menu
Bar
Tools Icon
Upside-down Triangle
(Back Arrow)
2. Scroll down and touch the “Diagnostics” icon as shown in Figure 12.

Diagnostics
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Figure 12
3. Touch the tab marked “AMP 3K/5K CE diagnostics tab”. See Figure 13
Figure 13
The Stripping Module I/O can be viewed and changed (outputs).
CAUTION
!
The user should be completely familiar with all stripping module mechanisms before attempting to change any
outputs, otherwise diagnostics mode is not recommended and the user should instead go to “Single Step”
operation on the “Production Screen”