TE Connectivity Basic AMP-O-LECTRIC K 1-471273-3 Reference guide

©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
409-5128
READ THIS FIRST ! . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Basic AMP-O-LECTRIC* Model “K"
Terminating Machine 471273-[ ], Main
Accessories and Most Common Modifications 17 JAN 12 Rev Z
SAFETY PRECAUTIONS
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1. Physical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2. Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3. Vertical Reel Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4. Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3. RECEIVING INSPECTION AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1. Receiving Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2. Factors Affecting Machine Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.1. Hand Cycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.2. Production Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5. PREVENTIVE MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.1. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.2. Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.3. Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6. TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7. ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.1. Crimp-Height/Shut-Height (Base Mount) Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . 17
7.2. Feed Connecting Rod Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.3. Feed Mechanism Damper Screw and Rear Stop Screw Adjustment. . . . . . . . . . . . . 18
7.4. Guard Installation and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8. REPLACEMENT AND REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.1. Trip Control Box Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.2. Foot Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
9. PARTS LIST AND EXPLODED VIEW DRAWINGS FOR BASIC MACHINE . . . . . . . . . . 21
10. MACHINE ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
11. MODIFIED MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
12. ROHS INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
13. REVISION SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

409-5128
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.
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

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Figure 1
1. INTRODUCTION
This manual covers basic AMP-O-LECTRIC Model "K" Terminating Machine 1-471273-3 and 1-471273-4
(shown in Figure 1), main accessories, and most common modifications.
MACHINE NUMBER MACHINE DESCRIPTION
1-471273-3 115 Vac, 60 Hz, and comes with Mechanical Feed Option 692140-2 factory installed
1-471273-4 230 Vac, 50 Hz, and does NOT include Mechanical Feed Option 692140-2
The machine is used to power the applicator that applies strip-fed terminals to wire. In addition, the machine is
also used as the principal component in other special application equipment covered in separate customer
manuals. These manuals refer to this one for basic machine information and parts.
Sections 1 through 9 provide a machine description and information on its installation, operation, maintenance,
troubleshooting, adjustment, repair, and parts replacement. Section 10 covers the accessories used to modify
the basic machine to a different configuration. When the accessories are factory installed, the machine part
number on the nameplate changes from the basic number to one identifying the modified configuration. Section
11 discusses these modified configurations by part number. The accessories are also available as kits for field
conversion, in which case the machine part number will no longer identify the configuration.

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Packaged with every applicator is a parts list identifying the required machine number for that applicator. The
parts list also identifies the accessories necessary to convert the machine to the required configuration.
The basic machine is fitted to accept standard applicators, which are semi-permanently mounted to the machine
for production of one size and type of terminal without the need for frequent changeover of applicators or
changes in the applicator crimp height. The most frequent field conversion is a kit to adapt the machine for
miniature quick-change applicators, which are easily installed and removed and allow simple adjustment of the
crimp height. Instruction sheet 408-8022 provides a parts list for the kit and the necessary instructions for
converting a basic machine for standard applicators to miniature quick-change applicators.
An instruction sheet, packaged with each applicator, provides information on applicator installation, care, and
adjustment. The instruction sheet, the applicator parts list, and this manual collectively provide complete
documentation for the various production setups involving applicators and the Model "K" terminating machine.
When reading this manual, pay particular attention to DANGER, CAUTION, NOTE statements.
DANGER
STOP
Denotes an imminent hazard which may result in moderate or severe injury. 


!
CAUTION
Denotes a condition which may result in product or equipment damage. 


NOTE
i
Highlights special or important information. 


NOTE
i
Dimensions in this manual are in metric units [with U.S. customary units in brackets]. 


Reasons for reissue of this document are provided in Section 12, REVISION SUMMARY.
See Figure 2 for specifications for the machine.
DIMENSIONSs:
Height 610 mm [24 in.]
Width 533 mm[ 21 in.]
Depth 508 mm [20 in.]
WEIGHT
Basic machine without aplicator 104 Kg [230 lbs]
POWER REQUIREMENTS
Electrical (1-471273-3) 115 Vac, single phase with separate ground, 60 Hz, 6 Amps
Electrical (!-471273-4) 230 Vac, single phase with separate ground, 50 Hz, 3 Amps
Air (if used) 552-827 kPa [80 - 120 psi]
Figure 2
2. DESCRIPTION
2.1. Physical Description
The basic machine consists of a cast-iron frame with a flywheel guard in back that is hinged to the frame. Inside
the guard is a 1/4-hp motor, flywheel assembly, transmission assembly, toggle lever, and feed actuating
components. Mounted on the right side of the frame, facing the operator, is the feed arm drive shaft and the

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vertical reel bracket assembly. The electrical system consists of a main power switch, work lamp, and panel light
located on the left front of the machine; a trip control box assembly inside the back cover; a foot switch; and
electrical wiring. The motor is bolted to a mounting plate that is hinged to the machine frame by a support pin.
The weight of the motor provides enough tension to the V-belt for driving the flywheel.
The basic machine does not contain a ram or base mount. These are supplied with the applicator or the
conversion kit. The ram is mounted behind the ram retaining plate on the front of the frame.
The frame contains holes for bolting the machine to a bench at a height convenient for the operator as described
in Section 3.
2.2. Functional Description
The motor-flywheel assembly runs continuously when the control switch is "on." The flywheel turns on the main
shaft of the transmission until the foot switch is depressed to actuate the solenoid on the transmission. The
energized solenoid pulls up the stop bar (see Figure 3) to release the clutch dog (sliding key), which is then
forced toward the flywheel by spring pressure. The end of the clutch dog then slides into the first opening it
encounters in the drive plate on the rotating flywheel. This connects the rotating flywheel and the drive shaft to
start the machine cycle.
At approximately 270° in the rotation cycle, the beveled forward edge of the notch in the clutch dog encounters
the dog wedge ramp on the face of the dog retainer support. As the clutch dog slides up this ramp against spring
pressure, it is withdrawn from the flywheel drive plate.
Transmission Operation
To Solenoid
Stop Bar (Pawl)
Clutch Dog
(Sliding Key)
Toward Front of
Machine
Shaft
Center Line
Backup Latch
(Pawl)
Cam
Lobe
Stop Collar Dog Retainer
Support
Drive Plate 
(On Flywheel)
Dog Wedge Ramp
Machine in REST Position
Figure 3
During the cycle, the cam on the rear face of the stop collar rides over the pin on the rear finger of the stop bar,
forcing it down to retain the clutch dog in the rest position at the end of the cycle. This brings the end of the front
finger of the stop bar in position to contact one side of the lobe on the front of the stop collar to prevent further
forward rotation of the drive shaft. At the same time, spring tension forces the backup latch in against the
opposite side of the lobe on the stop collar to prevent reverse rotation.
An eccentric arm is keyed to the forward end of the main shaft (see Figure 9). The arm is at TOP-DEAD-
CENTER when the machine is in the rest position. Attached to the arm is a spherical bearing link that actuates
the toggle lever subassembly.

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The toggle lever subassembly is secured in the frame by the toggle arm pin at the front (see Figure 4). This pin
acts as the pivot point. Another pin connects the link to the lever, and the opposite end of the link is connected to
the ram by a pin.
The feed actuating mechanism (see Figure 13) is driven by the toggle lever. The feed connecting rod is joined to
the toggle lever by a pin and clevis. A compression spring is installed over the connecting rod, extending from
the clevis to the feed actuating block at its lower end. The spring absorbs the overaction and allows for feed
adjustment. The feed actuating arm joins the feed actuating block on its inner end, and the feed arm drive shaft
on the outer end, to oscillate the shaft in the bracket attached to the frame. The upward travel of the arm is
limited by the forward stop screw and its downward travel by the damper screw.
To Feed Actuating
Mechanism
Ram “Down”
Toggle Arm Pin
Pivot 
Pins
Crimping Position
Spherical 
Bearing Link
Toggle
Link
Toggle 
Lever Clevis
Ram “UP"
Down
Up
Toggle 
Lever
Rest Position
Toggle Lever Subassembly Operation
Figure 4
The feed actuating mechanism is used to drive the feed arm assembly when using standard applicators that
require a mechanical feed or for operating air valves for air feed and air blasts (when installed). These
assemblies are covered in Section 10.
2.3. Vertical Reel Bracket Assembly (Figure 18)
The vertical reel bracket assembly, supplied with the machine, is adaptable to the broadest range of reel bracket
requirements. Three locations for the reel shaft on the vertical bracket allow mounting of all sizes of vertically
mounted reels. By changing the shaft to the inclined tab on top of the vertical reel support, conical reels can also
be installed. From either location of the reel shaft, the terminal strip is fed around the stock guide and into the
applicator from the right side of the machine.
When using the vertical reel bracket assembly for feeding miniature end-feed applicators, the stock guide
bracket must be tilted downward. This is accomplished by moving the left screw to the upper mounting hole in
the vertical reel support.
The assembly also adapts to feed the terminal strips into applicators from the left side of the machine for
miniature side-feed applicators, and into applicators mounted at a 30_ angle, with the use of available
assemblies (see Section 10).

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2.4. Electrical System (Figure 5 and Figure 6 )
The electrical system of the basic machine consists of a motor, trip control box, transmission solenoid, foot
switch, barrier strip, main power (control) switch, work lamp, panel light, and wiring. The basic electrical system
may be modified when adapted for special applications.
The machine must be connected to an adequate electrical outlet. Refer to Figure 2 for machine voltage and
current specifications. The electrical current is supplied directly to the double-pole, single-throw main power
switch (S2) and to the work lamp (DS1) which contains an integral switch (S1). Power from the main power
switch, when placed in the "on" position, is supplied to the barrier strip (TB1) and to the panel light (DS2). From
the barrier strip, power is supplied to the motor (B1), which runs continuously when the control (main) switch is
"on."
The trip control box (A1) and transmission solenoid (L1) are connected to the barrier strip and are controlled by
the foot switch (S3). When the foot switch is depressed, it activates the trip control to provide a pulse of electric
current to energize the solenoid. The solenoid will not energize again until the foot switch is released, then
depressed again. This prevents double-cycling of the machine.
Some applicators require an interlock switch. The switch is wired in series between the trip control box and the
transmission solenoid to prevent the solenoid from being energized until the switch is mechanically actuated.
Basic machine wiring is shown in Figure 5 and the electrical schematic is shown in Figure 6.
NOTE
i
For accurate, up-to-date drawings, see the drawings shipped with the machine. 

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
ensure the proper functioning of each machine before packaging and shipping.
However, damage may occur during shipment. While unpacking the machine, remove the outer bands from the
carton or crate, lift off the outer box, and CAREFULLY inspect the complete machine for damage. If damage is
evident, file a claim against the carrier and notify Tyco Electronics Corporation, Harrisburg, Pennsylvania.
3.2. Factors Affecting Machine Placement
The location of the machine in relation to the operator is essential to both safety and efficiency. Studies have
repeatedly shown that fatigue will be reduced and efficiency increased if particular attention is paid to the bench,
the location of the machine on the bench, the operator's chair, and the placement of the foot switch (see 
Figure 7).
A. Bench
A sturdy bench 711 to 762 mm [28 to 30 in.] high aids comfort by allowing the operator's feet to rest on the
floor and the weight and leg position to be easily shifted. The bench should have rubber mounts to reduce
noise. An open area under the bench should allow the chair to slide far enough in for the operator's back to be
straight and supported by the chair backrest.
B. 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 152 to 203 mm [6 to 8 in.] from the front
edge. This eliminates unnecessary operator motion and helps prevent back strainand fatigue. The target area
should face the front of the bench and be parallel to the edge (access to the back of the machine must also be
provided).
C. Operator's Chair
The operator's chair should swivel, and the seat and backrest should be padded and independently
adjustable. The backrest should be large enough to support the back both above and below the waist. In use,
the chair should be pulled far enough under the bench so that the operator's back is straight and supported by
the backrest.

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Figure 5

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Figure 6

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D. Foot Switch
When the operator is correctly positioned in front of the machine, the foot should rest on the switch
comfortably and easily. The switch should be placed on a rubber mat: this allows it to be movable and permits
the operator to shift positions to reduce fatigue, while at the same time the mat prevents the switch from
sliding unintentionally.
The preference for locating the switch varies among operators. Some like the switch located so that their foot
rests on the switch when their leg is in the natural sitting position (calf perpendicular to the floor). Others
prefer it slightly in front of the natural position. The important thing is that the foot be about 90_ to the calf
when resting on the switch. Those who prefer the switch slightly forward may require a wedge-shaped block
placed under it.
Figure 7
3.3. Installation
The machine is bolted to the shipping pallet. Cut away the remaining carton, remove the bolts securing it to the
pallet, then remove the yellow plug and top access hole cover. Attach the hook of an adequate hoist to the
machine, as shown in Figure 8, to lift it from the pallet and place it in the selected location. The approximate
weight of a complete machine is 123 Kg [272 lb.].
Place the machine on a sturdy bench conforming to the requirements in Paragraph 3.2. The location must have
the necessary electrical supply (with a separate ground) and, for air-equipped machines, the necessary air
supplies. A 1/4-in. NPT male fitting is required to connect the air to the machine.
CAUTION
!
Do NOT connect the machine to the electrical outlet, or to the air, until specified. The adequacy of both the electrical
power and air supply should be checked at the machine location..
Install a 40-watt appliance bulb, of the proper voltage rating, in the work lamp. A bulb of greater wattage will
damage the shade. Position the foot switch on the floor convenient for the operator.
BEFORE connecting the machine to the electric source and air supply, hand-cycle it according to the procedure
in Paragraph 4.1 to ensure proper alignment and adjustment of tooling in the applicator (if installed) to prevent
damage.

NOTE
i
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When machines are shipped with an applicator installed, an attached package will contain an envelope with crimped
product samples which will be to the customer's specifications. These samples should be used as a comparison. All
significant test results are recorded on the applicator parts list, included in the envelope, and were made under power.
Examination of the complete machine for evidence of loose screws, bolts, and other components is
recommended, after which it should be securely bolted to the bench to prevent movement during operation.
Perform several test cycles under power using the procedure specified for production operation in 
Paragraph 4.2.
Hoist Hook
Frame with Top Access
Hole Cover Removed
Hoisting Method
Figure 8
4. OPERATION
The machine is easy to operate, providing it is properly adjusted (see Section 7) and the applicator is also
properly adjusted (see applicable instruction sheet).
CAUTION
!
BEFORE connecting the machine to electrical power, and to the air supply, hand-cycle it to check for proper alignment of
tooling to prevent possible damage.
4.1. Hand Cycling (Figure 9)
CAUTION
!
MAKE SURE main switch is "off" and electrical plug is disconnected, unless otherwise specified.
DANGER
STOP
To avoid personal injury, ALWAYS disconnect electrical and air supply before removing flywheel guard.
1. Open flywheel guard to gain access to transmission and flywheel.
2. Manually close solenoid by raising stop bar. This will allow clutch dog to engage in drive plate on flywheel
during rotation.
3. By hand, slowly turn flywheel in the direction of the arrow as shown in Figure 9 (clockwise, as viewed from
the rear of the machine).
CAUTION
!
DO NOT ATTEMPT to turn flywheel backward (counterclockwise), since this may damage or jam the applicator.

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4. As the machine ram nears the bottom of the stroke, closely observe tooling for proper alignment. If
misalignment is evident, STOP rotation of flywheel and determine cause. If adjustment to machine is required,
see Section 7. If adjustments to the applicator are required, refer to the appropriate instruction sheet. If
machine is for a special application, see the appropriate customer manual.
5. To reset the machine, use a 7/16-in. wrench to turn the grease fitting on the end of the crankshaft in the
direction of the arrow as shown in Figure 9. Use a crescent wrench or 7/16-in. box end wrench to turn the
grease fitting on the flywheel in the direction of the arrow also shown in Figure 9.
Hand-Cycling of Machine
Eccentric Arm
Grease Fitting on
Flywheel
Crankshaft Mount
Stop Bar
Grease Fitting on
End of Crankshaft
Flywheel
Figure 9
4.2. Production Operation
CAUTION
!
Operation of the machine may vary slightly depending on the application for whichit is used. Should procedures
contained in the instructions for the applicator or other customer manuals differ from the following procedure, they shall
take precedence over this manual.
1. Connect electrical plug to an outlet with separate ground connection. If an air supply is used, make
connection.
2. Make sure machine is at TOP-DEAD-CENTER, and then move main switch (S2) to ON. Motor will start and
run continuously.
3. Perform several test cycles to check machine for proper operation. Each cycle is accomplished by
depressing the foot switch, and then releasing it before another cycle can be performed.
4. Perform production operation in the same manner as described in Step 3. Take periodic inspection samples
to ensure proper crimping of terminals.
5. At end of production operation, move main switch to OFF, and turn air supply OFF (if applicable).
Disconnect electrical plug.

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5. PREVENTIVE MAINTENANCE
Preventive maintenance is cleaning, inspecting, and lubricating the machine to keep it in continuous operation. It
is suggested that a regular maintenance program be established and followed to eliminate the cost of
unnecessary repairs. For applicators and special applications of the machine, refer to the publications supplied
with them.
DANGER
STOP
To avoid personal injury, ALWAYS disconnect electrical and air supply before performing preventive maintenance.
DANGER
STOP
Re-install ALL dust caps removed during maintenance, to prevent possible injury.
5.1. Cleaning
1. Using a CLEAN, dry cloth, wipe the entire machine to remove any dust or other foreign matter from
accessible areas.
2. Using a solvent or similar cleaning fluid, remove any oil or grease from machine.
3. Using an air hose, blow out any chips and metal particles that may be in the machine, especially in the work
area.
DANGER
STOP
Compressed air used for cleaning must be reduced to less than 206.8 kPa [30 psi], and effective chip guarding and
personal protective equipment (including eye protection) must be used.
5.2. Inspection
1. Inspect entire machine for loose components and hardware.
2. Inspect electrical wiring for loose connections, chafing, and broken wires or insulation.
3. Inspect moving parts for evidence of excessive wear.
4. Inspect machine for proper lubrication. If necessary, lubricate in accordance with Paragraph 5.3.
5.3. Lubrication
Lubricate the machine according to the tabulation and at the points indicated in Figure 10.

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Figure 10 (Cont’d)

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Figure 10 (End)

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6. TROUBLESHOOTING
Figure 11 is presented in order of normal sequence. The second column lists the probable causes in the order
most likely to occur and be checked. The third column lists the remedy for each of the probable causes and
references to other parts of the manual that should be helpful in remedying the problem.
TROUBLE PROBABLE CAUSE REMEDY
1.Motor does not run when main switch
(S2) is moved to ON.
Electrical plug disconnected or no power to
outlet. Insert plug or check power to outlet.
If panel light is not illuminated, switch or power
cord defective.
Replace switch or power cord. Refer to Section
9.
If panel light is illuminated, check for loose
wiring connections at switch, barrier strip, and
motor.
Connect wiring as required. Refer to 
Figure 5.
Defective wiring between switch and motor. Replace wiring as required. Refer to 
Figure 5.
Defective motor. Replace motor. Refer to Section 9.
2.Motor runs, but machine does not
cycle when foot switch is depressed.
Machine not at TOP-DEAD-CENTER (rest
position).
Hand-cycle to TOP-DEAD-CENTER. Refer to
Paragraph 4.1.
Check for loose wiring connections at barrier
strip.
Connect wiring as required. Refer to 
Figure 5.
Defective foot switch. Replace foot switch. Refer to Section 9.
Defective trip control. Replace trip control. Refer to 
Paragraph 8.1.
Defective solenoid on transmission. Replace solenoid. Refer to Section 9.
Defective transmission. See TROUBLE 4
3.Transmission does not engage when
solenoid is energized.
Machine did not return to TOP-DEAD-CENTER
(rest position).
Turn power off and hand-cycle machine to TOP-
DEAD-CENTER. Refer to
Paragraph 4.1.
Disconnect or broken linkage between solenoid
and stop bar.
Repair or replace linkage. Refer to
Section 9.
Clutch dog (sliding key) binding on shaft. Lubricate machine. Refer to Paragraph 5.3.
Broken spring behind clutch dog (sliding key). Replace spring. Refer to Section 9.
4.Machine does not return to TOP-
DEAD-CENTER after cycling under
power.
Clutch dog (sliding key) in transmission, or drive
plate on flywheel excessively worn.
Remove flywheel and inspect parts for rounded
edges. If necessary, replace parts. Refer to
Section 9.
If feed arm assembly is installed, forward stop
screw is set too low.
Make adjustments as required. Refer to Section
10.
Binding or defective applicator. Repair or adjust applicator. Refer to applicator
instruction sheet.
Less than two washers in front of top spherical
bearing link. Add washer(s). Refer to Section 9.
Seized pins in toggle lever-feed actuating
components.
Lubricate machine and if necessary, replace
parts. Refer to Paragraph 5.3 and Section 9.
5.Machine continues to cycle with foot
switch depressed or released.
Defective O-rings in stop bar. Replace O-rings. Refer to Section 9.
Defective or broken stop bar in transmission. Replace stop bar. Refer to Section 9.
Loose or worn stop collar in transmission. Replace stop collar and lubricate. Refer to
Section 9.
Worn dog wedge in transmission. Replace dog wedge. Refer to Section 9.
6.Transmission does not lock at TOP-
DEAD-CENTER when in rest position.
Backup latch or spring disconnected or broken. Repair or replace latch or spring. Refer to
Section 9.
Stop bar or O-rings worn or broken. Replace stop bar or O-rings. Refer to Section 9.
Figure 11

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7. ADJUSTMENTS
The following adjustments are required to maintain the machine in continuous operation and to set it up after
replacement of parts.
DANGER
STOP
To avoid personal injury, ALWAYS disconnect the electrical and air supply, before performing any adjustment, unless
otherwise specified.
7.1. Crimp-Height/Shut-Height (Base Mount) Adjustment (Figure 12)
Although essential to operation, the base mount is not supplied with the basic machine, but rather with standard
applicators, conversion kits, some modified machines (see Section 11), and some for special applications. In all
cases, reference is made to this manual for adjustment procedures, thereby eliminating the need to duplicate
them in applicator instruction sheets and in other customer manuals.
Frame Adjusting Screw
Base Mount Retaining
Cap Screws
Base Mount (Ref)
Figure 12
Adjustment of the base mount determines the distance between the base mount and the ram at the bottom of
the stroke (half cycle of the machine). This adjustment controls the crimp height of terminations produced in
standard applicators, and the shut height of the machine for miniature applicators.
For the standard applicators, the main part, including the lower tooling, is attached to the base mount. The
independent upper tooling is attached tothe machine ram. Raising or lowering the base mount, then, will change
the distance (and the resulting crimp height) between the upper and lower tooling at the bottom of the ram
stroke.
Machines shipped from the factory with the base mount installed for a particular application have the base
mount adjusted and the two retaining caps screws secured to discourage further adjustment. Only when it is
necessary to replace parts, or when converting the machine to another configuration, should adjustment be
required.
The miniature quick-change applicator has the upper tooling, lower tooling, and the means for adjusting their
relationship all incorporated in an integrated assembly. This type applicator requires a fixed shut height. In other
words, the distance between the base mount and ram at the bottom of the stroke is a given dimension not
subject to change. The required changes in crimp height are made by using the adjusting means (wire and
insulation discs) within the applicator.
CAUTION
!
If the machine is set up for miniature applicators, NEVER attempt to adjust the shut height without FIRST trying another
applicator that is known to produce terminations of thecorrect crimp height. If this applicator produces correct
terminations, the trouble is in the original applicator-and shut height MUST NOT BE CHANGED.
With a properly adjusted applicator installed in the machine, and loaded with terminals as described in the
applicator instructions, adjust for correct crimp height/shut height as follows:

CAUTION
!
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Rev Z
When specified to loosen the two base mount retaining cap screws in the following procedure, ALWAYS remove any
clearance between the adjustment block and the base mount by turning the adjusting screw COUNTERCLOCKWISE, as
viewed from left side of the machine.
NOTE
i
If the crimp height of the terminal is KNOWN to be GREATER than the specified crimp height, omit Steps 1 and 2;
otherwise perform ALL steps.
1. Loosen the two base mount retaining cap screws, and lower the base mount to lowest position by rotating
the adjusting screw clockwise, as viewed from left side.
2. After base mount has been lowered, tighten the base mount screws to secure it to frame.
3. Insert a wire of the proper gage into the lead terminal, and hand-cycle the machine through one complete
cycle.
4. Check crimp height of termination (for the method of measurement, refer to 408-7424. If crimp height is
greater than specified for the type terminal and wire size being used (refer to the data plate on applicator or to
the applicator parts list), continue with Step 5. If correct, continue with Step 6.
5. Loosen the two base mount retaining cap screws, then raise base mount by turning the adjusting screw
counterclockwise, as viewed from left side, one-quarter turn. This will raise the base mount approximately
0.41 mm [.016 in.]. Tighten the base mount screws, and repeat Steps 3 and 4.
6. After producing terminations of the correct crimp height by hand-cycling machine, produce terminations
under power to ensure crimp height is correct. If not, make further adjustment by repeating Steps 3 and 4.
7.2. Feed Connecting Rod Adjustment (Figure 13)
Adjustment of the feed connecting rod is not critical, and should never require adjustment unless it is necessary
to replace parts between the feed actuating arm and toggle lever. Adjustment is made by means of the adjusting
locknuts under the feed actuating block. When properly adjusted, three threads of the feed connecting rod are
exposed below the tightened locknuts.
7.3. Feed Mechanism Damper Screw and Rear Stop Screw Adjustments (Figure 13)
Although the damper screw and rear stop screw are supplied with the basic machine, they are used only with the
mechanical feed arm assembly (which is available as an accessory). When the feed arm assembly is not
installed, both screws are turned all the way in and secured with their jam nuts.
Should adjustment be required, see Paragraph 10.1.

Feed Actuating Mechanism
Toggle Lever
Subassembly (Ref)
Vertical Reel Bracket
Assembly
Feed Actuating Arm
Spherical Bearing Link
Feed Connecting Rod 
and Spring
Feed Actuating Block
Adjusting Locknuts
Damper Screw and Block
Feed Arm Drive Shaft
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Figure 13
7.4. Guard Installation and Replacement (Figure 14)
The "K" terminator is supplied with guarding for the most popular of AMP's end-feed and side-feed applicators.
The guarding consists of a metal shroud and a clear, plastic guard. Some applications require a special guard,
which may or may not be shipped with the terminal applicator. In some cases, the applicator log sheet (shipped
with the applicator) lists the guard required on the parts list. Check this log first to determine if it is specified. If it
is not, refer to the table in Figure 14 for a list of common inserts. If your application falls outside the options listed
in Figure 14, contact the Tooling Assistance Center to determine the correct guard required.
To install the correct plastic guard, remove the screws, spacers, washers, and nuts holding the plastic guard to
the metal shroud. Take care to note their positions for correct reinstallation. Replace the plastic guard with the
correct guard for your application and reinstall the fastener hardware to secure it in position with the access slot
aligned to the applicator.

Wire Access Slot
Side-Feed Guard
End-Feed Guard
End-Feed
Shroud
Side-Feed
Shroud
COMMON END-FEED APPLICATOR GUARDS
INSERT PART NUMBER OPENING SIZE (mm [In.]) DESCRIPTION
455745-1 6.35 [.250] Standard guard - insulation diameters up to Ø6.35 [.250]
457352-1 9.53 [.375] Insulation diameters from Ø6.35 [.250] to Ø9.53 [.375]Ø
457353-1 6.35 [.250] For terminals taller than 6.35 [.250]
455750-7 9.53 [.375] Air feed applicators - insulation diameters up to Ø6.35 [.250]
Includes new shroud.
455750-8 6.35 [.250] Air feed applicators - insulation diameters Ø6.35 [.250] to
Ø9.53 [.375] Includes new shroud.
COMMON SIDE-FEED APPLICATOR GUARDS
INSERT PART NUMBER OPENING SIZE (mm [In.]) DESCRIPTION
455749-1 6.35 [.250] Standard guard - insulation diameters up to Ø6.35 [.250]
457373-1 9.53 [.375] Insulation diameters from Ø6.35 [.250] to Ø9.53 [.375]
457910-1 9.53 [.375] Insulation diameters from Ø6.35 [.250] to Ø9.53 [.375]
and terminal heights from 9.65 [.38] to 12.7 [.50]
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Figure 14