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instruction sheet 1 of 18 ? 2016 te connectivity ltd. family of companies. all rights reserved. *trademark te connectivity, te connectivity (logo), and te (logo) are trademarks. other logos, product, and/or company names m ay be trademarks of their respective owners. product information 1- 800 - 522 - 6752 this controlled document is subject to change. for latest revision and regional customer service, visit our website at www.te.com . 408 - 10390 14 nov 16 rev m1 1. introduction ocean side-feed applicators are available with either a mechanical feed, air feed, or servo fee d system. each applicator accepts the end-feed strip-form of terminals identified on the applicator pa rts list and exploded view drawing (applicator log) to apply to pre-stripped wires. note dimensions in this instruction sheet are in metric units [with u.s. customary units in brackets]. figures are not drawn to scale. this instruction sheet, parts list, exploded-view drawing (packaged with applicator ), and applicable terminating machine manual provide all the information required to operate and maintain the applicator and machine. note terminating machine manuals are: 409 - 5128 basic amp-o-lectric* machine 409 - 5207 or 409 - 5289 model t terminating unit 409 - 5842 model g machine 409 - 10047 amp 3k* machines 1725950- [ ] and amp 5k* machines 1725900-[ ] 409 - 10099 amp 3k/40* machines 2119683-[ ] and amp 5k/40* machines 2119684- [ ] note the reasons for re-issue of this instruction sheet are provided in section 8, revision summary. note reference instruction sheet 408- 3500 8 for translations of the safety warnings specified herein. 2. description main components of the mechanical and air feed applicators are identified in figures 1 and 2, respectively. ocean end-feed applicators indicator notch/cutout ram assembly wire crimp disc terminal feeder assembly applicator housing end-feed strip-form terminal strip drag release lever insulation crimp dial stripper lead terminal (ref) anvil strip guide block strip guide plates base plate mechanical feed applicator figure 1
408 -10390 rev m1 2 of 18 figure 2 each applicator is individually designed for specific terminals. the wire crimp hei ght and insulation crimp height can be adjusted to accommodate different wire sizes and insulation ranges, respectively. the appli cator is also designed to accept modular-feed packages. the feeder assembly can be removed from the appl icator and replaced with any different style; mechanical, air, or servo feed; depending on the req uirements (s ee figure 3) . to change to a different feed type, use retro-fit kit pn 2119949 for the mechanical terminal feeder, retr o-fit kit pn 2119950 for the pneumatic terminal feeder, and retro-fit kit pn 2119951 for the servo terminal feeder. figure 3 air feed applicator feed arm feed backstroke/rear position adjustment feed pawl mounting screw (2 places) air feed cam air supply connection detent screw (2 places) end cap bolt (2 places) end cap feed stroke/feed forward position adjustment forward speed control retract speed control changing feeder assembly servo terminal feeder assembly pneumatic terminal feeder assembly servo feeder latch plate push rod bushing applicator mechanical terminal feeder assembly
408 -10390 rev m1 3 of 18 the ocean applicator can be used in various machines, provided the machine has the proper stroke l ength and all the necessary equipment. there are two basic applicator design styles, atlantic and pacific , to meet many of the terminator and leadmaker configurations worldwide (s ee figure 4) . though the applicator ram and base plate interfaces are different, most of the ocean applicator featur es and adjustments are the same. the terminal strip must be fed into the applicator, with the wire barrels facing up and firs t into the applicator, between the strip guide plates. it will pass the stock drag, and the lead terminal will be posi tioned over the anvil (for pre-feed applicators) or one terminal length from the anvil (for post-feed applicators ). the feed pawl will feed one terminal during each cycle of the machine. the ram post (also referred to as the ram mounting post) will engage the post adapter of the machine ram and the machine ram will actuate the applicator. the ram post interface is located just below the wire crimp disc, which is designed wi th a spring-loaded adjustment mechanism for precise crimp height adjustment increments of 0.01 mm [.0004 in.] and a total adjustment range of 1.50 mm [.059 in.]. by rotating the wire crimp disc, the ram interface raises and lowers relative to the applicator housing. the indicator notch of the ram points to the numbers on the outer diam eter of the wire crimp disc, indicating a relative crimp height. for proper crimp height, the number on the wire crimp disc must correspond to the number on the applicator identification tag and log sheet. the wire crimper is held in a pre-set position by the ram and the crimper bolt. the i nsulation crimper and the front shear depressor are also held by the crimper bolt. the insulation crimper is free to move u p and down so that the insulation crimp height can be adjusted via the insulation crimp dial by pull ing the spring-loaded dial out slightly and rotating to a different number. the slug blade, which cuts the connection tab from the strip between the lead and second terminal s, is also attached to the bottom of the ram. the spring-loaded terminal hold-down, located on the ram, holds the terminal in place during the crimping and slugging process. the applicator mounting surface is the base plate. the anvil, strip guide plate, and applicator ho using are mounted on the base plate. the strip guides, stock drag, front and rear shear plates, and strip hold -down plate are all mounted on the strip guide plate. the shear plates are spaced to allow the slug blade to pas s between them, removing the connecting tab between the terminals. ( atlantic) ( pacific) figure 4 bosses machine ram for ram post adapter ram post wire crimp disc applicator ram terminal hold-down insulation crimper wire crimper machine ram for ram post adapter ram clamp applicator ram insulation crimp dial crimper bolt insulation crimper terminal hold-down basic applicator design styles
408 -10390 rev m1 4 of 18 2.1. applicator with mechanical feed system with this applicator, the terminals are fed by the action of the feed cam and a series of rods and levers, which move the feed pawl. two feed cams are available and can be mounted in two different mounting holes depending on machine stroke length and feed type (s ee figure 5) . the spare feed cam, when not in use, can be mounted to the applicator housing in the spare feed cam storage location shown in figure 6 . note pacific applicators can only be used with 30-mm stroke machines and, therefore, only have the 30-mm feed cam mounting positions on the applicator ram. the post- feed feed cam advances the lead terminal over the anvil on the downward stroke of the ram assembly. the post-feed set up is typically used for leadmaker and end-feed bench appli cations. the pre- feed feed cam advances the lead terminal over the anvil on the upward stroke of the ram assembly so that a terminal is over the anvil when the machine is at rest. the pre-feed set up is typically us ed for side-feed bench applications. note the recommended setup for end- feed applications is post -feed. the applicator can be configured for pre- feed, but may encounter problems with some applications. feed issues or terminal jamming may occur in the pre-feed configuration. 2.2. applicator with air feed system with this applicator, the mechanical feed system feed cam and its mechanical system of rods , levers, and springs are replaced by an air cylinder module. in the air feed module, the feed action is started when the applicator ram moves. at the beginning of the rams downward stroke, the ram-mounted cam pushes the push rod. this actuates the valve inside the air feed housing causing the retract side of the cylinder (closest to the anvil) to be filled, shifting the feed pawl to the rear of the strip guide. note the air supply connection (shown in figure 2) must be connected to an air supply line providing continuous pressure of 5.00 to 6.00 bars [72 to 87 psi] at the applicator. figure 5 mounting feed cam 40 -mm [1 5 / 8 -in.] stroke machine 30 -mm [1 1 / 8 -in.] stroke machine mounting screw post-feed pre-feed post-feed pre-feed feed cam post-feed feed cam feed cam installed pre-feed mounting screw feed cam installed counter magnet
408 -10390 rev m1 5 of 18 figure 6 caution there is a marking (vertical etched line) on the air feed housing (shown in figure 2) to use as a visual aid to ensure that the piston assembly is located within the limits of the air cylinder position. the feed pawl holder must be positioned to the right of the marking. incorrect feed pawl positioning relative to the marking may contribute to premature failure of the air feed module. the ram continues downward, completes the crimping action, and starts back up. as it approaches the f ully raised position, the push rod drops off of the high portion of the ram mounted cam, shifting the ai r feed valve. the extend side of the cylinder is then filled, moving the feed pawl and terminal strip ov er the anvil for the next cycle. the exhaust control valves control the speed of the feed stroke and retract stroke. though all air feeds are pre-feed type, the feed cam position can be changed for use in different str oke machines: 40 mm [1 5 / 8 -in.] stroke or 30 mm [1 1 / 8 -in.] stroke (refer to figure 5 ). note that the air feed requires a different cam than the mechanical pre-feed or post-feed. note the ram collar needs to be installed when changing crimp tooling to prevent the ram from becoming captured. if this does occur, the air feed assembly will need to be removed to release the applicator ram. 2.3. applicator with servo feed system with this applicator, the wire crimp height and terminal feed are accomplished by the amp- o-lectric iii servo terminator or any machine that incorporates the te connectivity (te) precision controll er. refer to 409 C 10073 . note some applicators will not work with the standard feed pawl in the feeder. in these cases, the special feed pawl must be used. if originally ordered with the servo feed, the applicator will be shipped with the special feed pawl mounted to the applicator . each servo feed applicator comes equipped with a data chip that is part of the servo feeder latch p late (see figure 3). for a complete description of the data chip, refer to 409 -10073 . this device allows the storage of key operating parameters that allow easy setup between terminals and also contains reference data that can be useful for other machine setups and crimp inspection. applicator with mechanical feed system stock drag adjustment nuts fine feed adjust lock screw (far side) fine feed adjustment screw stroke length adjustment lock screw stroke pivot spare feed cam storage location feed mounting screw (2 places) feed pawl adjustment screw feed pawl feed pawl holder feed pawl pin applicator counter setscrew applicator counter
408 -10390 rev m1 6 of 18 note batteries directive 2006/66/ec introduces new requirements from september 2008 concerning removability of batteries from wa ste equipment in eu member states. to comply with this directive, this device is designed to allow the data chip to be easily removed by the end-user when it needs to be replaced. note always dispose of the old data chip in an environmentally responsible way in accordance with local waste regulations. contact local authority for battery recycling locations. the servo feed applicator works in conjunction with the ampomator* ii i servo terminator (or any machine that incorporates the te precision controller) to form a complete system that allows setup and op eration. the information on the data chip is listed in the three separate groups: applicator data terminal data maintenance data a significant amount of the data is reference data to aid in the setup of the machine and inspecti on of the final crimp. 2.4. applicator with non-servo feed system as with the data chip on the servo feed latch plate, optional data chip kit pn 2161326-[ ] al so allows storage for key operating parameters and contains reference data that can be useful for other machine setup an d crimp inspection. it requires compatible terminating equipment. for complete description of the da ta chip, refer to 409 C 10073 . 2.5. applicator with non-adjust head with this applicator, all wire crimp height adjustments are made by the machine. when built i n the factory, the applicator's non-adjust head is shimmed so that the applicator will crimp its assigned ter minal to the largest wire crimp height found on the applicator log while the terminating machine is set to normal s hut height. note if using an applicator with a fine-adjust head on a machine with a self-adjusting wire crimp height feature, always set the fine-adjust head to the largest wire crimp height called out on the applicator log. 2.6. applicator with pacific head the pacific applicator will only work in conjunction with a machine having a ram th at falls within the envelope shown in figure 7 . figure 7 ? 20.40 [.803] max ? 41.90 [1.650] max ? 27.70 [1.091] max 16.70 [.657] min 1 3.50 [.531] min 7.99 [.315] min 4.50 [.177] max note: dimensions are in millimeters with inches in brackets.
408 -10390 rev m1 7 of 18 3. applicator installation and removal danger to avoid personal injury, make sure that the power and air source to the machine is turned off and power cord/air supply are disconnected before installing or removing the applicator. note always make sure to remove the ram transportation collar after installing the applicator on a machine and be sure to install the ram transportation collar back onto the applicator ram just prior to removing the applicator from the machine. note with the applicator in the machine, never attempt to cycle machine under power without terminals properly loaded, as described in section 4; otherwise, the tooling may be damaged. danger to avoid personal injury, the applicator should be used only in an appropriate terminating machine. the pressurized air supply should only be connected after the applicator is properly installed in the terminating machine. 3.1. amp-o- lectric machine and model k machine (with mini -applicator conversion) installation th is machine must be equipped with machine conversion kit pn 690675-2 to adapt it for use with the miniature applicators. the kit includes applicator instruction sheet 408-8022 , which explains how an applicator with mechanical feed is installed and removed from the machine. removal 1. turn off, and disconnect, the power to the machine. 2. unload the applicator as described in section 4. 3. remove the hold-down bracket and movable stop, then slide the applicator away from the s top on the base mount until the ram post is clear of the machine ram. 3.2. mode l t terminating unit note for the atlantic applicator only. installation 1. turn off, and disconnect, the power to the machine. 2. push in the release bar on the quick-change base plate. the locking latch will pivot downward . 3. place the applicator on the quick-change base plate, then slide it back until two not ches engage the stops at the back of the plate. at the same time, guide the ram post into the ram post adapter. 4. flip the locking latch up to secure the applicator in place. removal 1. disconnect the power cord. 2. cut the terminal strip one or two terminals from the end of the applicator. 3. push in the release bar on the quick-change base plate. the locking latch will pivot downward . 4. slide the applicator forward until it is clear of the ram post adapter. 3.3. other terminating machines for installation and removal procedures for the basic amp-o- lectric machine, model g machine, amp 3k and amp 5k machines, and amp 3k/40 and amp 5k/40 machines, refer to the appropriate machine man ual given in section 1. for installation and removal procedures for terminating machines not listed, refer to the customer documentation supplied with the machine.
408 -10390 rev m1 8 of 18 note adjustment of the stripper may be required when moving the applicator between bench and leadmaker applications. 4. applicator loading and unloading some terminal strips require the use of a terminal lubricant. wick-type lubricators app ly lubricant to the terminal strip as it feeds into the applicator. terminal lubricants reduce tooling wear and hel p reduce damage to the plating on some terminals. ocean applicator lubricator assembly pn 2119955- 2 is available. caution depending on the final use of the crimped terminal, terminal lubricators are not always recommended. to determine if your applications warrant the use of a terminal lubricator, contact your field representative. if your application warrants the use of a terminal lubricator, the recommended lubricant is sto ner mechanical lubricant e807 available from stoner, inc. call 1 C 800 C 227 C 5538 or visit www.stonersolutions.com. 4.1. terminal strip loading note before loading terminal strip in applicator, make sure that the installed applicator is the right one for the terminal to be applied. compare the terminal part number on the reel with the numbers listed on the applicator parts list. 1. turn off, and disconnect, the power to the machine. 2. make sure that the ram assembly is all the way up. if necessary, hand-cycle the machine to rais e the ram. refer to the machine customer manual. 3. remove the applicator guard assembly. 4. raise the stock drag by turning the drag release lever upward . remove a length of the terminal strip left in the applicator by grasping the terminals at the strip guide entry, raising the feed pawl, a nd pulling the strip straight out of the applicator. 5. with the reel of terminals installed on the reel support, feed the terminal strip into the app licator between the strip guides. note make sure that the terminal strip enters the strip guides with the terminal wire barrel first and the wire barrel open side u p. 6. raise the feed pawl, and continue to feed the terminal strip until the lead terminal is ov er the anvil and the feed pawl engages the terminal in the proper position. 7. if terminals are post-feed, lift the feed pawl and pull the strip back one terminal length. t he lead terminal will then be moved over the anvil on the downward stroke of the ram assembly. make sure that the tip of the feed pawl is in the feed hole of the carrier strip. note some carrier strips have additional holes which are not used for feed purposes. 8. hand-cycle the machine several times to make sure the applicator is properly adjusted as descri bed in section 5. 9. re -install the applicator guard assembly. 4.2. terminal strip unloading 1. cut the terminal strip one or two terminals from the end of the applicator. note the applicator should never be unloaded unnecessarily. a section of terminal strip should always be left in the unit. since it is not necessary to remove the strip section for cleaning, lubrication, or repair, it should only be removed as a part of the loading procedure. 2. if terminals are post-feed, turn the drag release lever upward to raise the stock drag, lift the feed pawl, and move the lead terminal over the anvil.
408 -10390 rev m1 9 of 18 5. adjustments 5.1. wire crimp adjustment 1. select an increment number from 0 (largest crimp height) to 150 (smallest crimp height) from the d ata plate for the wire size to be used. each increment represents a change in crimp height of 0.01 mm [.0004 in.]. 2. turn the wire crimp height adjustment disc clockwise to decrease the crimp height and turn the wire crimp disc counterclockwise to increase the crimp height. 3. turn the wire crimp disc to line up with the specified increment number with the ind icator notch/cut out on the front of the ram. this provides the right crimp height for that wire (s ee figure 8). figure 8 4. make the insulation crimp adjustment described in paragraph 5.2, then make several test cycles and inspect the terminations closely. look for rough or sharp edges around the crimped barrels (fl ash), deformed crimps, bent terminals, or other defects caused by worn or broken tooling. if necess ary, replace tooling as described in section 6. if the terminations appear normal, measure the crimp height of each termination as described in instruction sheet 408-7424 , packaged with the applicator. the crimp height must agree with the measurement specified on the applicator log for the wire size being used. record crimp height dimensions for reference. if the crimp height is incorrect, remove the applicator, and install one that is known to produce terminations of correct crimp height. make several test cycles and repeat the inspection. if the crimp height is incorrect for this applicator, the problem is the machine shut height, and correcti ve information can be found in the appropriate machine manual. if the crimp height is correct, the problem is in the original applicator, and refer to paragraph 6.6 , adjustable crimp height repair , for corrective measures. 5. during extensive operation, periodically inspection the terminals as described i n step 4 to make sure that the applicator is producing correct terminations. 5.2. insulation crimp adjustment the insulation crimp is adjustable in increments of 0.19 mm [.0075 in.] by pulling the insu lation crimp dial out (refer to figure 4) and turning it to line up with the number (1 through 18) so that it is shown at the indicator notch on the ram: no. 1 makes the loosest crimp and no. 18 makes the tightest crimp. the total range of adjustment is approximately 3.30 mm [.130 in.]. to find the desired insulation crimp, start with no. 1, make test crimps, then increase the setting one number at a time until the proper insulation cri mp height is achieved. note some applicators may have a special insulation adjustment dial that differs in range and increments than described. refer to the marking on the front of the insulation crimp dial for correct increments. indicator notch/cut out insulation crimp dial wire crimp disc
408 -10390 rev m1 10 of 18 5.3. terminal strip feed adjustment mechanical feed applicator note when adjusting a mechanical feed applicator, always start by properly adjusting the stroke length. then adjust the fine feed adjustment to locate the terminal over the anvil. 1. with the terminal strip properly loaded, check the position of the lead terminal in r elation to the slug blade. locate the feed pawl in the desired position of the terminal (typically the end of the wire barrel). refer to figure 6. the slug blade must remove the connecting tab between lead and second terminals without deforming either terminal. 2. watch the feed pawl as the machine is hand-cycled (or slowly cycled) several ti mes. it should have enough over-travel on the backstroke to pick up the next terminal, but not so much over-travel that the feed pawl moves up onto the body of the terminal (s ee figure 9) . note if the pick -up point is the mating end of the terminal, the backstroke over-travel should be about equal to the distance between the wire barrel and the mating end of the terminal (see figure 1). for other types of terminals (for example, ring tongue), over-travel should be about the same, depending on the terminal features and configurations (for example, stud hole). figure 9 if the backstroke position is correct, the tab is correctly slugged out, and the terminals are not damaged, the feed adjustments are complete. if not, continue with the next step. note there are two adjustments that work in combination to properly position the lead terminal over the anvil and give the proper backstroke position to pick up the next terminal feed hole. use one or both adjustment types to properly adjust the applicator. 3. if the slug blade does not shear the terminal in the correct position, make note of the position and continue to cycle the applicator to check the backstroke position. if the lead terminal i s not slugged out correctly and the backstroke position is incorrect, both the stroke length and the fine feed po sition must be adjusted. stroke length (backstroke position) must be adjusted before final centering of other terminals under the slug blade. 4. loosen the stroke length adjustment lock screw (s ee figure 6). 5. turn the stroke length adjustment screw counterclockwise to reduce the stroke length or clockwise to increase the stroke length. 6. tighten the stroke length adjustment lock screw. 7. repeat steps 1 through 6 as required until proper stroke length is achieved. the terminal m ight not be slugged out correctly (or positioned under the slug blade correctly); this will be adjusted i n a later step. if the feed pawl stroke length is satisfactory and the backstroke position is correct, but the lead terminal is not slugged out correctly (or positioned under the slug blade correctly) and the str oke is correct, but the position is incorrect, an adjustment to the fine feed screw is required. continue with the next step. 8. adjust the feed pawl position as follows: a. loosen the fine feed adjust lock screw on the side of the feed pawl holder to allow the fine f eed adjustment screw to turn. refer to figure 6. note do not remove the fine feed adjust lock screw. a nylon plug is captured behind the lock screw. loss of this plug will cause damage to the fine feed adjustment screw threads when the lock screw is tightened. feed pawl
408 -10390 rev m1 11 of 18 b. turn the adjustment screw counterclockwise to move the feed pawl away from the anvil and clockwise to move the feed pawl toward the anvil. position the terminal under the slug blade. c. tighten the lock screw to secure the fine feed adjustment screw. 9. re -check the adjustment for the proper position and stroke as described in step 1. repeat the adjustment procedure as necessary. air feed applicator the feed mechanism is actuated by compressed air. refer to figure 2. danger to avoid personal injury, this applicator should be used only in an appropriate terminating machine. the pressurized air supply should only be connected after the applicator is properly installed in the terminating machine. danger take extra precautions during adjustments. when the machine is manually cycled, the mechanism will move forward and backward once during each machine stroke, unless the air is disconnected. the feed stroke is adjustable in a range from 0 to 49.8 mm, depending on the air feed part number , in stepped increments of 0.04 mm [.0016 in.] for the feed forward position and in 0.08-mm [.0031-in.] increments for the rear feed pawl position (backstroke). note for ease of adjustment, the end cap can be removed with a 3- mm wrench, exposing the tool - less adjustment knobs (recommended procedure). however, air feed module pn 2063440 can be adjusted with the end cap in place using a 3 - mm wrench or small screwdriver. 1. mount the applicator onto the machine. 2. insert the terminal strip until the lead terminal is located over the anvil. 3. connect the air supply to the applicator. 4. cycle the machine manually. the next terminal must now be located exactly over the anvi l and the slug blade must remove the connecting tab between the lead and second terminals without deforming either terminal. if that is not the case, proceed with the following. a. release the strip guide drag, and manually move the strip to the proper position a rough-position only. the fine adjustment will come in a later step. b. jog the machine down to the lower-dead-center position. the feed cylinder and pawl will be retracted away from the anvil. c. using the backstroke adjustment knob (see figure 2), position the feed pawl to the p roper back position, typically the end of the wire barrel (see figure 9. if the end cap is in place, use a 3- mm hex wrench or small screwdriver to reach through the end cap to rotate the feed adjustment knob. the adjustments are in 0.08-mm [.003-in.] increments or 30 degrees and can be felt as clicks. note to facilitate adjustments with certain machines or applications, the feed adjustments can also be made with the air pressure removed. this allows more tactile feel of the detents. this requires manually moving the feed forward and back to check feed positions. the air feed housing marking (shown in figure 2) indicates the maximum backstroke travel of the feed arm. make sure that the feed forward and back positions are verified after restoring air pressure. note if the pick -up point is the mating end of the terminal, the backstroke over-travel should be about equal to the distance between the wire barrel and the mating end of the terminal (see figure 1). for other types of terminals (for example, ring tongue), over- travel should be about the same, depending on the terminal features and configurations (for example, stud hole). d. jog the machine to top-dead-center. the feed will move the next terminal over the anvil. e. check position of the terminal over the anvil, noting if the terminal feed-forward position s hould be moved. f. cycle the machine manually until the feed pawl shifts back. this releases the air pres sure on the feed adjustment, making the adjustment detent positions easier to feel.
408 -10390 rev m1 12 of 18 g. using the feed-forward adjustment knob, change the feed-forward position based on the direc tion and amount noted in step 4.d. the adjustments are in 0.04-mm [.0016-in.] increments or 15 degrees and can be felt as clicks during the feed-stroke adjustment knob rotation. turning the feed forward adjustment knob clockwise moves the feed pawl away from the anvil and turning it counter-clockwise moves the feed pawl toward the anvil. note when adjusting, make sure that only the feed adjustme nt knob turns, not the entire shaft. the backstroke ad justment knob may have to be held stationary to prevent unintended backstroke adjustments (use a 3-mm wrench when the end cap is in place). h. cycle the machine back to top-dead-center, causing the feed to shift forward and feeding the terminal over the anvil. i. repeat steps 4.d . through 4.h. until the terminal is centered over the slug blade. 5. to adjust the air feed speed, proceed as follows: note the air feed speed has been set at the factory and should therefore require re-adjustment only in exceptional circumstances. note take extra precautions during adjustments. when the machine is manually cycled, the mechanism will move forward and backwards once during each press stroke unless the air is disconnec ted. caution do not tamper with the detent screws on feed adjustments (see figure 2), which were set up properly by the factory; otherwise, damage will occur. the feed mechanism has been adjusted at the factory to ensure that the terminal is advanced at t he lowest possible speed. in rare occasions, it is possible that the feed speed is not fast enoug h if the applicator is used on a fully automatic machine. the feed speed can be adjusted by means of the two exhaust restrictors. note excess i ve feed and/or retract speeds can cause inconsistent feeds and/or air feed module damage. a. open the exhaust restrictors or forward speed control and retract speed control (shown in figure 2 ) to increase the feed speed. note the speed controls should not be fully opened to maximize feed speed. it is recommended to only open the flow control valves two complete revolutions. b. loosen the locking ring, and turn the adjustment screw clockwise to decrease the speed and counter-clockwise to increase the speed. c. when complete, tighten the locking ring. servo feed applicator 1. with the terminal strip properly loaded, check the position of the lead terminal ove r the anvil by actuating the feeder to move the feed pawl to the extend position. the slug blade must r emove the connecting tab between lead and second terminals without deforming either terminal. if the lead terminal is centered on the anvil, the forward limit adjustment is correct. proceed wi th step 4. if it is not centered, continue with step 2. 2. adjust the extend position as described in the feeder instructions in customer manual 409-10073 . 3. repeat steps 1 and 2 as required. when the adjustment is correct, continue with step 4. 4. watch the feed pawl as the machine is cycled several times. it should have enough , but not too much over-travel on the retract (stroke) to pick up the next terminal. note at the end of the retract stroke, the feed pawl should be at the back edge of the feed hole to be used. the back stroke must not be longer than this; otherwise, the feed pawl might not drop into the feed hole. if the feed pawl stroke length is satisfactory, feed adjustments are complete.
408 -10390 rev m1 13 of 18 5.4. stock drag adjustment the stock drag must be adjusted to apply only enough pressure to the terminal strip so that it will stop at the end of the feed finger stroke. 1. turn the stock drag adjustment nuts (shown in figure 6 ) down to increase the drag and up to decrease the drag. 2. cycle the machine under power to ensure that the stock drag is properly adjusted. 5.5. strip guide adjustment danger to avoid personal injury, make sure that the power to the machine is turned off and the power cord is disconnected before taking the applicator out of the machine. the machine ram should be in the raised position. 1. remove the applicator from the machine as described in section 3 , applicator installation and removal. 2. remove the ram assembly from the applicator. 3. remove the two nuts holding the springs in place on the terminal drag plate. refer to figure 10 . 4. remove the drag plate and springs. 5. loosen (but do not remove) the six screws securing the lower strip guide. 6. with a terminal strip in place, adjust the guides to align and center the strip over the anv il. 7. securely tighten the four rear-most screws. the strip should slide easily between the guides with a minimum of clearance. 8. if present, adjust the strip hold-down plate (shown in figure 10 ) so that it is square with the terminal strip and positioned so that it will not interfere with the slug blade tooling on the ram ( shown in figure 4 ). 9. tighten the remaining screws on the strip guide. figure 10 adjusting strip guide lower strip guide screw (6 places) terminal drag plate drag spring and retaining nut (2 places) lower strip guide terminal strip aligned with anvil strip hold-down plate (if present)
408 -10390 rev m1 14 of 18 10. verify the alignment of the terminal strip with the anvil. the strip should be centered over th e anvil and in line with the radius nest on top of the anvil. 11. re -install the drag plate, drag springs, and securing nuts. 12. adjust the drag. 6. replacement and repa ir these procedures cover the applicator parts which most often need replacement or repair because o f wear. proceed with the following: note make sure to order replacements for parts that were used from the spare parts stock so that they will be available when needed. 1. remove the applicator from the machine before performing any maintenance work. danger before taking the applicator out of the machine, make sure that the power to machine is turned off and the power cord is disconnected. the machine ram should be in the raised positi on. 2. refer to the exploded view drawing on the applicator log and the parts list packaged wit h the applicator for identification of parts. 3. wipe the parts with a clean, dry cloth as they are removed from the applicator. then, when putti ng them back into applicator, wipe the mating surfaces with your fingers to make sure that all lint and other foreign matter have been removed. 6.1. anvil replacement 1. from the bottom of the base plate, remove the screw that holds the anvil to the base plate. 2. remove the anvil from the groove in the top of the base plate. 3. install the anvil using the reverse of the installation procedure. if a new anvil is needed, be sure the part number of the new anvil agrees with the number on the applicator parts list. 6.2. shear plate replacement 1. lift the stock drag and feed pawl, then pull the section of the terminal strip back so that the le ad terminal is between strip guides. 2. remove the two screws that fasten the shear plates and spacers (if used) to the strip plates. 3. remove the parts from the applicator. note the position of the front and rear shear plates in order to re -install them correctly. 4. check the worn shear plate(s) to determine if they can be re-positioned to provide another usable shearing edge as follows: most rear plates are the same at the front and rear. if so, and if the second side is not worn, turn the plate front to the rear, making sure that the widest part of the chip clearance groove is at the bottom. if the front plate is completely symmetrical, turn it so that any unused edge is at the top rear. if the front plate does not require spacers and is the same on the top and bottom, turn it top to bottom (if bottom edge is not already worn). make sure that the grooves are facing the rear shear plate. 5. with the old plates re-positioned or the new plates properly positioned, re-install the s hear plates and spacers (if used), and fasten them in place with the two screws. 6. hold the top of the ram assembly with one hand, while moving the feed pawl with the other hand. slo wly lower the ram assembly to check the alignment of the slug blade with the shear plates. if side- to -side alignment is needed, loosen the two screws holding the shear plates, and move the plates to line them up properly. re-tighten the screws.
408 -10390 rev m1 15 of 18 if front- to -back alignment is needed, lay the applicator carefully on its side, and slightly loosen the four screws that hold the strip guide plate to the base plate. move the strip guide plate in t he required direction until the slug blade can pass freely between the shear plates. with the slug blade between the shear plates, retighten the four screws. 7. set the applicator upright, and raise the ram assembly until the slug blade is clear of the shear plates. then, lower and raise the ram assembly several times to make sure that the slug blade moves in an d out of the shear plates freely. 8. lift the stock drag and feed pawl, and slide the terminal strip section forward until the lead te rminal is over the anvil. 6.3. crimper replacement 1. loosen the crimper bolt slightly and remove the ram assembly from applicator by pullin g upward. it may be necessary to move the feed pawl forward to release the ram assembly. 2. remove the crimper bolt that holds the front shear depressor, front shear depressor spacer, tubular spacer, insulation crimper, crimper spacer, and wire crimper in place on the ram asse mbly. note position of parts for re-installation. 3. re -install the parts using the reverse of the installation procedure. the upper end of the wire crimpe r must be up against shoulder of the ram assembly and the top hole on the crimper must mate with the roll pin in the ram assembly. tighten the crimper bolt only finger-tight. note insulation crimpers with legs of equal length that are identical in the front and back may be positioned with either side out. all other insulation crimpers must be positioned with the part number facing the direction noted during removal. if new parts are used, make sure that the part numbers agree with the numbers on the applicator parts list. 4. put the ram assembly back into the applicator, and install the applicator in machine. 5. lift the feed pawl and pull the terminal strip back until the lead terminal is between th e strip guides. 6. form a piece of heavy paper over the anvil, then slowly hand-cycle the machine while watching alignment of the crimpers with the anvil. when the ram assembly has reached the bo ttom of the stroke, carefully tighten the crimper bolt to a torque between 10.8 and 13.6 nm [8 and 10 ft-lb]. the crimpers must move freely over the anvil after the heavy paper is removed. 6.4. air feed bushings, piston rods, and o-rings replacement air feed module rebuild kits pn 2217901-[ ] are available to replace worn air feed bushings, pi ston rods, and o-rings. call the number at the bottom of page 1 for applicable kit. for installation procedure, refer to 408 -32121 . 6.5. applicator housing to base plate alignment each applicator is properly aligned and the base plate bolts are sealed by the factory; however, it is possible to misalign the applicator housing from the base plate due to mishandling or dropping the applicator . if the applicator becomes misaligned, contact a te field service representative or order end-feed ap plicator alignment gage pn 2161422- 3. when aligning the applicator, make sure to torque the base plate screws and, if needed, the gib s crews to the proper specification. the base plate screws should be torqued to 11.298 nm [100 in.-lbs] and the g ib screws should be torqued to 5.649 nm [50 in.-lbs]. 6.6. adjustable crimp height repair the crimp height shim can break or become dislodged under some severe operating conditions or applications. this could cause the applicator to produce terminations with a different crimp height than specifi ed. to correct this, refer to figure 11, and proceed with the following. 1. subtract the specified nominal crimp height from the average crimp height recorded under paragra ph 5.1 , wire crimp adjustment. this difference will be the thickness of the shim(s) ( pn 2119957-1) to be added under the spacer. 2. remove the ram assembly from the applicator, and remove the single revolution limiter bolt.
408 -10390 rev m1 16 of 18 replacing crimp height shim (atlantic) (pacific) figure 11 3. hold the ram assembly with the ram post (or clamp, depending on the applicator style) pointing up. then unscrew the ram post (or clamp) from the ram, exposing the adjustment screw assembly. if necessary, the ram may be placed in a soft jaw vise to free both hands for turning the ram post (or clamp). 4. loosen and unscrew the ram post (or clamp) from the adjustment bolt to access the shim(s). 5. place the shim(s) having the thickness determined in step 1 on the ram post (or clamp). if th e old washer is broken and must be replaced, measure the thickness of the broken washer with a micrometer. add this measurement to the amount to be added (determined in step 1), and select the new shim(s) having this thickness. place the new shim(s) on the ram post (or clamp). 6. re - ti ghten the ram post to the adjustment bolt with the spacer and new shim(s) placed in between. note lightly grease the threads of the adjustment bolt with the recommended greases before re-assembling. 7. hold the ram with the hole facing up, assemble the adjustment screw assembly into the ram, and tighten it by hand until it bottoms in the ram. make sure not to tighten the adjustment screw ass embly. just turn it in the assembly until it stops. ram post spacer adjustment bolt ram clamp note : pacific applicators only when installing setscrews, 3 of 5 holes must be used that will not interfere with ramp clamp device numbered wire crimp height adjustment dial shim single revolution limiter bolt
408 -10390 rev m1 17 of 18 8. re -install the single revolution limiter bolt back into the ram. make sure that the numbered wire cr imp height adjustment dial lines up properly with the indicator wedge cut-out pointing to the zero on the numbered wire crimp disc. note if necessary, loosen the 3 setscrews holding the numbered wire crimp and height adjustment dial to the ram post and turn it until the dial indicates a zero reading, then re-tighten the 3 setscrews against the ram post. caution when tightening the setscrews, turn each setscrew 60 C 90 degrees after contacting the center hub. tightening more than 90 degrees can compromise the numbered wire crimp height adjustment dial and cause it to crack. also, apply loctite 222 threadlocker to the setscrews before tightening them. 9. put the ram assembly back into the applicator. 10. install applicator in machine, and make some test crimps. measure the crimp heights, and c heck them against the crimp height specified on the applicator parts list. if the crimp heights are wit hin specified tolerances, the applicator may be placed in service. if not, repeat this procedure, starting with step 1. 6.7. counter magnet orientation the applicator counter magnet will properly actuate the applicator counter (shown in figure 5 ) only if it is installed with the correct side facing out from the ram. if for any reason the magnet is removed, it will need to be determined (before re-installing the magnet in the ram) which side of the magnet actuates the counte r by running the magnet behind the counter by hand to see which side of the magnet actuates the counter pro perly. 6.8. wire depressor accessory refer to figure 12 to determine the parts required to add this accessory if it is not installed on th e applicator from the factory. 7. cleaning, lubrication, and storage for best performance and minimum downtime, the applicator should be cleaned (daily and monthly) , inspected, lubricated, and stored as indicated in instruction sheet 408 -8059 . 8. revision summary revisions to this instruction sheet include: ? added to figure 12: note: when crimper spacer pn 455888-5 or 455888-6 are fitted to the applicator, only the wire depressor and corresponding spacer need to be used. loctite is a trademark.
408 -10390 rev m1 18 of 18 figure 12 part number- to -crimper spacer thickness cross-reference step 1 determine replacement crimper spacer thickness using the following formula: se - 0.64 mm [.025 in.] = sr note : use the table to determine which crimper spacer or combination of crimper spacers is required to achieve proper replacement crimper spacer thickness. note: the existing crimper spacer must be at least 0.64 mm [.025 in.] thick in order to add a wire depressor t o an existing applicator. step 2 choose a wire depressor based on the wire size range: pn 2119791 -5 0.008 -1.305 mm2 [38-16 awg] pn 2119791 -9 0.150 -5.270 mm2 [20-10 awg] step 3 order replacement components: washer spacer pn 2119943 -1 wire depressor (chosen in step 2) crimper spacer/spacers (chosen in step 1) n ote : w hen crimper spacer pn 455888-5 or 455888-6 are fitted to the applicator, only the wire depressor and corresponding spacer need to be used. se = existing crimper spacer thickness (see cross-reference for part number- to -crimper spacer thickness) choose wire depressor based on wire size range sr = replacement crimper spacer thickness wire depressor washer spacer pn 2119943 -1 required part number thickness mm [in.] 455888 -1 0.25 [.010] 455888 -2 0.30 [.012] 455888 -3 0.38 [.015] 455888 -4 0.51 [.020] 455888 -5 0.66 [.026] 455888 -6 0.79 [.031] 455888 -7 0.89 [.035] 455888 -8 1.02 [.040] 455888 -9 1.14 [.045] 1- 455888 -0 1.27 [.050] 1- 455888 -1 1.40 [.055] 1- 455888 -2 1.52 [.060] 1- 455888 -3 1.57 [.062] 1- 455888 -4 1.65 [.065] 1- 455888 -5 1.78 [.070] 1- 455888 -6 1.91 [.075] 1- 455888 -7 2.03 [.080] 1- 455888 -8 2.16 [.085] 1- 455888 -9 2.29 [.090] 2- 455888 -0 2.36 [.093] 2- 455888 -1 2.41 [.095] 2- 455888 -2 2.54 [.100] 2- 455888 -3 2.67 [.105] 2- 455888 -3 2.67 [.105] 2- 455888 -4 2.79 [.110] 2- 455888 -5 2.92 [.115] 2- 455888 -7 3.18 [.125] 2- 455888 -8 4.37 [.172] 2- 455888 -9 5.08 [.200] 3- 455888 -2 3.63 [.143] 3- 455888 -7 3.56 [.140] 7- 455888 -2 4.83 [.190]

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