TE Connectivity OCEAN 2.0 User manual

Instruction Sheet
1 of 26
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408-35042
08 APR 19 Rev C
1. INTRODUCTION
The OCEAN 2.0 side-feed applicators are available with either a mechanical terminal feeder or a pneumatic
terminal feeder assembly. Each style of applicator accepts side-feed strip terminals and applies 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.
NOTE
This instruction sheet, the exploded-view drawing with the associated parts list packaged with the applicator, along with the
applicable customer manual provide all the information required to operate and maintain the applicator and machine.
Following is a list of the terminating machine customer manuals that apply:
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
Refer to Instruction Sheet 408-350051for translations of the Safety Warnings specified herein.
2. DESCRIPTION
Overview
1. Main components of the mechanical and air feed applicators are identified in Figures 1 and 2,
respectively.
Figure 1
1Future Release
OCEAN 2.0 Side-Feed Applicators
Mechanical Feed Applicator
Base Plate
Side-Feed Strip-Form
Terminals
Rear Strip Guide Plate
Mechanical Terminal
Feeder Assembly
Mounting Screw (2 Places)
Feed Pawl
Ram Assembly
Applicator Housing
Front Strip Guide Plate

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Figure 2
2. Each applicator is individually designed for specific terminals. The wire crimp height and insulation
crimp height can be adjusted to accommodate different wire sizes and insulation ranges. The
applicator is also designed to accept modular-feed packages.
Figure 3
Air Feed Applicator
Air Supply
Connection
Retract Speed Control
Forward Speed Control
Feed Arm
Feed Pawl
Pneumatic Terminal
Feeder Assembly
Mechanical Terminal
Feeder Assembly
Mounting Screw (2 Places)
Ram Assembly
Applicator
Housing
Pneumatic Terminal
Feeder Assembly
Front Strip Guide Plate
Rear Strip Guide Plate
Base Plate
Vertical Etched Line

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3. The OCEAN applicator can be used in various machines; provided the machine has the proper stroke
length and all the necessary equipment.
There are two basic applicator design styles; Atlantic and Pacific, to meet the many terminator and
leadmaker configurations worldwide (see Figure 4).
Figure 4
NOTE
The Pacific applicator will work only when used with a machine having a ram that falls within the dimensional envelope shown
in Figure 5.
Figure 5
Atlantic
Machine Ram for
Ram Post Adapter
Basic Applicator Design Styles
Pacific
Machine Ram for
Ram Post Adapter
Wire Crimp Disc
Ram Clamp
Ram Post
Insulation
Crimp Dial
Insulation Crimper
Front Shear Depressor
Crimper Bolt
Front Shear Depressor
Wire Crimper
Wire Crimper
Insulation Crimper
Note:
Dimensions are in millimeters with inches in brackets.
Pacific Applicator Requirements

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4. Though the Atlantic and Pacific applicator ram and base plate interfaces are different, most of the
OCEAN 2.0 features and adjustments are the same.
The terminal strip must be fed into the applicator with the wire barrels facing out; between the Front
(outer) and Rear (inner) Strip Guides. The terminal strip passes the Stock Drag, and the lead terminal
is positioned 1) over the Anvil for pre-feed applicators, or 2) 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 Wire Crimp Disc is located just below the ram post interface, which is designed with a spring-
loaded adjustment mechanism for precise crimp height adjustment in increments of 0.01 mm [.0004
in.]; with a total adjustment range of 1.45 mm [0.057 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 diameter of the Wire Crimp Disc, indicating a relative crimp height.
The Wire Crimper is held in a pre-set position by the Ram and the Crimper Bolt. The Insulation
Crimper and the Front Shear Depressor are also held by the Crimper Bolt. The Insulation Crimper is
free to move up and down so the insulation crimp height can be adjusted via the Insulation Crimp Dial
by pulling the spring-loaded dial outward slightly and rotating to a different number.
The applicator mounting surface is the base plate. The Anvil, Front Shear Holder, Terminal Support,
Strip Guide Plate, and applicator housing are mounted on the base plate. The Stock Drag, and Front
and Rear Strip Guides are mounted on the Strip Guide Plate.
Terminals with dual-carrier strips
When terminals with dual-carrier strips are to be processed, an additional Shear Depressor, Rear
Shear Holder, and Rear Floating Shear are required. The Rear Shear Depressor will push the Rear
Floating Shear down to cut the terminal from the rear carrier strip and the Terminal Hold-Down will
keep the terminal from raising during the crimping and shearing process. The Rear Floating Shear
and Rear Shear Holder are mounted on the base plate.
Figure 6
Rear Shear Holder
Rear Floating Shear
Rear Shear Insert
Front Shear Holder
Front Shear Insert
Front Floating Shear

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5. Lubrication
Some terminal strips require the use of a terminal lubricant. Wick-type lubricators apply lubricant to the
terminal strip as it feeds into the applicator. Terminal lubricants reduce tooling wear and help reduce
damage to the plating on some terminals.
OCEAN applicator, Side-Feed Lubricator Assembly PN 2119955-1 is available.
For rear-carrier style terminals, Lubricator Assembly PN 2119955-5 is available.
CAUTION
Depending on the final use of the crimped terminal, terminal lubrication is not always recommended. To determine if your
applications warrant the use of a terminal lubricator, contact your Field Representative.
NOTE
If your application warrants the use of a terminal lubricator, the recommended lubricant is Stoner Mechanical Lubricant E807
available from Stoner, Inc. Call 1-800-227-5538 or visit www.stonersolutions.com.
Applicator with Mechanical Feed System
With a Mechanical Feed 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 (Pre-Feed and Post Feed) and can be
mounted in two different mounting holes depending on machine stroke length and feed type (see Figure 7).
The Post-Feed feed cam advances the lead terminal over the Anvil on the downward stroke of the ram
assembly; leaving the Anvil clear when the machine is at rest.
The Pre-Feed feed cam advances the lead terminal over the Anvil on the upward stroke of the ram assembly;
leaving a terminal over the Anvil when the machine is at rest.
NOTE
When not in use, the spare Feed Cam can be mounted to the applicator housing in the spare feed cam storage location (see
Figure 8).
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.
Figure 7
Mounting Feed Cam (Atlantic Applicator w/Mechanical Feed shown)
40-mm [15/8-in.] Stroke Machine
30-mm [11/8-in.] Stroke Machine
Pre-
Feed
Pre-
Feed
Post-
Feed
Post-
Feed
Mounting
Screw
(typ)
Mounting
Screw
(typ)
Mounting
Screw
(typ)
Mounting
Screw
(typ)

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Figure 8
Applicator with Air Feed System
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.
NOTE
NO oil lubrication of air for the OCEAN Air Feed module is required after receiving and use within a production environment.
The ram continues downward, completes the crimping action, and starts back up. As it approaches the fully
raised position, the push rod drops off the high portion of the ram mounted cam, shifting the air feed valve. The
extend side of the cylinder is then filled, moving the feed pawl and terminal strip over 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 stroke
machines: 40-mm [15/8-in.] stroke or 30-mm [11/8-in.] stroke (refer to Figures 7 and 9).
Note that the air feed requires a different cam than the mechanical pre-feed or post-feed.
Figure 9
Air Feed Cam
Installed
Pre-Feed
Mounting Screw
Mounting Screw
Air Feed Cam
Installed
Pre-Feed
Mounting Feed Cam (Atlantic Applicator w/Pneumatic Feed shown)
40-mm [15/8-in.] Stroke Machine 30-mm [11/8-in.] Stroke Machine
Spare Feed Cam Storage Location

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3. APPLICATOR INSTALLATION AND REMOVAL
DANGER
To avoid personal injury, make sure 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 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.
AMP-O-LECTRIC Machine and Model “K” Machine (with Mini-Applicator Conversion)
A. Installation
This machine must be equipped with Machine Conversion Kit PN 690675-2 to adapt it for use with the
OCEAN 2.0 applicators. The kit includes applicator Instruction Sheet 408-8022, which explains how an
applicator with mechanical feed is installed and removed from the machine.
B. 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 stop on
the base mount until the Ram Post is clear of the machine ram.
Model “T” Terminating Unit
NOTE
For the Atlantic Applicator only.
A. 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 notches 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.
B. 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.

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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 409 Series
Customer Manual specified in Section 1.
For installation and removal procedures for terminating machines not listed, refer to the customer
documentation supplied with the machine.
NOTE
Adjustment of the Stripper may be required when moving the applicator between bench and leadmaker applications.
4. APPLICATOR LOADING AND UNLOADING
Terminal Strip Loading
NOTE
Before loading the terminal strip in applicator, make sure 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 print.
1. Turn off and disconnect the power to the machine.
2. Make sure the ram assembly is all the way up. If necessary, hand-cycle the machine to raise the Ram.
Refer to the applicable 409 Series 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, and
pulling the strip straight out of the applicator (see Figure 10).
5. With the reel of terminals installed on the Reel Support, feed the terminal strip into the applicator
between the Strip Guides.
NOTE
Make sure the terminal strip enters the Strip Guides with the terminal open-side up and the wire barrel end toward the Stock
drag.
6. Raise the Feed Pawl and continue to feed the terminal strip until the lead terminal is over the Anvil
and the Feed Pawl engages the hole in the carrier strip.
Figure 10
Stock Drag
Drag Release Lever

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7. If terminals are post-feed, lift the Feed Pawl and pull the strip back one terminal length (the lead
terminal will then be moved over the Anvil on the downward stroke of the ram assembly).
8. Turn the Drag Release Lever downward to lower the Stock Drag.
9. Make sure the tip of the Feed Pawl is in the feed hole in the carrier strip.
NOTE
Some carrier strips have additional holes which are not used for feed purposes.
10. Hand-cycle the machine several times to make sure the applicator is properly adjusted as described in
Section 5.
11. Re-install the applicator guard assembly.
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.
5. ADJUSTMENTS
Wire Crimp
A. Crimp Height
1. The wire crimp is adjustable by rotating the Wire Crimp Disc from 0 (largest crimp height) to 14.5
(smallest crimp height) in increments of .01 mm [.0004 in.].
2. Select a crimp height reference setting number from 0 (largest crimp height) to 14.5 (smallest crimp
height) from the applicator print for the wire size to be used.
3. Turn the Wire Crimp Disc to line up with the specified crimp height reference setting number with the
indicator notch/cut out on the front of the Ram (see Figure 11).
4. Turn the Wire Crimp Disc clockwise to decrease the crimp height and turn the Wire Crimp Disc
counterclockwise to increase the crimp height. Each increment represents a change in crimp height of
0.01 mm [.0004 in.].
Figure 11
Wire Crimp Disc
Indicator Notch/Cut Out
Insulation Crimp Dial

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5. 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 (flash),
deformed crimps, bent terminals, or other defects caused by worn or broken tooling. If necessary,
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 print
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 corrective information can be found in the applicable 409 Series Customer
Manual. If the crimp height is correct, the problem is in the original applicator, and refer to Paragraph 6.7; Adjustable
Crimp Height Repair, for corrective measures.
6. During extensive operation, periodically inspect the terminals as described in Step 4 to make sure the
applicator is producing correct terminations.
B. Wire Crimp Adjust Lock Position
1. The wire crimp height adjusts can be locked in position by changing the Detent Pin orientation (see
Figure 12).
Verify the setup dimension (distance from Crimper Seating Feature on the Ram) to the top of the
Crimp Height Adjust Head (see Figure 13).
NOTE
This distance is also provided on the Applicator Print.
Hold down the spring-loaded Detent Pin and turn the Adjust Head out of the Ram until the Detent
Pin can be removed.
DANGER
The spring-loaded pin can injure if released unexpectedly.
Invert the pin so the locking end will contact the Detent Plate and re-install the pin and spring.
While holding the pin down, turn the Adjust Head until the proper set-up dimension is reached.
Verify the crimp height as shown in Paragraph 5.1.A.
CAUTION
When changing crimp height while in the locked orientation, the spring-loaded Detent Pin must be depressed to rotate the
number ring, or damage will occur.

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Figure 12
Figure 13
Pin in DETENT Orientation
Pin in LOCK orientation
Fine Adjust Head
Setup Distance
SEE
DETAIL
Adjust Set to 0 (Zero)
DETAIL
Ring Stop
Detent Pin

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Insulation Crimp
The insulation crimp is adjustable in increments of 0.19 mm [.0075 in.] by pulling the Insulation Crimp Dial out
(see Figure 11) and turning it to line up with the number (1 through 18) 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 maximum 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 crimp height is achieved.
NOTE
Some applicators may have a special Insulation Crimp Dial that differs in range and increments than described. Refer to the
marking on the front of the Insulation Crimp Dial for correct increments.
Terminal Strip Feed –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 over the Anvil. Locate
the Feed Pawl in the desired feed pilot hole of the carrier strip. Actuate the applicator to move the
Feed Pawl forward. The lead terminal must be centered over the Anvil.
2. Watch the Feed Pawl as the machine is hand-cycled (or slowly cycled) several times. 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 passes completely over the feed hole.
NOTE
At the end of its backstroke, the Feed Pawl should be at the back edge of the feed hole to be used. The backstroke must not
be longer than this; otherwise, the Feed Pawl might not drop into the feed hole.
If the forward limit and backstroke setting are correct, 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 lead terminal is not centered on the Anvil, make note of the position and continue to cycle the
applicator to check the backstroke position.
NOTE
At the end of its backstroke, 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 lead terminal is not centered over the Anvil and the backstroke position is incorrect, both the stroke
length and the fine feed position must be adjusted. Stroke length (backstroke position) must be adjusted
before final centering of the terminal over the Anvil. Continue with the next step.
4. Loosen the Stroke Length Adjustment Lock Screw (see Figure 14).

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Figure 14
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 the proper stroke length is achieved. Note: The terminal
might not be centered over the Anvil; this will be adjusted at a later step.
If the feed pawl stroke length is satisfactory, and the backstroke position is correct, but the lead terminal is
not centered over the Anvil, the stroke is correct; however, the Feed Pawl position is incorrect. In this
case, an adjustment to the fine feed screw is required.
8. Adjust the Feed Pawl position as follows:
Loosen the Fine Feed Adjust Lock Screw on the side of the Feed Finger Holder to allow the Fine
Feed Adjustment Screw to turn (see Figure 14).
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.
9. Adjust the Feed Pawl position by turning the adjustment screw counterclockwise to move the Feed
Pawl away from the Anvil and clockwise to move the Feed Pawl toward the Anvil. Center the terminal
over the Anvil.
10. Re-check the adjustment for the proper position and stroke as described in Step 1. Repeat the
adjustment procedure as necessary and tighten the Fine feed Adjust Lock Screw.
Stroke Length Adjustment Screw
Stroke Pivot
Stroke Length Adjustment Lock Screw
Fine Feed Adjustment Screw
Fine Feed Adjust Lock Screw
Feed Pawl
Feed Pawl Holder
Strip Guide Locking Screw
Strip Guide Adjusting Screw

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Terminal Strip Feed –Air Feed Applicator
OCEAN applicators equipped with Air Feed Module PN 2063440-1, -2 or -3: Refer to Section 5.4.A.
OCEAN applicators equipped with Air Feed Module PN 2844940-1 or -2: Refer to Section 5.4.B.
A. Air Feed Modules PN 2063440-1, -2, or -3
The feed mechanism is actuated by compressed air (see 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.
NOTE
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 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 3mm wrench, exposing the “tool-less” adjustment knobs
(recommended procedure). However, air feed module 2063440 can be adjusted with the end cap in place using a 3mm
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 above the anvil. If that is
not the case, proceed with the following:
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).
Jog the machine down to the lower-dead-center position. The feed cylinder and pawl will be
retracted away from the anvil.
Using the Retract Speed Control knob (see Figure 2), position the feed pawl to the proper back
position. Back the edge of the feed pawl to the back of the terminal strip feed hole. 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. Make sure that the feed forward and back positions are verified after restoring air pressure.
NOTE
At the end of the backstroke, the feed pawl should be at the back edge of the feed hole to be used. The backstroke must not
be longer than this; otherwise, the feed pawl might not drop into the feed hole.
Jog the machine to top-dead-center. The feed will move the next terminal over the anvil.
Check position of the terminal over the anvil, noting if the terminal feed-forward position should be
moved.
Cycle the machine manually until the feed pawl shifts back. This releases the air pressure on the
feed adjustment, making the adjustment detent positions easier to feel.

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Using the feed-forward adjustment knob, change the feed-forward position based on the direction
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 adjustment knob turns, not the entire shaft. The backstroke adjustment knob may
have to be held stationary to prevent unintended backstroke adjustments (use a 3-mm wrench when the end cap is in place).
Cycle the machine back to top-dead-center, causing the feed to shift forward and feeding the
terminal over the anvil. Repeat steps 4.d. through 4.h. until the terminal is centered over the anvil.
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 disconnected.
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 was adjusted at the factory to ensure the terminal is advanced at the lowest
possible speed. On rare occasions, the feed speed may not be fast enough if the applicator is used
on a fully automatic machine. The feed speed can be increased by adjusting the two exhaust
restrictors.
(1) 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. Excessive feed and/or retract speeds can cause
inconsistent feeds and/or air feed module damage. It is recommended to only open the flow control valves two complete
revolutions.
(2) Loosen the locking ring, and turn the adjustment screw clockwise to decrease the speed and
counter-clockwise to increase the speed. When complete, tighten the locking ring.
B. Air Feed Modules PN 2844940-1 or -2
Figure 15
Valve Assembly
Air Cylinder
Slide Assembly

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The feed mechanism is actuated by a constant supply of compressed air (see 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.
DANGER
When air pressure is supplied to the air feed module, If the ram of the applicator is moved up and down, either by hand when
removed from the terminator or by the terminator ram moving, the feed may cycle.
CAUTION
Use caution when operating a machine with the guard open and air supplied to the air feed.
NOTE
Opening the machine guard will not remove air pressure from the air feed module.
DANGER
It is recommended to remove the air to the air feed module if any adjustments are to be performed.
CAUTION
Do not tamper with the set screws located in the air feed valve assembly.
NOTE
The life of the piston seal can be extended by applying either MAGNALUBE-G or Parker Super O-Lube to the outer diameter
of
the air cylinder piston shaft.
1. Feed Adjustment
The feed stroke (terminal pitch), terminal position, and feed speed are set from the factory. If
adjustment is necessary, follow the instructions below:
Feed Stroke (terminal pitch)
NOTE
Feed stroke and feed positions adjustments are made using a 2.5mm ball end hex key wrench.
NOTE
At the end of the backstroke, the feed pawl should be at the back edge of the feed hole to be used. The backstroke must not
be longer than this; otherwise the feed pawl might not drop into the feed hole.
NOTE
One-quarter (¼) turn of the backstroke adjustment screw adjusts the back stroke 0.20mm (0.008 inch).
(1) Remove air pressure from the air feed module.
(2) Release terminal drag.
(3) Install the terminal strip in the applicator until the feed pawl drops into the first feed hole.
(4) Pull the terminal strip back until the feed finger hole stops on the feed pawl.
(5) Engage the terminal drag.
(6) Manually extend the feed arm.
(7) Manually retract the slide until the feed pawl is at the rear edge of feed hole for the next
terminal (feed pitch) (reference Figure 16).
MAGNALUBE is a trademark.

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Figure 16
(8) If the feed pawl is at the rear edge of the feed hole before the slide hits the rear stop adjust
screw, turn the rear stop adjust screw clockwise until the screw meets the slide, as follows:
Figure 17
(a) Loosen the Rear Stop Locking Screw.
(b) Turn the Rear Stop Adjust Screw clockwise until it meets the slide.
(c) The Feed Pawl must be positioned to the rear edge of the feed hole.
(d) After verifying positions, tighten the locking screw.
(9) If the slide hits the rear stop adjust screw before the feed pawl is at the rear edge of the next
hole, the rear stop adjust screw needs to be adjusted. Adjust the rear stop adjust screw
counter-clockwise until the feed pawl is at the rear edge of the feed hole.
(a) Loosen the Rear Stop Locking Screw.
(b) Turn the Rear Stop Adjust Screw counter-clockwise.
(c) Push the slide against the rear stop adjust screw.
(d) The Feed Pawl must be positioned to the rear edge of the feed hole. Repeat steps (b) and
(c) until the feed pawl is at the rear edge of the feed hole.
(e) After verifying positions, tighten the locking screw.
(10) Extend the slide manually, then retract the slide. Check to ensure the feed finger is in the
middle of the feed hole. If it isn’t, repeat steps (7) and (8) to adjust the rear stop position of the
feed finger.
(11) Apply pressurized air to the air feed module.
(12) Cycle the terminator in jog mode or manually until the feed pawl retracts.
(13) Verify the pawl is in the correct location. If it is not in the correct position, repeat steps (7) thru
(12).
Feed Pawl to Rear of
Terminal Feed Hole
Clockwise
Rear Stop Adjust Screw
Rear Stop Locking Screw

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Feed Position (terminal position over the anvil)
(1) Remove the air supply from the module.
(2) Manually feed the terminal by fully extending the feed and then fully retracting the feed until a
terminal is over the anvil.
(3) If the terminal position is left of the anvil (under-fed), turn the Fine Feed Adjust Screw
clockwise to move the terminal to the right of the anvil (see Figure 18).
NOTE
One (1) “click” of the Fine Feed Adjust Screw equals 0.025mm (0.001 inch) of adjustment.
Figure 18
(4) If the terminal position is right of the anvil (over-fed), turn the Fine Feed Adjust Screw counter-
clockwise to move the terminal to the left of the anvil.
(5) After making an adjustment, retract and extend the feed slide to feed a terminal.
(6) If the terminal is not centered over the anvil, repeat steps (3) thru (5).
Feed Speed
The feed mechanism has been adjusted at the factory to ensure that the terminal is advanced at the
lowest possible speed. In rare occasions, it is possible that the feed speed is not fast enough if the
applicator is used on a fully automatic machine. The feed speed can be adjusted by means of the two
exhaust restrictors.
NOTE
The air feed speed has been set at the factory and should therefore require re-adjustment ONLY in exceptional
circumstances.
NOTE
The speed controls should not be fully opened to maximize feed speed. Excessive feed and/or retract speeds can cause
inconsistent feeds and/or air feed module damage.
NOTE
TE recommends adjusting the Retract Flow Control first to try to speed up the feed cycle.
(1) Hold the control knob while loosening the locking nut with a hex wrench.
(2) Turn the knob clockwise (in) to decrease the speed. Turn the knob counter-clockwise (out) to
increase the speed.
(3) Hold the control knob while tightening the locking nut.
NOTE
TE recommends adjusting the flow controls only ½ turn before testing the feed cycle.
Clockwise
Fine Feed Adjust Screw
2.5mm Ball End
Hex Key Wrench

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Figure 19
Strip Guide Plate and Feed Pawl
This procedure moves the plate on which the Strip Guides are mounted. Since the terminal strip is fed into the
applicator between the Strip Guides, it is moved front and back over the Anvil as the Strip Guides are moved.
NOTE
Getting the adjustment of the Feed Pawl to match any change in the position of the Front Strip Guide is also described here.
1. From the front of the strip guide plate, loosen the Strip Guide Plate Locking Screw (see Figure 20).
2. With the lead terminal centered over the Anvil, lift and hold (or block) the Feed Pawl up to clear the
Front Strip Guide.
3. Turn the Strip Guide Plate Adjustment Screw clockwise to move the Strip Guide Plate toward the rear
or counterclockwise to move it toward the front. Note: The insulation barrel of the lead terminal should
be as close as possible to the Floating Shear. Tighten the locking screw to hold the Strip Guide Plate
in position.
4. Hand-cycle the machine, checking for proper terminal feed and Strip Guide Plate alignment.
5. If necessary, re-position the Feed Pawl and the Shear Holder(s).
Figure 20
Strip Guide Plate Locking Screw
Strip Guide Plate Adjustment Screw
Feed Pawl
Front Strip Guide
Rear Strip Guide

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Strip Guide
This adjustment is only needed when the Rear Strip Guide is not parallel to the Strip Guide Plate, the Front and
Rear Strip Guides are not parallel to each other, or there is a variation in strip width.
NOTE
The Front and Rear Strip Guides are correctly positioned on the Strip Guide Plate when the applicator is built and normally
does not need adjustment.
NOTE
Do not use this procedure for front-to-rear positioning of the strip—refer to Paragraph 5.5, Strip Guide Plate and Feed Pawl.
1. Lift and hold (or block) the Feed Pawl up to clear the Front Strip Guide, then loosen the screws
holding the Rear Strip Guide to the Strip Guide Plate.
2. Move the Rear Strip Guide in the desired direction, making sure it is parallel to the Strip Guide Plate,
and then re-tighten the holding screws.
3. Align the Front Strip Guide with the holes in the terminal carrier strip, but make sure the Front are
Rear Strip Guides are parallel, and that the terminal strip can move freely with a minimum of side
clearance. Re-tighten the screws.
NOTE
Adjust the Feed Pawl with the Front Strip Guide, if necessary.
4. Hand-cycle the machine, checking for proper terminal feed and strip guide alignments.
Shear(s) and Shear Holder(s)
With the lead terminal centered over the Anvil, check if the Floating Shear(s) cuts the terminal from the carrier
strip(s) correctly. If necessary, make the following adjustments.
Remove the applicator ram before proceeding.
NOTE
The applicator must be removed from the machine for this procedure. See the removal procedure in Section 3.
A. Front Shear
1. From the bottom of the base plate, loosen the two screws that secure the Shear Holder to the base
plate.
2. Move the Shear Holder and Floating Shear in the desired direction and re-tighten the screws.
NOTE
There should be minimal clearance between the Floating Shear and the Anvil; the shear must move up and down freely, and
must be square to the back of the Anvil.
3. With the applicator ram replaced and the lead terminal centered over the Anvil, check that the Floating
Shear correctly cuts the terminal from the carrier strip. If the shearing action is not correct, repeat
Steps 1 and 2, or check for worn or damaged tooling.
NOTE
Some center carrier terminals are fed using the terminal body, not the carrier strip.
B. Rear Shear
The rear shear is more likely to need adjustment because it is affected by differences in terminal strip
widths and Strip Guide Plate adjustments.
1. From the bottom of the base plate, loosen the two screws that hold the Rear Shear Holder to the base
plate.
2. With the terminal strip inserted into the applicator, and the lead terminal centered over the Anvil, move
the Rear Shear Holder in the direction required to obtain the proper cutoff tab.
3. Check that the shear is square to the end of the terminal and then tighten the holding screws.