TE AMP 3K/40 Reference guide

Customer Manual
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PRODUCT INFORMATION 1-800-522-6752
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For latest revision and Regional Customer Service,
visit our website at www.te.com.
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SAFETY PRECAUTIONS —AVOID INJURY —READ THIS FIRST!......................................2
1. INTRODUCTION ..................................................................................................................3
2. DESCRIPTION .....................................................................................................................5
2.1.Functional Description....................................................................................................5
2.2.Electrical Description......................................................................................................8
2.3.Machine Guard...............................................................................................................8
3. RECEIVING INSPECTION AND INSTALLATION ...............................................................8
3.1.Receiving Inspection ......................................................................................................8
3.2.Installation ......................................................................................................................9
3.3.Considerations Affecting Placement of Bench Machines (Figure 8) ............................10
4. OPERATION ......................................................................................................................11
4.1.Control Panel Operation...............................................................................................11
4.2.Applicator Installation ...................................................................................................11
4.3.Setup............................................................................................................................13
4.4.Mode Selection and Operation.....................................................................................13
4.5.Adjusting the Motor Speed...........................................................................................14
4.6.Crimp Height Adjustment .............................................................................................14
4.7.End-Feed/Side-Feed Applicator Conversion................................................................14
5. PREVENTIVE MAINTENANCE .........................................................................................14
5.1.Cleaning .......................................................................................................................14
5.2.Lubrication....................................................................................................................15
6. ADJUSTMENTS.................................................................................................................15
6.1.Measuring the Shut Height...........................................................................................16
6.2.Shut-Height Adjustment ...............................................................................................16
6.3.Crimp Height Adjustment Using Precision Adjustment Mechanism .............................17
6.4.Guard Insert Adjustment ..............................................................................................18
7. MACHINE OPTIONS AND INSTALLATION OF THE AIR FEED VALVE
ASSEMBLY........................................................................................................................19
8. TROUBLESHOOTING .......................................................................................................21
8.1.Error Codes..................................................................................................................21
8.2.Diagnostics...................................................................................................................22
9. SOTWARE VERSION IDENTIFICATION ..........................................................................22
10. DISPOSAL .........................................................................................................................22
11. REPLACEMENT AND REPAIR .........................................................................................23
12. RoHS INFORMATION........................................................................................................23
13. REVISION SUMMARY .......................................................................................................23
AMP 3K/40* CE Terminating Machines
PN 2161400-[ ] and AMP 5K/40* CE
Terminating Machines PN 2161500-[ ]
ORIGINAL INSTRUCTIONS

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SAFETY PRECAUTIONS —AVOID INJURY —READ THIS FIRST!
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 approved eye protection while operating
equipment.
Always wear appropriate ear protection while using
equipment.
Moving parts can crush and cut. Always keep guard(s)
in place during normal operation.
Electrical shock hazard.
Always turn off the main power switch and disconnect
the electrical cord from the power source when
performing repair or maintenance on the equipment.
Never insert hands into installed equipment.
Never wear loose clothing or jewelry that may catch in
moving parts of the equipment.
Never alter, modify, or misuse the equipment.
SUPPORT CENTER
CALL TOLL FREE 1-800-522-6752 (CONTINENTAL UNITED STATES AND PUERTO RICO ONLY)
The Support 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 SUPPORT CENTER
When calling the Support 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 Support 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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Figure 1
1. INTRODUCTION
This manual contains information on operation, preventive maintenance, and adjustments of the AMP 3K/40 and
AMP 5K/40 CE Terminating Machines PN 2161400-[ ] and PN 2161500-[ ] respectively. See Figure 1.
Descriptions in this manual pertain to the controls and adjustments on the AMP 3K/40 and AMP 5K/40 machines
only.
The various applicators that can be used in the machines are covered in applicator instruction sheets packaged
with each applicator. Applicator instruction sheets provide information on applicator installation, care, and
adjustment.
The specifications and requirements for the AMP 3K/40 and AMP 5K/40 CE Terminating Machines are as listed
below:
— Deflection: 0.13 mm [.0046 in.] Maximum per 4,448 Newtons [1,000 lb] Crimp Force
— Noise: Less than 82 dBa Typical at operator position with standard mechanical feed applicator
— Weight: 77.3 Kilograms [170.4 lb]
— Height: 585 mm [23 in.] without reel supports
— Electrical: 100-240 Vac, 50/60 Hz, Single-Phase Current. Operating current is 3 amp.
— Air: 620-760 kPa [90-100 psi], 2.83 liters/sec (6 scfm) When required for use with air-feed applicators
— Physical Environment: Temperature: 4.45-40° C [40.5-104° F]
Relative Humidity: Less than 95% (non-condensing)
Transportation and Storage: Store in a clean, dry environment after coating
all
surfaces lightly with a rust preventing oil

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When reading this manual, pay particular attention to DANGER, CAUTION, NOTE statements.
DANGER
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
Highlights special or important information.
Always wear approved eye protection while operating the equipment.
Always wear approved hearing protection while operating the equipment.
Use caution working with this equipment.
Main electric ON/OFF switch.
Do NOT operate the equipment 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.

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2. DESCRIPTION
The AMP 3K/40 and AMP 5K/40 CE terminating Machines were designed to be used as stand-alone semi-
automatic bench units. They are assembled with metric hardware.
NOTE
Measurements are in metric units [followed by U.S. customary units in brackets] unless otherwise indicated. Some commercial
items may contain non-metric hardware.
These machines accepts a wide variety of miniature (mini) quick-change applicators, with minor adjustments,
thus providing a great selection of terminals for many applications. Figure 2 lists changeover cams required to
run 1 1/8-in. stroke cams (for AMP-O-LECTRIC* Model “K" terminating machines) and 1 5/8-in. stroke cams
(for Model “T" and Model “G" Terminating machines) in the machines.
ORIGINAL APPLICATOR
FEED TYPE
CHANGEOVER CAMS (PN) FOR THE MACHINES
41.25 mm [1 5/8-in.]
Stroke Machines
30 mm [1 1/8-in.]
Stroke Machines
1 1/8-in. Stroke Applicator for Model “K"
Terminating Machine
Pre-Feed
690602-6
---
Post Feed
690501-4
---
1 5/8-in. Stroke Applicator for Model “T"
and Model “G" Terminating Machines
Pre-Feed
---
690602-5
Post Feed
---
690501-3
Heavy-Duty Industrial (HD-I) Applicator
Pre-Feed/Post Feed
Refer to the HD-I Applicator customer drawing for part numbers.
Figure 2
2.1. Functional Description
These machines provide the force required to crimp terminals in the applicator. A terminal is attached to the
wire by placing the wire in the crimp area and pressing the foot switch. The machine consists of four functional
areas:
1. The motor group includes a dc motor which drives a crankshaft. See Figure 3 and Figure 4. The
motor is activated each cycle and rotates the crankshaft one full revolution. A hex key is located on
the end of the motor, which allows the motor to be cycled manually. The hex key is accessed by
unplugging the power cord from the rear of the motor.
Figure 3
Hex Key Location
for Manual Cycling
Power Cord
Receptacle

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Figure 4
2. The crankshaft-ram group conveys the motor rotational force to the up-and-down action of the ram
for driving the applicator during the crimping cycle.
3. The base plate provides the mounting surface on which the applicator is installed. The quick-release
latching feature permits fast, easy installation and removal of the applicator. See Figure 5.
4. The crimp height adjustment group uses an eccentric located in the ram linkage, along with
detented stops in the mechanism to adjust the crimp height. Indexing the mechanism in either
direction will change the crimp height in increments of approximately 0.013 mm [.0005 in.] per step.
Refer to Figure 5 for the Precision Crimp Height Adjustment Mechanism.
Motor Gearbox
Assembly
Electrical Control
Box Assembly
Terminal Strip Guide
Mounting Surface for
End-Feed Applicators

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Figure 5

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2.2. Electrical Description
The PN 2161400-[ ] and PN 2161500-[ ] machine electrical components consist of the operator control panel,
the motor, and the CPU/motor controller and safety circuit package. The machine operates on 100/240 Vac,
50/60 Hz, single-phase current with ground. The machine will automatically detect the supply voltage and
adjust the controller accordingly.
The operator control panel (Figure 6) is mounted on the left side of the machine frame. The control panel
consists of five button membrane key pad and a two line by eight column display. The membrane key pad has
icons representing the function of each button.
Figure 6
A main power switch/circuit breaker (Figure 6) is located on the front of the control panel. The main power
switch/circuit breaker connects ac power to the control system. The CPU/motor controller and safety circuit are
located in the electrical control box.
2.3. Machine Guard
A guard is installed to provide protection for the operator while maintaining proper visibility of the work area.
The guard swings open to allow easy access for applicator installation and setup. A safety switch on the guard
prevents machine operation if the guard door is open.
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
insure the proper machine functioning before packaging and shipping.
To protect against damage that may have occurred during shipment, remove the machine from the crate
(paragraph 3.2.) and carefully inspect the machine for damage. If damage is evident, file a claim against the
carrier and notify TE immediately.
Membrane Keypad
Button(s)
Display
ON/OFF Switch

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3.2. Installation
Remove all mounting bolts securing the machine to the shipping pallet. Install lift ring (see Figure 7) on top of
the machine.
NOTE
Lift ring (M1220 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.
Figure 7
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.
Connect the power cord to a suitable electrical supply.
NOTE
The machine will automatically detect the supply voltage and adjust the controller accordingly.
Lift point for the equipment.
Base Plate Assembly
Hole for Customer
Supplied Lift Ring
Tongue Operated
Safety Switch

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3.3. Considerations Affecting Placement of Bench Machines (Figure 8)
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:
the bench is of appropriate height, preferably with sound-deadening rubber mounts;
the machine is properly located on the bench with ample work areas on both sides to facilitate work flow;
the operator uses a swivel chair with padded seat and back rest which are independently adjustable; and
the foot switch, on machines so equipped, is placed on a rubber mat to maintain its movability, while
preventing it from sliding unintentionally.
Figure 8 illustrates proper machine location, operator position, and recommended foot switch position.
Figure 8
Bench
The bench to be used should be of sturdy construction, preferably with rubber mounts to minimize noise.
A height of 762 to 812.8 mm [30 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.
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 152.4 to 203.2 mm [6 to 8 in.] -- minimum 50.8 mm [2 in.] from the front
edge. 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).
DANGER
Machines should be securely bolted to the bench using the machine mounting holes shown in Figure 5. Hardware is customer
supplied. Machines should not extend beyond the front of the bench.
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.