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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
equipment.
Always wear appropriate ear protection while using
equipment.
Moving parts can crush and cut. 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
the electrical cord from the power source when
performing repair or maintenance on the equipment.
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.
Use caution when working with this 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.
Never enter the electrical enclosure immediately after
turning off the machine power switch and disconnecting
the electrical cord from the power source. High residual
voltages may be present in the electrical enclosure.
Read the warning label on the electrical enclosure lid
before entering the enclosure.
TOOLING ASSISTANCE CENTER
CALL TOLL FREE 1-800-722-1111 (CONTINENTAL UNITED STATES AND PUERTO RICO ONLY)
The
Tooling Assistance Center
offers a means of providing technical assistance when required. In addition,
Field Service Specialists are available to provide assistance in the adjustment or repair of the application
equipment when problems arise which your maintenance personnel are unable to correct.
INFORMATION REQUIRED WHEN CONTACTING THE TOOLING ASSISTANCE CENTER
When calling the Tooling Assistance Center regarding service to equipment, it is suggested that a person
familiar with the device be present with a copy of the manual (and drawings) to receive instructions. Many
difficulties can be avoided in this manner.
When calling the Tooling Assistance Center, be ready with the following information:
1. Customer name
2. Customer address
3. Person to contact (name, title,
telephone number, and extension)
4. Person calling
5. Equipment number (and serial number if
applicable)
6. Product part number (and serial number
if applicable)
7. Urgency of request
8. Nature of problem
9. Description of inoperative component(s)
10. Additional information/comments that
may be helpful
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Rev D
409-32035
AMP-O-LECTRIC Model G II Terminator
(With CQM II), PN 2217000-2
CQM II
Host Module
Terminator Part Number
2217000-1
2217000-2
2217001-1
2217001-2
2217002-1
2217002-2
2844800-1
2844800-2
2844810-1
2844810-2
2844820-1
2844820-2
DESCRIPTION
AMP-O-LECTRIC Model G II Terminator
AMP-O-LECTRIC Model G II Terminator (With CQM II)
AMP-O-LECTRIC Model G II Terminator (With Stripping Module)
AMP-O-LECTRIC Model G II Terminator (With Stripping Module and CQM II)
AMP-O-LECTRIC Model G II Through-Splice Terminator
AMP-O-LECTRIC Model G II Through-Splice Terminator (With CQM II)
AMP-O-LECTRIC Model G II+ Terminator
AMP-O-LECTRIC Model G II+ Terminator (With CQM II)
AMP-O-LECTRIC Model G II+ Loose Piece Terminator
AMP-O-LECTRIC Model G II+ Loose Piece Terminator (With CQM II)
AMP-O-LECTRIC Model G II+ Through-Splice Terminator
AMP-O-LECTRIC Model G II+ Through-Splice Terminator (With CQM II)
Figure 1
INTRODUCTION
Read and understand the entire manual before using the equipment.
When reading this manual, pay special attention to DANGER, CAUTION, and NOTE statements.
DANGER
Denotes an imminent hazard that may result in moderate or severe injury.
CAUTION
Denotes a condition that may result in product or equipment damage.
NOTE
Highlights special or important information.
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409-32035
This manual contains information on the operation, preventive maintenance, and adjustments of the
AMP-O-LECTRIC Model G II and G II+ Terminator Machines (reference Figure 1).
Descriptions in this manual pertain to the controls and adjustments on the AMP-O-LECTRIC Model G II and
G II+ Terminator 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-O-LECTRIC Model G II and G II+ Terminator Machines are
as listed below:
Max Crimp
Force
Nominal Frame
Deflection
Noise
Weight
Height
Electrical
Air
Temperature
Physical
Relative Humidity
Environment Transportation and
Storage
‡
Acceptable Range is 90
–
265 VAC
◊
Acceptable Range is 191
–
253 VAC
G II Terminator
G II+ Terminator
G II Terminator
G II+ Terminator
G II Terminator
G II+ Terminator
G II Terminator
G II+ Terminator
22,250 Newtons [5,000 lbs]
44,500 Newtons [10,000 lbs]
0.04 mm per 1,000 Newtons [.007 in. per 1,000 lb] Crimp Force
0.025 mm per 1,000 Newtons [.004 in. per 1,000 lb] Crimp Force
< 82 dBa typical at operator position with standard mechanical feed applicator
105 Kilograms [230 lb]
116 Kilograms [255 lb]
585 mm [23 in.] without reel supports
Nominal: 100-240 VAC‡, 50/60 Hz, Single Phase Current. Operating current is 3 amps
Nominal: 208-240 VAC◊, 50/60 Hz, Single Phase Current. Operating current is 5 amps
620-760 kPa [90-100
psi], 2.83 liters/sec (6 scfm) when req’d for use w/air-feed
applicators
4° to 40° C [40° to104° F]
Less than 95% (non-condensing)
Store in clean, dry environment after coating all surfaces lightly with rust preventing oil
Figure 2
DESCRIPTION
2.1. By Model
The AMP-O-LECTRIC Model G II and G II+ Terminator 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.
1. AMP-O-LECTRIC Model G II Terminating Machine (PN 221700-[ ])
Terminating Machine PN 221700-[ ] accepts a wide variety of miniature (mini) quick-change
applicators, with minor adjustments, thus providing a great selection of terminals for many
applications. Figure 3 lists changeover cams required to run 1 1/8-in. stroke cams (for AMP-O-
LECTRIC Model
“K” terminating machines).
ORIGINAL APPLICATOR
1 1/8-in. Stroke Applicator for
Model “K" Terminating Machine
Heavy-Duty Industrial (HD-I) Applicator
CHANGEOVER CAM PN FOR THE MACHINES
(1 5/8-in. [41.25 mm] Stroke Machines)
Pre-Feed
690602-6
Post-Feed
690501-4
Pre-Feed/Post-Feed
Refer to the HD-I Applicator customer drawing for part numbers
Figure 3
FEED TYPE
2. AMP-O-LECTRIC Model G II+ Terminating Machine (PN 2844800-[ ])
The Model G II+ Terminator Machines (PN 2844800-[ ]) accept a wide variety of Mid-Size applicators,
thus providing a great selection of terminals for many larger wire applications.
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409-32035
3. AMP-O-LECTRIC Model G II+ Terminating Machine (PN 2844810-[ ])
The G II+ Loose Piece Terminator (PN 2844810-[ ]) (Figure 4) was designed to be used as a stand-
alone semi-automatic bench machine. The modifications described below allow application of loose
piece terminals.
The front guard and guard insert of the standard G II+ Terminator have been modified to allow access
to the sliding terminal support for loose piece terminal applications (refer to Figure 4). These guards
work together with the applicator guards to protect the operator. An additional safety switch has been
added to the terminator frame and the sliding terminal support. The terminator will not cycle without
an applicator in place and the sliding terminal support in the closed position.
The front guard retains its keyed interlock to actuate the guard safety switch when closed.
The modified guards on the G II+ Loose Piece Terminator will work with Mid-Size Loose Piece
