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

©2012 Tyco Electronics Corporation, a TE Connectivity Ltd. Company
All Rights Reserved
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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.