AMP-O-MATIC* Side-Feed Stripper-Crimper III Machine No [ ] customer manual TOOLING ASSISTANCE CENTER

Transcription

1 AMP-O-MATIC* Sde-Feed Strpper-Crmper III Machne No [ ] Customer Manual DEC 11 SAFETY A. PRECAUTIONS READ THIS FIRST! customer manual 1. INTRODUCTION DESCRIPTION RECEIVING INSPECTION AND INSTALLATION MACHINE OPERATION PREVENTIVE MAINTENANCE ADJUSTMENTS REPAIR AND REPLACEMENT TROUBLESHOOTING OPTIONAL PNEUMATIC COUNTER ROHS INFORMATION REVISION SUMMARY Tyco Electroncs Corporaton, a TE Connectvty Ltd. Company All Rghts Reserved *Trademark TOOLING ASSISTANCE CENTER Ths controlled document s subject to change. For latest revson and Regonal Customer Servce, vst our webste at TE Connectvty, TE connectvty (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of ther respectve owners. 1 of 26 LOC B

2 DANGER STOP SAFETY PRECAUTIONS AVOID INJURY Safeguards are desgned nto ths applcaton equpment to protect operators and mantenance personnel from most hazards durng equpment operaton. However, certan safety precautons must be taken by the operator and repar personnel to avod personal njury, as well as damage to the equpment. For best results, applcaton equpment must be operated n a dry, dust-free envronment. Do not operate equpment n a gaseous or hazardous envronment. Carefully observe the followng safety precautons before and durng operaton of the equpment: ALWAYS wear approprate ear protecton. ALWAYS wear approved eye protecton when operatng powered equpment. ALWAYS keep guard(s) n place durng normal operaton. ALWAYS nsert power plug nto a properly grounded receptacle to avod electrcal shock. ALWAYS turn off the man power swtch and dsconnect electrcal cord from the power source when performng mantenance on the equpment. NEVER wear loose clothng or jewelry that may catch n movng parts of the applcaton equpment. NEVER nsert hands nto nstalled applcaton equpment. NEVER alter, modfy, or msuse the applcaton equpment. TOOLING ASSISTANCE CENTER CALL TOLL FREE (CONTINENTAL UNITED STATES AND PUERTO RICO ONLY) The Toolng Assstance Center offers a means of provdng techncal assstance when requred. In addton, Feld Servce Specalsts are avalable to provde assstance n the adjustment or repar of the applcaton equpment when problems arse whch your mantenance personnel are unable to correct. INFORMATION REQUIRED WHEN CONTACTING THE TOOLING ASSISTANCE CENTER When callng the Toolng Assstance Center regardng servce to equpment, t s suggested that a person famlar wth the devce be present wth a copy of the manual (and drawngs) to receve nstructons. Many dffcultes can be avoded n ths manner. When callng the Toolng Assstance Center, be ready wth the followng nformaton: 1. Customer name 2. Customer address 3. Person to contact (name, ttle, telephone number, and extenson) 4. Person callng 5. Equpment number (and seral number f applcable) 6. Product part number (and seral number f applcable) 7. Urgency of request 8. Nature of problem 9. Descrpton of noperatve component(s) 10. Addtonal nformaton/comments that may be helpful 2 of 26

3 AMP-O-MATIC Sde Feed Strpper-Crmper III Machne (wthout Crmp Qualty Montor) AMP-O-MATIC Sde Feed Strpper-Crmper III Machne (wth Crmp Qualty Montor) C.E. Verson AMP-O-MATIC Sde Feed Strpper-Crmper III Machne (wthout Crmp Qualty Montor) C.E. Verson AMP-O-MATIC Sde Feed Strpper-Crmper III Machne (wth Crmp Qualty Montor) 1. INTRODUCTION Fgure 1 Ths manual provdes the nformaton requred for operaton and mantenance of AMP-O-MATIC* Sde Feed Strpper-Crmper III Machne, No [ ]. See Fgure 1. Informaton ncludes: descrpton; recevng nspecton and nstallaton; machne operaton; preventve mantenance; adjustments; repar and replacement; and Documentaton Package. The -2 machne s avalable wth the Crmp Qualty Montor (CQM). For further nformaton, contact your TE Connectvty Feld Representatve. Measurements n ths document are n metrc unts [wth U.S. customary unts n brackets]. The compact 68 klogram [150-lb] (approxmate) machne s ntended for bench-top operaton. The sze s approxmately 355 mm wde x 457 mm deep x 838 mm hgh [14 n. wde x 18 n. deep x 33 n. hgh], ncludng the reel support (less termnal reel). For operaton, the machne requres a constant ar supply of 552 to 690 klopascals (kpa) [80 to 100 ps] wth adequate volume (1.6 lters/sec. [3.5 scfm]) to mantan a mnmum of 552 kpa [80 ps] throughout the cycle of operaton. Electrcal power s not requred for machne operaton, however electrcal power s requred for the work lamp to lght the target area. 3 of 26

4 Retan Documentaton Package for reference and orderng replacement parts. Although not suppled or sold by TE, a pneumatc counter can be nstalled by the customer. Refer to Secton 9, OPTIONAL PNEUMATIC COUNTER. When readng ths manual, pay partcular attenton to DANGER, CAUTION, statements. DANGER Denotes an mmnent hazard whch may result n moderate or severe njury. STOP CAUTION! Denotes a condton whch may result n product or equpment damage. Hghlghts specal or mportant nformaton. Dmensons n ths manual are n metrc unts [wth U.S. customary unts n brackets]. For nformaton beyond the scope of ths manual, call the Toolng Assstance Center at DESCRIPTION 2.1. Physcal Descrpton (Fgure 2 and Fgure 3) The machne s supported on four levelng pads and s totally enclosed n a plastc cover, except for the reel support whch extends above for easy nstallaton of termnal reels. The termnal strp from the reel passes around the stock gude on the left sde of the machne, then enters the applcator nsde the front door. The front door s hnged for easy access to the applcator toolng and target area whch s vsble through the clear door. Durng operaton, wres are nserted through the openng n the wndow nto the target area for termnaton. The machne conssts of fve major assembles: the machne assembly, wre grpper assembly, strpper assembly, ar-valve assembly, and flter/regulator assembly. Descrptons of the assembles are ncluded n ths manual. Also ncluded s a descrpton of typcal sde-feed applcator used n the machne. Ths machne s provded wth a lockout valve. Ths dsables the machne to prevent njury whle troubleshootng or performng mantenance. When the valve s n the closed poston, a hole allows nstallaton of a lock. A. Machne Subassembly The machne assembly conssts of a cast frame whch provdes the mountng facltes for the pneumatc system and the mechancally operated components, ncludng the applcator. Between the vertcal frame members s the man cylnder whch provdes the power requred by the applcator for crmpng the termnals. Ths s accomplshed through a lnkage to the ram whch s drectly connected to the applcator ram. The lnkage s also mechancally connected to the termnal feed mechansm, and the scrap shear for operaton durng the crmpng cycle. The front of the frame provdes the mountng facltes for the easly replaced applcators. In front of the applcator s the wre grpper assembly whch s actuated by an ar cylnder to secure the wre durng the strppng and crmpng acton. 4 of 26

5 The lockout valve, extendng through the back of the machne cover, supples ar pressure to the two flters and one regulator mounted on the rght sde of the frame. The gage s readable through the clear door. No ar lne lubrcator s requred because the cylnders and valves are desgned to operate on dry ar. The ar logc components are mounted on the left sde of the frame. The termnal feed mechansm s also mounted on the left sde of the frame n algnment wth the applcator. It s actuated by the applcator ram to feed the termnal strp nto the target area. A termnal lubrcator assembly s ncluded wth the machne. Termnal Reel Reel Support Termnal Strp Power Jack Machne Frame Operatng Pressure Gage Safety Valve (LV5) Operatng Pressure Flter/Regulator Lockout Valve Ar Supply Connecton Auto-Hand Knob Lght Swtch Flter Target Area (Fgure 8) Auto Mode Senstvty Valve (LV4) Strppng Mechansm Scrap Shear Threshold Sensor Feed Return Adjustment Screw Levelng Pad (Typ 4 Places) Fgure 2 5 of 26

6 Power Valve (P2) Reel Support One Shot Valve Ar Logc Components (RV1 and RV2) Stock Gude Lmt Valve (LV2 and LV3) (Hdden) Termnal Feed Mechansm (Fgure 10) Power Valve (P3) Lmt Valve (LV1) Termnal Lubrcator Strppng Mechansm Power Valve (P3) Wre Grpper Power Valve and Pressure Adjust Fgure 3 B. Strppng Mechansm Subassembly (Fgures 10 and 11) Beneath the man cylnder, and between the vertcal frame members s the strppng mechansm whch sldes n gbs. The strppng blades are actuated (closed and opened) by the strppng cylnder mounted at the back of the mechansm. After closng of the blades, the mechansm s moved to the rear by a separate ar cylnder, to strp the nsulaton from the wre beng termnated. The wre sensor, actng as a wre stop, s mounted at the back of the strp blades. When the machne s beng operated n the automatc mode, selected by the AUTO- HAND knob on the front of the machne, the wre placement s detected by the wre sensor and automatcally cycles the machne, provded that the foot valve s beng held depressed. The use of the sensor ensures exact postonng of the wre for each termnaton. 6 of 26

7 Applcator Ram Assembly Pads Ram Post Wre Dsc Insulaton Dsc Front Shear Depressor Applcator Ram Crmper Bolt Termnal Hold-Down Insulaton Crmper Stock Drag Wre Crmper Slot Termnal Support Strp Gudes Anvl Base Plate Floatng Shear (Front) Lower Toolng Assembly Fgure 4 C. Applcator (Typcal, Fgure 4 and Fgure 10) The sde feed applcators used n ths machne are the pre-feed type, and are nterchangeable to provde a wde range of termnatons. The crmpers, anvl, and the rear floatng shear (when used) are the same as those used n the heavy duty mnature quck-change applcators. The upper porton of the applcator s the applcator ram contanng the upper toolng. The lower porton s the base plate whch supports the anvl (lower toolng), the strp gudes, and the stock drag. The upper and lower portons have dentfcaton tags whch carry dentcal seral numbers to prevent mxng of portons wth those of other applcators. 7 of 26

8 The applcator ram s held n the machne frame by a ram cap. The ram post s nserted between the bosses of the machne ram whch contact a par of pads on the wre dsc. There may be as many as four pars of pads (A through D - each par s a dfferent heght) to provde four dfferent crmp heghts per applcator. Refer to the applcator parts lst for applcable settng per wre sze. The pad letter vsble at the front and center of the applcator ndcates the settng to obtan the specfed crmp heght. Under the wre dsc s the nsulaton dsc (when applcable) whch has eght pads (1 through 8) on the bottom sde. Each pad s a dfferent heght. The lowest number s for the loosest crmp. Each pad, when algned wth the nsulaton crmper, provdes a dfferent nsulaton crmp heght. The wre crmper, nsulaton crmper, spacers, and front shear depressor are attached to the ram by the crmper bolt. The wre crmper s statonary n relaton to the ram, whle the nsulaton crmper s free floatng to permt varatons between the two crmpers. On the back of the ram s the cam whch operates the termnal feed mechansm. The lower porton of the applcator s postoned on the machne base plate by two dowel pns and retaned wth quck release left and rght hold-downs. So that both pns and sockets may be termnated n the applcator wthout re-adjustng each tme, the applcator provdes an adjustment for the strp gude plate, and also the scrap gude. These may be adjusted to mnmze the effects of dfferences n camber of the varous carrer strps. The desgn of the front floatng shear s unque to ths applcator. The termnals used wth the applcators n ths machne are reeled the same as those on TE Mnature Quck-Change Applcators Functonal Descrpton It shall be assumed that the machne has been properly nstalled, loaded wth termnals, connected to the ar supply, and s ready for producton operaton as descrbed n Secton 4. The followng sequence descrbes the machne through one complete cycle of operaton. Refer to the pneumatc dagram, drawng n the Documentaton Package, for sequence of component operaton. 1. If the machne s beng operated n the automatc mode, the operator depresses and holds the foot valve. Ths step does not apply for the manual mode of operaton. 2. The operator nserts the wre through wndow nto target area untl t contacts the wre sensor (wre stop), keepng wre as low and horzontal as possble. 3. If machne s beng operated n the manual mode, operator depresses foot valve momentarly to start machne cycle. In the automatc mode, the machne starts to cycle when the wre contacts the wre sensor, provdng the foot valve s depressed. 4. Wre grppers close to secure wre and strppng blades close to cut nsulaton. 5. Strppng mechansm starts to rear, pullng nsulaton from wre. 6. The ram starts to move downward. 7. As the ram fully bottoms, t crmps the termnal onto the wre. Strppng blades and wre grppers open. 8. The ram s then rased to ts orgnal poston, and the termnated wre s released. 9. The strppng mechansm s moved toward the front after an adjustable delay for wre removal. 8 of 26

9 3. RECEIVING INSPECTION AND INSTALLATION 3.1. Recevng Inspecton The machne s thoroughly nspected durng and after assembly. Before t s shpped, a fnal seres of tests and nspectons are made to ensure proper functonng. Stll, the followng nspecton should be performed as a safeguard aganst problems durng shpment. 1. Carefully uncrate the machne and place t on a sturdy bench where ther s enough lght to permt a careful examnaton. 2. Remove the cover, and thoroughly nspect the entre machne for evdence of damage that may have occurred durng transt. If the machne s damaged, fle a clam aganst the carrer and notfy TE mmedately. 3. Check all components and parts to be certan they are secure. 4. Check wrng for loose connectons and for frayed or broken wre and nsulaton. 5. Check all ar lnes for evdence of loose connectons or damage Machne Requrements Fgure 5 lsts the power requrements for the AMP-O-MATIC Strpper-Crmper III Machne, along wth the machne's approxmate weght and sze. In addton, Fgure 5 lsts approxmate machne rates. Electrcal Requrements: Ar Supply Requrements: Machne Sze: Approxmate Machne Weght: Number of Fnshed Assembles Per Hour: 115 Vac, 60 Hz sngle-phase power (-1 and -2 Machnes) 230 Vac, 50 Hz sngle-phase power (-3 and -4 Machnes) Constant ar supply of 552 to 690 klopascals (kpa) [80 to 100 ps] wth adequate volume (1.6 lters/sec. [3.5 scfm]) to mantan a mnmum of 552 kpa [80 ps] throughout the cycle of operaton 355 mm [14 n.] wde x 457 mm [18 n.] deep x 838 mm 33 n.] hgh ncludng the reel support (less the termnal reel). 68 klograms [150 lbs] Approxmately 1000 leads per hour for 24 AWG jacketed cable wth prepared 25.4 mm [1 n.] breakout. Approxmately 1400 leads per hour for dscrete wre. Fgure Consderatons Affectng Machne Placement Proper locaton of the machne n relaton to the operator s essental to both safety and effcency. Studes have repeatedly shown that fatgue wll be reduced and effcency ncreased f partcular attenton s pad to the bench, the operator's char, and the placement of the foot valve f one s used. A. Bench A sturdy bench 711 to 762 mm [28 to 30 n.] hgh ads comfort by allowng the operator's feet to rest on the floor and the weght and leg poston to be easly shfted. The bench should have rubber mounts to reduce nose. The open area under the bench should allow the char to slde far enough n for the operator's back to be straght and supported by the back rest. B. Machne Locaton on Bench The machne should be located near the front of the bench, and the machne work area (the area where the product s appled) should be 152 to 203 mm [6 to 8 n.] from the front edge. Access to the back of the machne must be provded for mantenance purposes n most cases. C. Operator's Char The operator's char should swvel, and the seat and back rest should be padded and ndependently adjustable. The back rest should be large enough to support the back both above and below the wast. In use, the char should be far enough under the bench so that the operator's back s straght and supported by the back rest. 9 of 26

10 D. Foot Valve (When Used) When the operator s correctly postoned n front of the machne, the foot should rest on the valve comfortably and easly. The valve should be placed on a rubber mat; ths allows t to be movable and permts the operator to shft postons to mnmze fatgue, whle at the same tme the mat prevents the valve from sldng unntentonally. The preference for locatng the swtch vares among operators. Some lke the valve located so that ther foot rests on the valve when ther legs are n the natural sttng poston (calf perpendcular to the floor). Others prefer t slghtly n front of the natural poston. The mportant thng s that the foot be about 90_ to the calf when restng on the valve. Those who prefer the valve slghtly forward may requre a wedge-shaped block placed under t. Fgure 6 shows proper locaton and poston. Fgure 7 shows a typcal layout for the effcent handlng of materals. Fgure 6 shows the physcal consderatons as recommended, and the operator n a desrable poston. Note that the char heght and back rest are properly adjusted, and that the char s properly located n respect to the bench. Thus, the operator's back s straght, and supported by the char. Note also that the operator's upper arms are n a drect lne wth the torso. The plan vew, Fgure 7, dentfes typcal locatons for supply and appled product, and serves as an ad n vsualzng the convenence n materals handlng afforded by proper setup and correct operator postonng. Fgure 6 Fgure 7 4. MACHINE OPERATION Ths secton pertans to loadng and unloadng of termnal strp, and operaton of the machne n producton use. It shall be assumed that the machne has been properly nstalled n accordance wth Secton Termnal Strp Loadng and Unloadng (Fgure 8) A. Loadng 1. Place reel of termnals on reel support and secure wth flange. Strp must unreel and enter left sde of machne wth wre barrels of termnals toward front of machne and wth open U up. 2. Turn drag release lever upward to rase stock drag. 3. Feed termnal strp through strp gudes untl lead termnal s over anvl, then pull back slghtly on strp to assure feed pawl s properly engaged n feed pont of strp. 4. Turn drag release lever down to apply drag to termnal strp. 5. After makng several termnatons, make sure carrer strp enters scrap shear to the rght of applcator. B. Unloadng 1. Release stock drag. 10 of 26

11 Ram Speed Adjustment Machne Ram Shut Heght Adjustable Lockng Screw Shut Heght Dsc Indcator Normal Grpper Pressure ( kpa [20-40 ps]) Adjustable Wre Grpper Assembly -1, -3 Ram Cap -2, -4 CQM Ram Cap Feed Mechansm Typcal Applcator Ram Crmpers Target Area Foot Swtch Termnal Strp Scrap Shear Wre Locator Grpper Heght Lock Screw Crmp Qualty Montor Stock Drag Grpper Heght Adjustng Screw Fgure 8 2. Whle rasng and holdng feed fnger up, pull termnal strp back through strp gudes untl clear. 3. Roll termnal strp onto reel to prevent dstorton untl loaded agan nto machne Producton Setup (Fgure 8) 1. Check the wre dsk pad settngs and strppng blades for sze of wre to be run. 2. Place an adequate supply of wre wthn easy reach of the operator's poston. 3. Be sure that an adequate supply of termnals s on the reel. 4. Connect ar supply and lft lockout valve to OPEN. Turn work lght ON. DANGER Machne assembly may move when the ar s turned on. To avod personal njury, keep clear of movable toolng when performng Step 4. STOP 11 of 26

12 5. Check operatng pressure for 552 kpa (80 ps). If necessary, remove rear cover and adjust the regulator. 6. Select the desred mode of operaton wth AUTO-HAND knob on front of machne Producton Operaton 1. If operatng n the automatc mode, depress and hold foot valve. 2. Insert a wre nto the target area and aganst wre stop, keepng wre as low and straght as possble (perpendcular to front of machne). If operatng n the automatc mode, machne wll cycle when wre contacts the wre stop. If operatng n the hand mode, momentarly depress the foot valve to cycle the machne. Remove termnated wre at end of cycle. If the machne does not cycle n the automatc mode when the wre stop s touched by a pece of wre, refer to the senstvty adjustment n Paragraph Repeat steps 1 and 2 untl desred number of wres has been run. Perodcally nspect for proper termnatons and for correct heght. Measure crmp heght as descrbed n nstructon sheet At completon of run, slde lockout valve closed. Ths s requred so that the pre-flter wll dran tself. If machne s not to be used agan n a short perod of tme, turn work lamp off. 5. PREVENTIVE MAINTENANCE Preventve mantenance conssts of cleanng, nspecton, and lubrcaton of the machne to mantan t n contnuous servce wth a mnmum amount of repars and/or down tme. The frequency of mantenance shall be by shft or weekly and monthly. DANGER STOP To avod personal njury, ALWAYS DISCONNECT POWER to the machne before performng any mantenance. Turn off the man power swtch/crcut breaker. ALWAYS CLOSE LOCKOUT VALVE, to dsconnect ar supply from machne Daly Inspecton 1. Close lockout valve and dsconnect ar supply. 2. Open front door of machne. 3. Vsually nspect machne for general appearance and functonal operaton. 4. Close front door of machne. 5. Connect ar supply and open lockout valve. 6. Crmp two or more termnals and closely nspect the termnatons for evdence of damaged toolng Daly Cleanng 1. Close lockout valve and dsconnect ar supply. 2. Open front door of machne. 3. Usng a small brush, remove all peces of nsulaton and carrer strp chps, especally n and around the target area. 4. Close front door of machne. 5. Connect ar supply Weekly Inspecton And Cleanng 1. Close lockout valve and dsconnect ar supply. 2. Remove machne cover. 3. Check flters n ar system for mosture and contamnaton. The mcro flter drans automatcally when t reaches a gven level. 4. Remove applcator as descrbed n Paragraph 7.1, Applcator Replacement. 12 of 26

13 5. Thoroughly nspect the machne for loose, damaged, or worn parts. Specal attenton should be pad to the applcator toolng and scrap shear; replace toolng f necessary as descrbed n Secton 7, REPAIR AND REPLACEMENT. 6. Usng a small brush, remove all peces of nsulaton and carrer strp chps, n and around the entre machne Monthly Cleanng, Inspecton and Lubrcaton 1. Close lockout valve, and dsconnect the ar supply. 2. Remove the machne cover and applcator ram. 3. Remove the strppng assembly and proceed as follows: a. Thoroughly clean both the strppng assembly and the area n and around the gbs. b. Inspect strppng assembly for damaged parts. c. Lghtly ol the blade holders. d. Remove excess lubrcant. 4. Install the strppng assembly. 5. Remove the wre grppers and proceed as follows: a. Thoroughly clean the assembly, removng all nsulaton strp ends and wre strands. Pay partcular attenton to the area between the grpper actuator levers and the ar cylnder housng. b. Inspect the assembly for worn or damaged parts; replace f necessary. c. Lghtly ol all pvot ponts. d. Check the grppers for proper algnment and adjust as requred. 6. Install grpper assembly. 7. Remove the spool and bumper O rngs from the one shot valve (see Fgure 9) and clean and lghtly ol wth two drops of a SAE 5 or 10 non-detergent non-synthetc ol. For the followng refer to the lubrcaton chart for the locaton of the grease fttngs and ol ponts. 8. Usng a grease gun wth multpurpose grease, lubrcate the two fttngs for the strppng mechansm slde n Fgure 11 and the three fttngs on the ram lnkage are found n Fgure 9; to gan access to some of these fttngs, the ram must be at the bottom of ts stroke, not shown. 9. Apply a few drops of ol to all pvot ponts usng SAE 20 non-detergent ol. 10. Fll termnal lubrcator wth lubrcant part number E807 from: STONER INCORPORATED PO BOX 65 QUARRYVILLE, PA Phone Remove excess lubrcant. DO NOT USE AIR LINE LUBRICANT. All cylnders and valves are desgned to operate on clean dry ar. 12. Apply a thn flm of grease to the four corners of the applcator ram and the face of the feed cam. 13. Install applcator and ram as descrbed n Paragraph 7, REPAIR AND REPLACEMENT. 14. Install machne cover. 15. Load termnals n applcator as descrbed n Paragraph 4, MACHINE OPERATION. 13 of 26

14 Man Cylnder Rear Pvot Ponts One-Shot Valve Block Stablzer Ram Cap Ram Lnkage (Hdden) Feed Arm Assembly Multpurpose grease SAE 20 non-detergent ol SAE 5 or 10 non-detergent, non-synthetc ol for the one-shot valve Fgure Connect ar supply and open lockout valve. 17. Close front door of machne. 18. Operate the machne as descrbed n Secton 4, to determne f the unt s operatng properly. 14 of 26

15 6. ADJUSTMENTS The followng adjustments may be necessary to mantan the machne n contnuous servce, or n the event t s necessary to replace parts and/or components. DANGER STOP To avod personal njury, ALWAYS DISCONNECT POWER to the machne before performng any mantenance. Turn off the power at the man power swtch/crcut breaker. ALWAYS CLOSE LOCKOUT VALVE, to dsconnect ar supply from machne Wre Crmp Heght Adjustment (Fgure 4) 1. Open front door of machne to gan access. 2. Select pad letter (A, B, C, or D) specfed on Applcator Parts Lst (Log), suppled wth the partcular applcator nstalled n machne, for AWG wre sze and termnal beng used. 3. Turn wre dsc (upper dsc) so that selected pad letter s vsble to FRONT and center of applcator. Ths provdes the proper crmp heght for termnal and wre sze beng used. 4. After makng nsulaton crmp adjustment as descrbed n Paragraph 6.2, make several test crmps by operatng machne as descrbed n Secton 4, then perform the followng: a. Inspect termnatons for rough or sharp edges around crmped barrels (flash), deformed crmps, bent termnals, or other defects caused by worn or broken toolng. If necessary, replace toolng as descrbed n Secton 7. b. If termnatons appear normal, measure crmp heght of each termnaton as descrbed n nstructon sheet Crmp heght must agree wth measurement specfed on Applcator Parts Lst (Log) suppled wth the applcator beng used. Record crmp dmensons for reference. c. If crmp heght s INCORRECT, remove applcator and nstall one that s known to produce termnatons of CORRECT crmp heght, as descrbed n Paragraph 7.1, Applcator Replacement. Make several test crmps and repeat Step b. If crmp heghts are stll INCORRECT for ths applcator, the problem s machne shut heght (see Step d.). Contact your TE Representatve, or call the Toolng Assstance Center: If the crmp heght s CORRECT for ths applcator, problem s n orgnal applcator, and crmp heght repar s descrbed n Secton 7. d. The shut heght fne adjust may be used, for example, when an applcator s not properly shmmed for the machne shut heght settng. The factory set machne ( ) s mm [5.346 n.]. To fne adjust the shut heght, unlock the screw adjust. Insert dowel pn nto holes of dsc ndcator (33) and move as requred; each ncrement on dsc ndcator s mm [.0005 n.]. 5. Durng extensve operaton, perodcally repeat Step 4 to make sure applcator s producng correct termnatons Insulaton Crmp Heght Adjustment (Fgure 4) The nsulaton crmp heght adjustment (when applcable) must be made n relaton to wre crmp heght as descrbed n Paragraph 6.1. To adjust, turn nsulaton dsc (lower dsc) to algn number (1 through 8) wth top of nsulaton crmper on applcator ram. The loosest crmp s produced at No. 1 settng and the tghtest at the No. 8 settng. To fnd a satsfactory nsulaton crmp for any wre nsulaton outsde dameter, start wth No. 1, makng test crmps. Increase settng one number at a tme untl desred crmp heght s obtaned. The crmp should hold the nsulaton frmly wthout cuttng nto t Termnal Strp Feed Adjustment (Fgure 10) Proper adjustment of the termnal strp feed s acheved when the applcator ram s fully rased and the feed fnger s fully extended to CENTER the lead termnal over the anvl. Adjustment may be necessary (especally when changng applcators) due to varatons n the feed ponts of dfferent termnal strps. The locaton of the pvot shaft n the adjustng plate for the feed arm may be a determnng factor to obtan proper adjustment. There are three adjustment postons n whch the pvot shaft may be located. In most cases the mddle hole s used. The bottom poston provdes the SHORTEST feed fnger stroke and the top poston provdes the LONGEST. When performng the followng procedure, and t s mpossble to obtan the proper adjustment, determne f a LONGER or SHORTER stroke s requred. 15 of 26

16 Termnal Feed-Back Stop Adjustment Pvot Block Forward Lmt Adjustment Knob Feed Fnger Wre Grppers Lock Knob Wre Locator Rear Strp Gude Feed Pawl Fgure 10 Strp Gude Plate Adjust Screw (Hdden) Front Strp Gude 1. Determne whch drecton the lead termnal must be moved (advanced or retracted). 2. Loosen small lock knob under larger adjustng knob. See Fgure To advance lead termnal, turn forward lmt adjustment knob COUNTERCLOCKWISE. To retract, turn knob CLOCKWISE. When makng adjustment, keep termnal strp pulled back aganst feed pawl, especally durng retracton adjustment. 4. At completon of adjustment, tghten lock screw. 5. Make several test crmps by operatng machne as descrbed n Secton 4. Observe for proper feedng of termnal strp and centerng of lead termnal over anvl. Check retracton of feed fnger for slght overtravel of feed pont n termnal strp. If no overtravel exsts, or f excessve, perform Step 6. If satsfactory, adjustment s complete. 6. For more feed return, turn feed return adjustment screw OUT (refer to Fgure 2). For less, turn t IN. Perform several test crmps whle makng adjustment to assure feed return s proper. 16 of 26

17 6.4. Strp Gude Plate, Bell Mouth and Feed Pawl Adjustments (Fgure 10) Ths procedure moves the plate on whch the strp gudes are mounted. Snce the termnal strp s fed nto the target area from between the strp gudes, t s moved toward the front or back when the plate s moved n ether drecton. The adjustment of the feed pawl to match any change n the poston of the front strp gude s also descrbed here. 1. Determne the drecton and amount of adjustment requred. 2. From bottom sde of base plate, loosen screw securng strp gude adjustment block to strp gude plate. 3. Turn strp gude plate adjustment screw n the drecton and the amount requred, as determned n Step 1. CLOCKWISE moves the termnal strp toward the rear, COUNTERCLOCKWISE moves t toward the front. Wth a pece of termnal strp nserted, and the lead termnal over the anvl, the nsulaton barrel of the lead termnal should be as close as possble to the floatng shear. Tghten screw to secure strp gude plate to strp gude adjustment block after adjustment. 4. Adjust feed pawl by loosenng screw securng t to feed fnger (holder). Move feed pawl toward front or back untl t drops FREELY nto slot n front strp gude, then tghten screw to secure Strp Gude Adjustment (Fgure 10) Ths adjustment s not often requred, because t s only needed when the strp gudes are not parallel to each other, or when there s a varaton n the strp wdth. The strp gudes were correctly postoned on the strp gude plate when the applcator was bult, and normally do not need adjustment. DO NOT use ths procedure for front-to-rear postonng of termnal strp; refer to Paragraph Open front door of machne. 2. Wedge feed pawl up to clear front strp gude. 3. Loosen screws securng strp gudes to strp gude plate. 4. Move one or both strp gudes as requred, makng sure they are parallel wth each other, then tghten screws to secure. 5. Check gudes to be sure they are parallel, and that termnal strp can move freely between them wth a mnmum amount of clearance. Repeat Step 4 f necessary. 6. Adjust feed pawl as descrbed n Paragraph Shear(s) and Shear Holder(s) Adjustments The front floatng shear should be just far enough from the anvl to allow t to move freely up and down. If n ths poston, t should not requre adjustment. The rear shear s more lkely to need adjustment because of possble dfferences n termnal strp wdths. 1. Open front door of machne. 2. Remove applcator ram. 3. Close lockout valve and dsconnect ar supply. 4. Remove lower porton of applcator as descrbed n Secton Wth a length of termnal strp nserted, and the lead termnal over the anvl, check to see f floatng shear(s) wll cut termnal from carrer strp at the proper locaton(s). If necessary, make the followng adjustment. 6. From bottom sde of base plate, loosen screws securng shear holder to base plate, then move shear holder and shear n the desred drecton. Tghten screws after adjustment to secure shear holder. 7. Repeat Step 5 to be assured of proper adjustment. 17 of 26

18 6.7. Strppng Blade Closure Adjustment (Fgure 11) The strppng blades must be adjusted to a depth that wll permt them to cut the nsulaton and strp t from the conductor, but they MUST NOT nck or scrape the conductor durng cuttng or removal of nsulaton. When changng from one wre sze (AWG) to another, t wll be necessary to adjust the closure. Adjust strppng blade depth as follows: Ths machne has been set up for strppng 24 AWG PTFE nsulated wre. Strppng blades for strppng the mddle wre sze specfed on the parts lst are suppled wth the applcator. 1. Open front door to gan access to machne. 2. Insert blade of screwdrver nto strp blade closng adjustment screw. For more closng (smaller wre), turn screw CLOCKWISE. For less closng (larger wre), turn screw COUNTERCLOCKWISE. CAUTION! DO NOT turn adjustng screw more than a few degrees ( clcks ) at a tme between test crmps, especally when adjustng for greater depth, to avod dullng strppng blades by cuttng or scrapng conductor. 3. Close front door of machne after completng adjustment. 4. Make several test crmps by operatng machne as descrbed n Secton 4 to determne f strppng blade closng s correct. 5. Repeat as necessary, Steps 1 and 2. Close front door when adjustment s satsfactory Wre Strp Length Adjustment (Fgure 11) The wre strp length requred may vary between applcators, and between termnals. When necessary, adjust strp length as follows: 1. Make several test crmps by operatng machne as descrbed n Secton 4 to determne f a longer or shorter strp length s requred. 2. To shorten strp length, turn adjustment screw CLOCKWISE. To lengthen, turn adjustment screw COUNTERCLOCKWISE. Ths moves the strp blades n relaton to the poston of the termnal for strppng the nsulaton between the wre and nsulaton crmpers. Each clck s approxmately 0.13 mm [.005 n.]. Although the wre stop s attached to the strppng mechansm, ths adjustment DOES NOT have any effect on the normal locaton of the wre stop. Refer to Paragraph 6.9 for wre stop adjustment Wre Stop Adjustment (Fgure 11) The wre stop has been pre-adjusted at the factory and should not requre further adjustment for regular termnals. Adjustment may be requred when usng wre such as twsted par, whch wll be straghtened by the acton of the strppng blades. Before makng ths adjustment, make sure that: (1) the termnals are correctly postoned (proper bellmouth and cutoff tab); (2) the strp length adjustment s correct; and (3) the strppng blades are not touchng the wre stop. 1. Turn screw CLOCKWISE to move wre stop back or turn t COUNTERCLOCKWISE to move wre stop forward. In ether drecton, only a few degrees should be suffcent. One full revoluton equals approxmate 0.81 mm [.032 n.]. 2. Perform several test crmps by operatng machne as descrbed n Secton 4. Inspect termnatons, and repeat procedure f necessary. 18 of 26

19 Termnal Strpper Strp Length Adjustment Screw Strppng Blades Closng Adjustment Screw Grease Fttng Paragraph 5.4) Grease Fttng Paragraph 5.4) Wre Stop (Wre Sensor) Wre Locator Wre Stop (Wre Sensor) Adjustment Screw Strppng Blade Feed Fnger Front Strp Gude Strppng Blade Not Included wth Machne (See Applcator Log) Fgure of 26

20 The adjustable wre grpper subassembly allows regulaton of ncomng lne pressure for two reasons: 1) to prevent nsulaton damage to an ncreased range of wre szes, nsulaton types, and thcknesses; and 2) to permt retenton of larger-sze wre for strppng Man Cylnder Speed Adjustment (See Drawng ) The speed of the ram on the downward stroke s controlled by the flow control adjustment screw on power valve (P2). Ths s the front screw on the front valve near port B. Turnng the screw CLOCKWISE wll slow the stroke. The rear screw on ths valve (near port A ) controls the speed on the upstroke Closng Delay Adjustment for Strppng Blades (Fgure 2) The machne cover must be removed to perform ths adjustment. The strppng blades must not close pror to the closng of the wre grppers. Ths s controlled by the adjustment screw n the front port (P1B) of the power valve P1 (rear of machne). If the strppng blades are closng before the wre grppers are fully closed, turn the adjustment screw CLOCKWISE as requred to slow the closng acton of the strppng blades. Re-nstall machne cover when adjustment s satsfactory Auto Mode Senstvty Adjust The auto mode senstvty valve s on the rght sde of the machne castng. See Fgure 2.The adjustment screw s on the rear of the auto sensor. To INCREASE the senstvty, turn screw COUNTERCLOCKWISE (1/4 to 1/2 turn from closed). To DECREASE the senstvty, turn screw CLOCKWISE Strppng Mechansm Speed Adjustment (Fgure 2) The speed of the strppng mechansm on the forward stroke s controlled by the flow control adjustment screw on the power valve, P3. The screw s on the front near Port B. 7. REPAIR AND REPLACEMENT Ths secton pertans to makng repars and replacng parts to mantan the machne n contnuous servce. The followng procedures are lmted to applcator replacement, toolng replacement n the applcator, and the replacement of machne parts that are recommended spares. Repar nformaton contaned heren apples to the pneumatc system, and to correctng the crmp heght, when requred. For repars and replacements not covered n ths secton refer to the Documentaton Package. A careful study of the drawng contanng the part(s) n queston wll help to determne the extent of dsassembly requred to accomplsh the repar or replacement. Followng re-assembly, refer to Secton 6 for adjustments necessary before operatng the machne. When orderng replacement parts, call the Toolng Assstance Center, lsted n the front of the manual. DANGER TO AVOID PERSONAL INJURY ALWAYS DISCONNECT POWER to the machne before performng any mantenance. Turn off the power at the man power swtch/crcut breaker. ALWAYS CLOSE LOCKOUT VALVE to dsconnect ar supply STOP from machne Applcator Replacement (Fgure 3) If only the applcator ram s to be removed, t s not necessary to remove cover from machne. Just open front door for access. 1. To remove applcator ram from machne, loosen four screws and lock washers securng ram cap. Pull ram cap upward then forward untl clear of machne ram, then lft out. Manually actuate feed mechansm to take pressure off feed cam. 2. Push down lockout valve and dsconnect ar supply. 3. If removng lower porton of applcator, unload termnal strp as descrbed n Secton Ram must be fully rased. 20 of 26

21 5. To remove lower porton of applcator, perform the followng: a. Manually retract strppng mechansm to clear applcator. b. Remove termnal lubrcator. c. Rotate hold-down, to the left sde of the applcator, CLOCKWISE to release applcator. d. Lft lower porton of applcator to clear algnment pns, then lft feed fnger and remove from the left sde of machne. 6. Install applcator n machne n the reverse order of removal. After nstallng lower porton of applcator, momentarly apply ar pressure to machne. Ths wll extend strppng mechansm and fully rase machne ram to provde clearance for nstallng applcator ram. 7. Before operatng machne, check applcator adjustments as descrbed n Secton Applcator Upper Toolng Replacement The applcator upper toolng conssts of a wre crmper and an nsulaton crmper attached to the applcator ram. To replace, perform the followng: 1. Remove applcator ram as descrbed n Paragraph Remove crmper bolt securng crmpers and related parts to applcator ram. Note orentaton of ALL parts for nstallaton purposes. 3. Install new toolng as requred, and re-nstall applcator ram n the reverse order of removal. DO NOT tghten crmper bolt at ths tme. 4. Form a pece of heavy paper over anvl. 5. Close flow control at power valve P2B to stop ram, then open flow control 1/4 turn. 6. Connect ar supply and open lockout valve. Manually actuate safety valve, LV5 door swtch, whle pressng foot valve to brng machne ram down slowly under power. Release safety valve and make sure nsulaton crmper does not strke floatng shear. 7. Tghten crmper bolt to secure crmpers n poston. Paper over anvl wll center crmpers n proper algnment. 8. Open flow control of valve P2B two turns to return ram for producton speed, and proceed as follows: a. Temporarly engage LV5 swtch. b. Remove paper from over anvl. 9. Load termnal strp and operate machne, as descrbed n Secton 4, to check for proper crmpng. Make any adjustments deemed necessary Applcator Lower Toolng (Anvl) Replacement The applcator lower toolng s the anvl attached to the base plate. To replace, perform the followng: 1. Remove applcator from machne as descrbed n Paragraph Remove screw from under base plate securng anvl. Note orentaton of anvl for nstallaton purposes. 3. Install new anvl, and re-nstall applcator n machne n the reverse order of removal. 4. Loosen crmper bolt and algn crmpers as descrbed n Paragraph Check applcator adjustments, as descrbed n Secton 6, BEFORE operatng machne under power Strppng Blades and Stablzer Bar Replacement (See Drawng ) 1. Push down lockout valve and dsconnect ar supply. 2. Open front door of machne to gan access. 21 of 26

22 3. Remove screw securng each strppng blade (refer to applcator Parts Lst), and stablzer bar (Item No. 64) on RIGHT sde, to blade mountng blocks. Note orentaton of blades and stablzer bar for nstallaton purposes. Make sure blades are seated n the recess of the blade mountng block. 4. Install new blades and/or stablzer bar n the reverse order of removal. 5. Adjust strppng blade closure as descrbed n Secton Close front door of machne after completng adjustments Feed Pawl Replacement (See Drawng ) The feed pawl (Item No.130) s attached to the feed fnger (133) and engages n the feed ponts of the termnal strp to advance the strp one poston for each cycle of the machne. To replace, perform the followng: 1. Push down lockout valve and dsconnect ar supply. 2. Open front door of machne to gan access. 3. Remove screw (131) and washer (127) securng feed pawl to feed fnger. 4. Install new feed pawl n the reverse order of removal. BEFORE tghtenng screw, move feed pawl as requred to algn tp wth feed pont n termnal strp. When properly centered n strp gude, the feed pawl can be rased and moved to front or back. 5. Perform several test cycles, by operatng machne as descrbed n Secton 4, to assure proper feedng of termnal strp and postonng of lead termnals over anvl. If necessary, adjust feed as descrbed n Secton Shear Blade and Shear Plate Replacement (See Drawng ) 1. Push down lockout valve and dsconnect ar supply. 2. Remove scrap gude, and remove shear assembly from base. 3. To replace shear plate (Item No. 84), remove four screws (85) securng scrap gudes (86), (87), and shear plate. Install new shear plate n the reverse order of removal. 4. To replace shear blade (81), remove retanng rngs and groove pn, then lft blade out of holder (82). Install new blade n the reverse order of removal Crmp Heght Repar Beneath the nsulaton dsc on top of the applcator ram s one or more washers whch may requre replacement. 1. Subtract specfed crmp heght from the average crmp heght of those recorded durng wre crmp adjustment n Secton 6. Ths wll be the thckness of washer(s) (Part No ) to be ADDED to thckness of exstng washers under nsulaton dsc. 2. Remove applcator ram from machne as descrbed n Paragraph Turn ram upsde down and secure ram mountng post. 4. Loosen setscrew n sde of applcator ram securng ram mountng post, then unscrew ram body from post leavng nsulaton dsc and wre dsc n poston. CAUTION! DO NOT REMOVE nsulaton and wre dscs from ram mountng post. There are detent balls and sprngs nstalled whch may pop out and become lost f dscs are removed. 5. Install a thckness of washer(s) on ram mountng post as determned n Step 1. If necessary, replace wth completely new washer of a thckness equal to the old washer plus the addtonal thckness determned n Step Install ram body on post and tghten by hand untl snug. 22 of 26

23 7. Check to determne that numbers on wre dsc and letters on nsulaton dsc are properly algned over nsulaton crmper. The dscs are retaned n poston by the detent balls. If necessary, turn ram body back slghtly untl proper algnment s obtaned, then tghten setscrew to secure ram body to post. Rotate wre dsc and nsulaton dsc to other postons, and when clck of detent ball s heard n each poston, check for centerng of letter or number on nsulaton crmper. 8. Install applcator ram n machne, as descrbed n Paragraph Adjust wre crmp and nsulaton crmp as descrbed n Secton Make several test crmps and measure crmp heght to assure t s satsfactory before placng machne n servce Pneumatc System Repars To make necessary repars, make proper connectons, and replace parts to the pneumatc system, refer to the pneumatc drawng found n the Documentaton Package Spare Parts A. Spare Machne Parts Ths lst ncludes the wearable parts whch are recommended customer spares: ITEM PART NUMBER DESCRIPTION QUANTITY O-RING, 1/16 n. ID x 1/8 n. OD (Ar Detect Nozzle) SPRING, Compresson, Termnal Strpper PAWL, Feed LAMP, Annuncator, Modfed 1 It s customer's responsblty to stock and replace tems dentfed as recommended spare parts n the lst above and on the drawngs n the machne Documentaton Package lsted below n Secton 8. Refer to the General Machne Polcy n the front of the manual. B. Spare Strppng Blades Strppng blades are a wearable part of any AMP-O-MATIC Strpper-Crmper applcator. To replace standard strp-blades, order two of the part number requred for your wre sze (AWG): WIRE SIZE (AWG) PART NUMBER WIRE SIZE (AWG) PART NUMBER WIRE SIZE (AWG) PART NUMBER C. Parts Lsts (See Documentaton Package ) When necessary to order replacement parts for the applcator, ALWAYS refer to the parts lst and exploded vew drawng suppled wth the partcular applcator nstalled n the machne. When necessary to order replacement parts for the machne, dentfy the part(s) on the approprate prnt n the Documentaton Package by tem number, then refer to the correspondng parts lst by tem number for the part number, descrpton, and quantty requred per assembly or subassembly. DO NOT order parts by tem number. Item numbers are used for reference ONLY, and are subject to change. A careful study of the Documentaton Package drawngs, pror to attemptng dsassembly, wll elmnate unnecessary removal of parts when makng repars or replacement. 23 of 26

24 8. TROUBLESHOOTING Fgure 12 contans a lst of possble problems, along wth the causes of the problems and the remedes. CAUTION! Lockout valve must be closed and ar must be dsconnected when cleanng, lubrcatng, or replacng any components, or when repostonng any msalgned parts. DANGER STOP To avod personal njury, KEEP HANDS CLEAR OF ALL MOVING COMPONENTS (ram, strppng assembly, and grppers) durng troubleshootng wth ar pressure appled. The followng condtons are requred to troubleshoot the machne n the manual mode: 1. Ar supply connected; 2. Lockout valve open; 3. Mnmum of 552 kpa [80 ps] on gage; 4. Front door closed; LV5 actvated; 5. Remove applcator f t s felt that t may be the cause of the problem. 9. OPTIONAL PNEUMATIC COUNTER 9.1. Descrpton An optonal pneumatc counter may be nstalled on the machne to total the machne cycles, and ths total equals the number of wre termnatons. The counter s not suppled by TE. It may be purchased from: ARO CORPORATION 1 ARO CENTER BRYAN, OH When orderng the counter from the manufacturer, specfy Model , Catalog No. A-8078-L Pneumatc Counter Installaton The counter may be attached to the machne at any locaton that wll not nterfere wth the machne operaton. Connect an ar lne between the counter and port 5 on power valve P1. Refer to Paragraph 2.2, Functonal Descrpton, and to pneumatc drawng RoHS INFORMATION Informaton on the presence and locaton of any substances subject to RoHS (Restrcton on Hazardous Substances) can be found at the followng webste: Clck on Check Complance Status and enter equpment part number. 11. REVISION SUMMARY Snce the prevous verson of ths manual, the followng changes were made: Replaced trademark references to PTFE. Updated product complance webste nformaton. Smplfed table of contents on frst page. Updated document to corporate requrements. 24 of 26

25 PROBLEM CAUSE REMEDY Ar NOT present at RV1, Port A, Lne 1 when Clean or replace blocked flter. foot valve s depressed. Machne wll not start; No ar HISS or POP at foot swtch when depressed. Repar blocked or open lockout valve, 552 kpa [80 ps] on meter. Defectve or OPEN foot valve. Defectve Hand/Auto swtch. Ar NOT present at RV2, Port 3, Lne 2. S1 Defectve. Door OPEN. Grppers and blades close, then machne stops. LV5 defectve or msadjusted. : LV5 must be engaged for troubleshootng from ths pont on. Ar NOT present at RV2, Port 2, Lne 3, Clean/Lubrcate or replace RV2. when foot valve s depressed. Threshold sensor. Ar NOT present at P3, Port B, Lne 5. Clean/Lubrcate or replace defectve RV1. Grpper and blades WILL NOT close when Clean/Lubrcate or replace defectve P1. foot valve s depressed. Ar NOT present at P3, Port B, Lne 5. Clean/Lubrcate or replace defectve LV1. Reposton msalgned LV1. Clean/Lubrcate or repar strppng assembly. Ar present at P3, Port B, Lne 5. Clean/Lubrcate or replace defectve P3. Grppers and blades close and retract, then machne stops. Ram down, machne stops, blades and grppers close. Ar NOT present at P2, Port A, Lne 6. Replace defectve retract cylnder. Reposton msalgned LV6. Replace defectve LV6. Ar present at P2, Port A, Lne 6. Clean/Lubrcate or replace defectve P2. Ram not completely down. Defectve man cylnder; call Techncal Assstance Center for assstance. See Page 2. Inspect for loose or bndng/broken lnkage - lubrcate. Defectve man cylnder; call Techncal Assstance Center for assstance. See Page 2. Ar NOT present at P1, Port B, Lne 7 Repar/Replace Defectve LV2 Ar s present at P1, Port B, Lne 7. Clean/Lubrcate or replace defectve P1. Clean/Lubrcate or repar strppng assembly. Ram down, machne stops, blades and grppers open. Clean/Lubrcate or replace defectve strp blade cylnder. Ar s present at P1, Port A, and B. Clean RV2. Ar NOT present at P2, Port B, Lne 8. Replace defectve LV3. Ar s present at P2, Port B, Lne 8. Clean/Lubrcate or replace defectve P2. Fgure 12 (Cont d) Inspect for loose or bndng/broken lnkage - lubrcate. 25 of 26