TE Connectivity OCEAN 2.0 User manual

Instruction Sheet
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408-35043
20 JUN 19 Rev C
1. INTRODUCTION
The OCEAN 2.0 End-feed applicators are available with either a mechanical terminal feeder or a pneumatic
terminal feeder assembly. Each style of applicator accepts end-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
Reference Instruction Sheet 408-350081for translations of the Safety Warnings specified herein.
2. DESCRIPTION
Overview
Main components of the mechanical and air feed applicators are identified in Figures 1 and 2,
respectively.
Figure 1
Indicator Notch/CutOut
Ram Assembly
Terminal Feeder Assembly
Applicator Housing
End-Feed Strip-Form
Terminal Strip
Drag Release Lever
Insulation Crimp Dial
Stripper
Lead Terminal (Ref)
Anvil
Strip Guide Plate
Strip Guide
Base Plate
Mechanical Feed Applicator
OCEAN 2.0 End-Feed Applicators
1Future Release
Wire Crimp Disc

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Figure 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, respectively.
The applicator is also designed to accept modular-feed packages.
Figure 3
Applicator
Pneumatic Terminal
Feeder Assembly
Changing Feeder Assembly
Mechanical Terminal
Feeder Assembly
Air Feed Applicator
Feed Pawl
Feed Arm
Air Feed Cam
Air Supply Connection
Lock Nut
Retract Speed Control
Extend Speed Control
Mounting Screws

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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).
(Atlantic) (Pacific)
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
Applicator
Ram
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
Insulation
Crimp Dial
Crimper Bolt
Insulation Crimper
Terminal
Hold-Down
Basic Applicator Design Styles
Note:
Dimensions are in millimeters with inches in brackets.
Pacific Applicator Requirements

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Though the Atlantic and Pacific ram and base plate interfaces are different, most of the Ocean
applicator features and adjustments are the same.
The terminal strip must be fed into the applicator, with the wire barrels facing up and first into the
applicator, between the strip guide plates. It will pass under the stock drag, and the lead terminal will
be positioned 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 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 increments of 0.01 mm [.0004 in.]
and a total adjustment range of 1.45 mm [.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 and Insulation Crimper are held in a pre-set position by the ram and the crimper
bolt. The insulation crimper is free to move up and down so that the insulation crimp height can be
adjusted via the insulation crimp dial by pulling 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 terminals,
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 housing
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 pass between them, removing the connecting tab between the terminals.
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. The OCEAN applicator End-Feed Lubricator Assembly PN
2119955-2 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 and can be mounted in two different mounting
holes depending on machine stroke length and feed type (see Figure 6).
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.
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.
NOTE
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 applications. 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 used for side-feed bench applications.
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 7.

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Applicator Counter
Figure 6
Figure 7
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.
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 Holder
Feed Pawl Pin
Applicator Counter Setscrew
Stroke Length
Adjustment Screw
Mounting Mechanical Feed Cam

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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 ram’s downward stroke, the ram-mounted cam pushes 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.
The ram continues downward, completes the crimping action, and starts back up. As it approaches the fully
raised position, the valve spool 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 Figure 8).
Note: 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.
Figure 8
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.
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
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.
Mounting Air Feed Cam

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B. Removal
Turn off, and disconnect, the power to the machine.
Unload the applicator as described in Section 4.
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 [Atlantic Applicator ONLY]
A. Installation
Turn off, and disconnect, the power to the machine.
Push in the release bar on the quick-change base plate. The locking latch will pivot downward.
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.
Flip the locking latch up to secure the applicator in place.
B. Removal
Disconnect the power cord.
Cut the terminal strip one or two terminals from the end of the applicator.
Push in the release bar on the quick-change base plate. The locking latch will pivot downward.
Slide the applicator forward until it is clear of the ram post adapter.
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 manual
given 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. TERMINAL STRIP LOADING AND UNLOADING
Loading
NOTE
Before loading the terminal strip in the 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 print.
Turn off, and disconnect, the power to the machine.
Make sure that the ram assembly is all the way up. If necessary, hand-cycle the machine to raise the
ram. Refer to the machine customer manual.
Remove the applicator guard assembly.
Raise the stock drag by pushing the drag 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.
With the reel of terminals installed on the reel support, feed the terminal strip into the applicator
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 up.
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 terminal in the proper position.

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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.
Hand-cycle the machine several times to make sure the applicator is properly adjusted as described in
Section 5. Re-install the applicator guard assembly.
Unloading
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.
If terminals are post-feed, push the drag 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
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.].
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.
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 9).
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 9
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 6.5, Adjustable
Crimp Height Repair, for corrective measures.
Wire Crimp Disc
Indicator Notch/Cut Out
Insulation Crimp Dial

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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
The wire crimp height adjusts can be locked in position by changing the Detent Pin orientation (see
Figure 10).
a. Verify the setup dimension (distance from Crimper Seating Feature on the Ram) to the top of the
Crimp Height Adjust Head (see Figure 11).
NOTE
This distance is also provided on the Applicator Print.
b. 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.
c. Invert the pin so the locking end will contact the Detent Plate and re-install the pin and spring.
d. While holding the pin down, turn the Adjust Head until the proper set-up dimension is reached.
e. 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
Figure 10
Pin in DETENT Orientation
Pin in LOCK orientation
SEE
DETAIL
DETAIL
Ring Stop
Detent Pin

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Figure 11
Insulation Crimp
The insulation crimp is adjustable in increments of 0.19 mm [.0075 in.] by pulling the Insulation Crimp Dial out
(see Figure 9) 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
A. 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.
With the terminal strip properly loaded, check the position of the lead terminal in relation 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 7. The slug blade must remove the connecting tab between lead and second terminals
- without deforming either terminal.
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 moves up onto the body of the terminal (see Figure 12).
NOTE
If the pick-up point is the mating end of the terminal, the backstroke over-travel should be approximately 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 12
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.
Fine Adjust Head
Setup Distance
Adjust Set to 0 (Zero)
Feed Pawl

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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.
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 is not slugged out
correctly 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 other
terminals under the slug blade.
Loosen the stroke length adjustment lock screw (see Figure 7).
Turn the stroke length adjustment screw counterclockwise to reduce the stroke length or clockwise to
increase the stroke length.
Tighten the stroke length adjustment lock screw.
Repeat steps 1 through 6 as required until proper stroke length is achieved. The terminal might not be
slugged out correctly (or positioned under the slug blade correctly); this will be adjusted in 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 stroke is
correct, but the position is incorrect, an adjustment to the fine feed screw is required. Continue with
the next step.
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 feed
adjustment screw to turn. Refer to Figure 7.
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.
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.
Re-check the adjustment for the proper position and stroke as described in step 1. Repeat the
adjustment procedure as necessary.
B. Air Feed Applicator
OCEAN applicators that are equipped with Air Feed Modules PN’s 2063440-1, -2, or -3, refer to
Section 5.3.B.1.
OCEAN applicators that are equipped with Air Feed Modules PN’s 2844940-3 or -4, refer to
Section 5.3.B.2.
Air Feed Modules PN’s 2063440-1, -2 or -3
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.

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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.
a. Mount the applicator onto the machine.
b. Insert the terminal strip until the lead terminal is located over the anvil.
c. Connect the air supply to the applicator.
d. Cycle the machine manually. The next terminal must now be located exactly over the anvil 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.
(1) Release the stock drag, and manually move the terminal strip to the proper position—a rough-
position only. The fine adjustment will come in a later step.
(2) Jog the machine down to the lower-dead-center position. The feed cylinder and pawl will be
retracted away from the anvil.
(3) Using the backstroke adjustment knob (see Figure 2), position the feed pawl to the proper
back position, typically the end of the wire barrel (see Figure 12). 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).
(4) Jog the machine to top-dead-center. The feed will move the next terminal over the anvil.
(5) Check position of the terminal over the anvil, noting if the terminal feed-forward position should
be moved.
(6) 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.
(7) 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
have to be held stationary to prevent unintended backstroke adjustments (use a 3-mm wrench when the end cap is in place).
(8) Cycle the machine back to top-dead-center, causing the feed to shift forward and feeding the
terminal over the anvil.
(9) Repeat steps 4.d. through 4.h. until the terminal is centered over the slug blade.

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e. 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 has been adjusted at the factory to ensure that the terminal is advanced at the
lowest possible speed. On 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
Excessive feed and/or retract speeds can cause inconsistent feeds and/or air feed module damage.
(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. 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.
(3) When complete, tighten the locking ring.
Air Feed Modules PN’s 2844940-3 or -4
Figure 13
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.
Valve Assembly
Slide Assembly
Air Cylinder
MAGNALUBE is a trademark.

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a. Feed Adjustment
The feed stroke (terminal pitch), terminal position, and feed speed adjustments are set from the
factory. If adjustment is necessary, follow the instructions below:
If the pick-up point is the end of the wire barrel, the backstroke over-travel should be
approximately 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).
b. Feed Stroke Adjustment (Terminal Pitch) (see Figure 14)
Figure 14
NOTE
One-quarter turn of the back-stroke 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 backstroke position.
(4) Engage terminal drag.
(5) Manually extend the feed arm.
(6) Manually retract the slide until the feed pawl is at the backstroke position for the next terminal
(feed pitch).
(7) If the feed pawl is at the backstroke position before the slide hits the rear stop adjust screw,
adjust the rear stop adjust screw clockwise until the screw meets the slide. (see Figure 15).
(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 backstroke position.
(d) After verifying positions, tighten the locking screw.
NOTE
Feed stroke and feed positions adjustments are made using a 2.5mm ball end hex key wrench.
Figure 15

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(8) If the slide hits the rear stop adjust screw before the feed pawl is at the backstroke position,
the feed screw needs to be adjusted out. Adjust the rear stop adjust screw counter-clockwise
until the feed pawl is at the backstroke position.
(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 at the backstroke position. Repeat steps b and c
until the feed pawl is at the backstroke position.
(e) After verifying positions, tighten the locking screw.
(9) Extend the slide by hand, then retract the slide. Check to ensure the feed finger is in the
backstroke position. If it isn’t, repeat steps (7) and (8) to adjust the rear stop position of the
feed finger.
(10) Apply pressurized air to the air feed module.
(11) Cycle the terminator in jog mode or by hand until the feed pawl retracts.
(12) Verify the pawl is in the correct location. If it is not in the correct position, repeat steps (6) thru
(10).
c. Feed Position Adjustment (Terminal Position Over the Anvil)
(1) Initial set-up
(a) Remove the air supply from the module.
(b) Manually feed the terminal by extending the feed fully, then retracting the feed fully until a
terminal is over the anvil.
(c) If the terminal position stops before the anvil (under fed), turn the feed adjust screw
clockwise to move the terminal over the anvil (see Figure 16).
NOTE
One “click”of the feed adjust screw equals 0.025mm (0.001 inch) of adjustment. It is recommended to make small
adjustments before checking the feed.
Figure 16
(d) If the terminal position is past the anvil, (over fed), turn the feed adjust screw counter-
clockwise to move the terminal before the anvil.
(e) After making an adjustment, retract the feed slide and terminals by pulling back on the
terminal strip, then extend the feed slide to feed a terminal.
(f) If the terminal is not centered properly, repeat steps (c) thru (e).
NOTE
It is not necessary to remove air pressure from the air feed module before making a feed adjustment.

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d. Feed Speed Adjustment
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.
(1) 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: It is recommended to open the retract
flow control first to try to speed up the feed cycle.
(2) Adjusting the feed speed
(a) Loosen the locking nut with a hex wrench (ensure the setting does not change while
loosening the locking nut).
(b) Turn the knob clockwise (in) to decrease the speed. Turn the knob counter-clockwise (out)
to increase the speed (whichever is desired).
(c) Hold the control knob while tightening the locking nut.
NOTE
Only adjust the flow controls ½ turn before testing the feed speed.
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.
Turn the stock drag adjustment nuts (shown in Figure 7) up to increase the drag and down to
decrease the drag.
Cycle the machine under power to ensure that the stock drag is properly adjusted.
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.
Remove the applicator from the machine as described in Section 3, APPLICATOR INSTALLATION
AND REMOVAL.
Remove the ram assembly from the applicator.
Remove the two nuts holding the springs in place on the terminal drag plate. Refer to Figure 17.
Remove the drag plate and springs.
Loosen (but do not remove) the four screws securing the lower strip guide.
With a terminal strip in place, adjust the guides to align and center the strip over the anvil.
Securely tighten the two rear-most screws. The strip should slide easily between the guides with a
minimum of clearance.
If present, adjust the strip hold-down plate (shown in Figure 17) 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).
Tighten the remaining screws on the strip guide.
Verify the alignment of the terminal strip with the anvil. The strip should be centered over the anvil and
in line with the radius nest on top of the anvil.
Re-install the drag plate, drag springs, and securing nuts.
Adjust the drag.

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Figure 17
6. REPLACEMENT AND REPAIR
These procedures cover the applicator parts which most often need replacement or repair because of 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.
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 position.
For proper identification, refer to the exploded view drawing and parts list on the applicator print
packaged with the applicator.
Wipe the parts with a clean, dry cloth as they are removed from the applicator. Then, when putting
them back into applicator, wipe the mating surfaces with your fingers to make sure that all lint and
other foreign matter have been removed.
Anvil Replacement
From the bottom of the base plate, remove the screw that holds the anvil to the base plate.
Remove the anvil from the groove in the top of the base plate.
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.
Adjusting Strip Guide
Lower
Strip Guide Screw
(4 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)

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Shear Plate Replacement
Lift the stock drag and feed pawl, then pull the section of the terminal strip back so that the lead
terminal is between strip guides.
Remove the two screws that fasten the shear plates and spacers (if used) to the strip plates.
Remove the parts from the applicator. Note the position of the front and rear shear plates in order to
re-install them correctly.
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.
With the old shear plates re-positioned or the new shear plates properly positioned, re-install the shear
plates and spacers (if used), and fasten them in place with the two screws.
Hold the top of the ram assembly with one hand, while moving the feed pawl with the other hand.
Slowly 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.
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 the
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.
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 and
out of the shear plates freely.
Lift the stock drag and feed pawl and slide the terminal strip section forward until the lead terminal is
over the anvil.
Crimper Replacement
Loosen the crimper bolt slightly and remove the ram assembly from applicator by pulling upward. It
may be necessary to move the feed pawl forward to release the ram assembly.
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 assembly. Note
position of parts for re-installation.
Re-install the parts using the reverse of the installation procedure. The upper end of the wire crimper
must be up against the shoulder of the ram assembly. Tighten the crimper bolt only finger-tight.
NOTE
Crimpers must be positioned with the part number facing up. If new parts are used, make sure that the part numbers agree
with the numbers on the applicator parts list.
Put the ram assembly back into the applicator and install the applicator in machine.
Lift the feed pawl and pull the terminal strip back until the lead terminal is between the strip guides.
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 bottom 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 without interference over the anvil after the heavy paper is removed.
Before using applicator, set wire disc crimp height reference setting to zero, and then, incrementally
adjust toward desired crimp height. A crimp height reference setting larger than needed may
cause damage to the crimp tooling.

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Air Feed Bushings, Piston Rods, and O-Rings Replacement
Air feed module rebuild kits PN 2217901-[ ] are available to replace worn air feed bushings, piston rods, and
O-rings. Call PRODUCT INFORMATION (1-800-522-6752) for applicable kit. For installation procedure, refer to
408-32121.
Adjustable Crimp Height Repair [Reference Figure 18]
A. Replacement of Detent Plate
Under severe, long-term use, the Detent Plate may become worn and make it difficult to feel the
increments of adjustment. To replace the Detent Plate:
Note the number indicated on the Wire Crimp Disc.
Turn the disc to 0 (zero), against the stop.
Measure the set-up dimension from the Crimp Height Adjust Head to the Crimper Seating Feature on
the Ram (see Figure 11). Note: The factory setting is listed on the Applicator print.
While depressing the Detent Pin, rotate the disc and head assembly out of the Ram.
Remove all (3) M3 flat-head screws from the disc.
Separate the disc from the head.
Inspect the Detent Plate for wear in the areas the Detent Pin contacts. Replace the plate if webs of
ring are broken.
NOTE
In some cases, the plate can be rotated or flipped over so the Detent Pin contacts a new (unused) section.
Re-assemble, keeping the (3) M3 screws loose to allow the disc to rotate on the head.
Figure 18
Apply grease to the Detent Plate to lubricate the Detent Pin contact surface.

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After re-installing the Crimp Head assembly and Detent Pin, rotate the head assembly until the proper
set-up dimension is re-established.
Turn the Wire Crimp Disc to the stop. 0 (zero) should be indicated on the Number Ring.
Torque the (3) M3 flat-head screw to 6-8 lbf-in [0.7-0.9 Nm].
Verify proper crimp height as in Paragraph 5.1.A.
B. Recalibration of Crimp Height Adjustment Mechanism
If the crimp height adjust mechanism has been removed for any reason, it MUST be re-calibrated. The
Applicator print lists the proper setup dimension for the applicator. To perform a Ram Fine Adjust
Calibration:
Loosen (3) M3 flat-head screws on the Wire Crimp Disc.
The disc must freely rotate on the head.
Using calipers, measure the distance between the Crimp Height Adjust Head and the Crimper Seating
Feature on the Ram (see Figure 11).
Rotate the Head Assembly up or down to achieve the measurement listed on the Applicator print.
NOTE
As the head rotates, the Wire Crimp Disc should remain free to rotate relative to the Head Assembly (the Detent/Locking Pin
prevents continued disc rotation).
Turn the Wire Crimp Disc against the Detent/Lock Pin, to the 0 (zero) position.
Torque the (3) M3 flat-head screws to 6-8 lbf-in [0.7-0.9 Nm].
CAUTION
An applicator cycled under power that HAS NOT been calibrated to the proper setup dimension is highly likely to be damaged
at startup and imperil nearby personnel.
Counter Magnet Orientation
The applicator counter magnet will properly actuate the applicator counter (shown in Figure 7) 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 counter by
running the magnet behind the counter by hand to see which side of the magnet actuates the counter properly.
Wire Depressor Accessory
Refer to Figure 19 to determine the parts required to add this accessory if it is not installed on the 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
Replaced Figure 2, 3 and 6 with most current illustrations.
Inserted new Figures 8, 13, 14, 15, and 16 and renumbered existing figures accordingly.
Revised Section 5.4.B. and added Air Feed Modules PN 2844940-3 and PN 2844940-4).
Corrected reference in Paragraph 5.1.A.5.
Added MAGNALUBE trademark citation on page 13.