AMP-O-LECTRIC* Model G II Terminators PNs 2217000- , Customer Manual 2217001- and 2217002- , and Model G II+ Terminators 409-32035 PNs 2844800- , 2844810- , and 2844820- 01 AUG 17 Rev D SAFETY PRECAUTIONS - AVOID INJURY .............................................................. 2 1. INTRODUCTION .................................................................................................................. 3 2. DESCRIPTION ..................................................................................................................... 4 2.1. By Model ..................................................................................................................... 4 2.2. Functional .................................................................................................................... 7 2.3. Electrical ...................................................................................................................... 8 2.4. Machine Guard ............................................................................................................ 8 3. RECEIVING INSPECTION AND INSTALLATION ............................................................... 9 3.1. Receiving Inspection ................................................................................................... 9 3.2. Installation ................................................................................................................... 9 3.3. Considerations Affecting Placement of Bench Machines (Figure 12) ....................... 10 4. OPERATION ....................................................................................................................... 11 4.1. Applicator Installation ................................................................................................ 11 4.2. Control Panel ............................................................................................................. 12 4.3. Mode Selection .......................................................................................................... 12 4.4. Setup ......................................................................................................................... 14 4.5. Adjusting Motor Speed .............................................................................................. 14 4.6. Crimp Height Adjustment .......................................................................................... 14 4.7. End-Feed/Side-Feed Applicator Conversion ............................................................. 14 5. PREVENTIVE MAINTENANCE .......................................................................................... 15 5.1. Cleaning .................................................................................................................... 15 5.2. Lubrication ................................................................................................................. 15 5.3. Safety System Check ................................................................................................ 16 6. ADJUSTMENTS ................................................................................................................. 17 6.1. Shut Height ................................................................................................................ 17 6.2. Crimp Height ............................................................................................................. 18 6.3. Guard Insert .............................................................................................................. 19 7. MACHINE OPTIONS AND INSTALLATION OF THE AIR FEED VALVE ASSEMBLY Figures 21, 22, and 23 ............................................................................... 20 7.1. The following machine options are available for the AMP-O-LECTRIC Model G II and G II+ Terminator Machines: ................................................................................ 20 8. TROUBLESHOOTING ....................................................................................................... 22 8.1. Error Codes ............................................................................................................... 22 8.2. Diagnostics ................................................................................................................ 23 9. SOFTWARE VERSION IDENTIFICATION......................................................................... 23 10. DISPOSAL .......................................................................................................................... 23 11. REPLACEMENT AND REPAIR ......................................................................................... 23 12. RESTRICTION ON HAZARDOUS SUBSTANCES (RoHS) INFORMATION .................... 24 13. REVISION SUMMARY ....................................................................................................... 24 2017 TE Connectivity family of companies TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change. 1 of 24 All Rights Reserved For latest revision and Regional Customer Service, *Trademark visit our website at www.te.com. TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and/or company names may be trademarks of their respective owners. ORIGINAL INSTRUCTIONS 409-32035 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 approved eye protection while operating Use caution when working with this equipment. equipment. Always wear appropriate ear protection while using Never insert hands into installed equipment. equipment. Never wear loose clothing or jewelry that may catch in moving parts of the equipment. Moving parts can crush and cut. Always keep guard(s) in place during normal operation. Never alter, modify, or misuse the equipment. Always insert power plug into a properly grounded receptacle to avoid electrical shock. Never enter the electrical enclosure immediately after turning off the machine power switch and disconnecting the electrical cord from the power source. High residual Always turn off the main power switch and disconnect voltages may be present in the electrical enclosure. the electrical cord from the power source when Read the warning label on the electrical enclosure lid performing repair or maintenance on the equipment. before entering the enclosure. Do not operate the equipment without guards in place. Never stare at the bright light used for machine lighting. Bright light can damage the eye. Lift point for equipment. Never use the machine for other than what it is designed, which is crimping terminals to wire. Do not use the machine for crushing any items. 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 6. Product part number (and serial number if applicable) 2. Customer address 7. Urgency of request 3. Person to contact (name, title, telephone number, and extension) 8. Nature of problem 4. Person calling 9. Description of inoperative component(s) 5. Equipment number (and serial number if 10. Additional information/comments that applicable) may be helpful 2 of 24 Rev D