Instruction Sheet
408-8322
Heavy Duty Industrial (HD-I)
Side-Feed Type Applicator
18 DEC 08
Rev C
Ram Post
Locking Screw
Ram
Front Floating Shear
Anvil
Stock Drag
Base Plate
Terminal Support
Drag Release
Lever
Strip Guide
Front Shear Holder
Strip Guide
Adjustment Block
Figure 1
1. INTRODUCTION
CAUTION
Denotes a condition which may result in product
or equipment damage.
The Heavy Duty Industrial (HD–I) Side–Feed Type
Applicator applies side–feed strip terminals to
pre–stripped wires. Each applicator accepts the strip
form of certain terminals, which are identified on the
applicator parts list and exploded view drawing
(Applicator Log) for each applicator. Some terminals
have two carrier strips, others just one.
!
NOTE
Highlights special or important information.
i
These instructions, the parts lists and exploded view
drawings packaged with the machine, and the
appropriate machine manual (409–5128 for the Basic
AMP–O–LECTRIC* Machine; 409–5207 or 409–5289
for the Model “T” Terminating Unit; or 409–5842 for
the Model “G” Terminating Machine), provide all the
information required to operate and maintain the
applicator and machine (or unit).
Reasons for reissue of this document are provided in
Section 10, REVISION SUMMARY.
When reading this document, pay particular attention
to DANGER, CAUTION, NOTE, statements.
2. APPLICATOR DESCRIPTION
DANGER
Denotes an imminent hazard which may result in
moderate or severe injury.
E
2008 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
NOTE
Dimensions in this document are in metric units.
i
This applicator is similar in design and function to the
Heavy Duty Miniature Quick–Change Type applicator.
The strip guide area has been re–designed and the
applicator uses metric hardware.
TOOLING ASSISTANCE CENTER 1-800-722-1111
This controlled document is subject to change.
PRODUCT INFORMATION 1-800-522-6752
For latest revision and Regional Customer Service,
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.
visit our website at www.tycoelectronics.com
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LOC B
408-8322
Heavy Duty Industrial (HD-I) Side-Feed Type Applicator
Pivot Shaft
and Bushing
19mm
Hex Nut
Pivot Block
Shear
Depressor
Stroke Forward Limit
Adjustment Screw
Stripper
Feed Pawl
Rear Strip
Guide Plate
Strip Guide Plate
Adjustment Screw
Feed Finger Pin
Strip Guide Assembly Lockscrew
Figure 2
Although HD–I applicators accept only certain
terminals, they provide valuable application flexibility.
The wire crimp can easily be adjusted for as many as
four different wire sizes, and the insulation crimp can
be adjusted to accept eight insulation diameters.
HD–I applicators can be used in various terminating
machines, provided that the machines have the
proper stroke length and all the necessary equipment.
NOTE
The applicator can be used in either 30 or 40mm
bench machines) feed terminals as the ram moves
up. Post–feed applicators (normally used for
lead–maker applications) feed terminals as the ram
moves down. The feed pawl feeds one terminal
during each cycle of the terminating machine. The
terminals are fed by the action of the feed cam and a
series of rods and levers which move the feed pawl.
The ram post (also referred to as the ram mounting
post) engages the post adapter of the machine ram,
and it is the machine ram that actuates the applicator.
stroke terminating machines by adjusting the
i
position of the feed cam.
The main components of the applicators are identified
in Figures 1 and 2. The ram assembly is shown in
detail in Figure 3.
The terminal strip is fed into the applicator, from left to
right, with the wire barrel facing upward and the
insulation barrel facing toward the operator. The strip
passes under the strip drag as well as the front and
rear strip guides. The rear strip guide aligns with front
edge of the wire barrel. The lead terminal is
positioned over the anvil (for pre–feed applicators) or
one terminal pitch from the anvil (for post–feed
applicators). Pre–feed applicators (normally used for
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Just below the ram post are the wire disk and the
insulation crimp disk. The wire disk has as many as
four pairs of pins installed, depending on the number
of different wire sizes the terminals will accept. Each
pair of pins has a different height. By rotating the disk,
each pair of pins can be lined up with the two bosses
on the ram post adapter (see Figure 3) to change the
applicator crimp height. Some terminals accept more
than four wire sizes. Terminating additional wire sizes
will require adding or replacing pins in the wire disk.
Refer to the applicator assembly drawing and
Paragraph 7.6 for more information. The insulation
crimp disk contains eight pads of different heights.
When this disk is turned, the pads line up with the top
of the insulation crimper to change the insulation
crimp height.
Tyco Electronics Corporation
Rev C
408-8322
Heavy Duty Industrial (HD-I) Side-Feed Type Applicator
Ram Post
Pins
Wire Disk
Insulation Disk
Machine Ram
(or Ram Post
Adapter)
Applicator
Ram
Feed Cam
Bosses
Insulation
Crimper
Terminal Hold-Down
Wire Crimper
Bumper
Figure 3
The wire crimper is located by two pins on the ram
assembly and is held by 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 can
be changed. The front shear depressor pushes the
front floating shear down to cut the crimped terminal
from the strip.
The hold–down bumper is attached to the ram and
holds the terminal in place during the crimping and
shearing process. (Note: Some applicators have a
solid metal hold–down that may require adjustment
when changing the wire size and/or crimp height.)
The applicator’s mounting surface is its base plate.
The anvil, the front shear holder, the rear shear holder
(if used), the terminal support, the strip guide
assembly, and the applicator housing are mounted on
the base plate. The stock drag and the front and rear
strip guides are mounted on the strip guide assembly.
This applicator can be used in terminating machines
which have either a 30mm or 40mm feed stroke. The
position of the feed cam must be changed to
accommodate the terminating machine being used.
See the applicator log drawing (shipped with the
applicator) for the proper position of the cam (either
post–feed or pre–feed).
NOTE
Terminals with dual carrier strips require a rear shear
depressor, spacer, and shear holder. These parts are
attached to the feed cam side of the ram assembly.
The rear shear depressor pushes the rear floating
shear down to cut the terminal from the rear carrier
strip, and the terminal holder keeps the terminal from
raising during the crimping and shearing process. The
rear floating shear and rear shear holder are mounted
on the base plate.
Rev C
Consult applicator log when adjusting the position
of the cam
i
.
3. APPLICATOR INSTALLATION AND REMOVAL
DANGER
Tyco Electronics Corporation
To avoid personal injury, be sure power to the
machine is turned off" and power cord is
disconnected before installing or removing
applicator.
3 of 15
408-8322
Heavy Duty Industrial (HD-I) Side-Feed Type Applicator
CAUTION
With 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.
3.4. Other Terminating Machines
Refer to the customer documentation supplied with
the machine.
3.1. AMP-O-LECTRIC Machine
4. APPLICATOR LOADING AND UNLOADING
A. Installation
4.1. Terminal Strip Loading
This machine must be equipped with Machine
Conversion Kit 690675–2, to adapt it for use with the
these applicators. The kit includes Applicator
Instruction Sheet 408–8022, which explains how an
applicator is installed and removed from the
terminating machine.
CAUTION
the installed applicator is the right one for
!
terminal to be applied. Compare terminal number
on reel with numbers listed on applicator parts
list.
DANGER
B. Removal
Before loading terminal strip in applicator, be sure
To avoid personal injury, be sure power to the
machine is turned off" and power cord is
disconnected.
1. Turn machine “off” and disconnect power cord.
2. Remove the shroud and guard assembly from
the machine.
3. Unload applicator as described in Section 4.
Remove hold–down bracket and movable stop,
then slide applicator away from stop on base
mount until ram post is clear of machine ram.
1. Turn “off” or disconnect power to machine.
2. Be sure ram assembly is all the way up. If
necessary, hand–cycle machine to raise the ram.
(Refer to the terminating machine manual for
hand–cycling instructions.)
3. Remove applicator/terminator guard assembly.
3.2. Model T" Terminating Machine
A. Installation
1. Turn “off” or disconnect power to terminating
unit.
2. Push IN release bar on the base plate. Locking
latch will pivot downward.
3. Place applicator on base plate, then slide it back
until two notches engage stops at back of plate. At
the same time, guide ram post into ram post
adapter.
4. Flip locking latch UP to secure applicator in
place.
B. Removal
4. Raise stock drag by turning drag release lever
upward. Remove length of terminal strip left in
applicator by grasping terminals with long–nose
pliers at the strip guide entry, raising the feed pawl,
and pulling strip straight out of applicator.
5. With reel of terminals installed on reel support,
feed terminal strip into applicator between strip
guides.
CAUTION
Be SURE terminal strip enters strip guides with
barrel (insulation) end toward the stock drag and
!
the open side up.
6. Raise feed pawl and continue to feed terminal
strip until lead terminal is over anvil and feed pawl
engages hole in carrier strip.
2. Cut terminal strip one or two terminals from end
of applicator.
7. If terminals are post–fed, lift feed pawl and pull
the strip back one terminal pitch. The lead terminal
will then be moved over the anvil on the downward
stroke of the ram assembly.
3. Push IN release bar on base plate. Locking
latch will pivot downward.
8. Turn drag release lever downward to lower the
stock drag.
4. Slide applicator forward until clear of ram post
adapter.
9. Be sure tip of feed pawl is in feed hole in carrier
strip.
1. Disconnect power cord.
NOTE
3.3. Model G" Terminating Machine
are not used for feed purposes.
Refer to Customer Manual 409–5842 for installation
and removal procedures.
4 of 15
Some carrier strips have additional holes which
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Tyco Electronics Corporation
Rev C
408-8322
Heavy Duty Industrial (HD-I) Side-Feed Type Applicator
10. Hand–cycle the machine several times to
make sure the applicator is properly adjusted as
described in Section 5.
30mm to 40mm stroke, or from 40mm to 30mm
stroke.
DANGER
11. Re–install applicator/terminator guard
assembly.
To avoid personal injury, be sure power to
machine is turned off" and power cord is
disconnected before taking the applicator out of
the machine. The machine ram should be in the
raised position.
4.2. Terminal Strip Unloading
1. Cut terminal strip one or two terminals from end
of applicator.
NOTE
Applicator should never be unloaded
1. Remove the applicator from the terminating unit.
2. Remove the applicator ram from the applicator
frame by pulling it straight out of the applicator.
unnecessarily. A section of terminal strip should
i
NOTE
always be left in the unit. Since it is not
lubrication, or repair, it should only be removed
It may be necessary to manually actuate the feed
mechanism to free the ram from the frame.
necessary to remove strip section for cleaning,
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as a part of the loading procedure.
2. If terminals are post–fed, turn drag release lever
upward to raise stock drag, lift the feed pawl, and
move the lead terminal over the anvil.
3. Remove the screw securing the cam.
4. Locate the feed cam on the ram. See Figure 4.
CAUTION
4.3. Terminal Lubrication
NOTE
Improper positioning of the cam in the applicator
can cause serious damage to the applicator, the
HD-I applicators are not supplied with terminal
!
terminating machine or both. Hand-cycle the
machine prior to running under power to ensure
that there are no mechanical interferences.
lubricators.
i
5.2. Wire Crimp Adjustment
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.
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 local field representative.
If your application warrants the use of a terminal
lubricator, the recommended lubricant is Stoner
Mechanical Lubricant E805, available from:
STONER, INC.
1–800–227–5538
1. Select pad letter (A, B, C, or D) from data plate
for wire size to be used.
2. Turn wire disk (upper disk) to line up selected
pad letter with the bosses on the machine ram (or
ram post adapter). See Figure 3. This provides the
right crimp height for that wire size.
3. After making wire crimp adjustment described in
Paragraph 5.2, make several test cycles and
inspect terminations closely.
a. Look for rough or sharp edges around
crimped barrels (flash), deformed crimps, bent
terminals, or other defects caused by worn or
broken tooling. If necessary, replace tooling as
described in Section 7, REPAIR AND
REPLACEMENT OF PARTS.
b. If terminations appear normal, measure crimp
height of each termination. Crimp height must
agree with measurement specified on parts list
for wire size being used. Record crimp height
dimensions for reference.
5. ADJUSTMENTS
5.1. Feed Cam Adjustment
NOTE
All side–feed applicators are setup at the factory to
meet the customer’s stroke requirements. Use the
following procedure to convert the applicator from
Rev C
Refer to 408-7424 for information concerning
crimp height measurement.
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Tyco Electronics Corporation
5
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408-8322
Heavy Duty Industrial (HD-I) Side-Feed Type Applicator
30mm Stroke Cam Configurations
40mm Stroke Cam Configurations
For AMP-O-LECTRIC
For Model G" and
Model K" Terminating
Machines
Model T" TerminatĆ
Pre-Feed Cams for
Typical Bench Applications
ing Machines
Post-Feed Cams for
Typical Lead-Maker
Applications
Figure 4
c. If crimp height is incorrect, remove applicator
and install one that is known to produce
terminations of correct crimp height. Make
several test cycles and repeat Step b. If crimp
height is incorrect for this applicator, problem is
machine shut height, and corrective information
can be found in appropriate machine manual. If
crimp height is correct, problem is in original
applicator, and corrective measures are
presented in Paragraph 7.5, Adjustable Crimp
Height Repair.
4. During extensive operation, periodically repeat
Step 3 to make sure that applicator is producing
correct terminations.
5.3. Insulation Crimp Adjustment
To adjust insulation crimp height, turn insulation crimp
disk (lower disk) to line up the number (1 through 8)
with top of insulation crimper on ram assembly. No. 8
makes the tightest crimp and No. 1 the loosest, a
6
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difference of approximately 1.78 mm. To find the
insulation crimp you want, start with No. 1 and make
test crimps. Increase the setting one number at a time
until you get the proper insulation crimp height.
5.4. Terminal Strip Feed Adjustment
1. With terminal strip properly loaded, check
position of lead terminal over anvil by actuating the
applicator to move the feed pawl to the forward
limit of its stroke. Lead terminal must be centered
on anvil.
2. If the lead terminal is centered on the anvil, the
forward limit adjustment is correct. Go on to
Step 5. If not centered, continue with Step 3.
3. Loosen screw on top of pivot block (see
Figure 2). Turn the stroke forward limit adjustment
screw counterclockwise to move the forward limit
toward anvil, or clockwise to move the forward limit
away from anvil. Tighten screw on top of pivot
block.
Tyco Electronics Corporation
Rev C
408-8322
Heavy Duty Industrial (HD-I) Side-Feed Type Applicator
4. Repeat Steps 1, 2, and 3 as required. When
adjustment is correct, go on to Step 5.
5. Watch the feed pawl as the machine is
hand–cycled several times. It should have enough
— but not too much — overtravel on the
backstroke to pick up the next terminal.
4. Loosen screw holding feed pawl to feed finger
(feed pawl holder). Move feed pawl until its tip
drops into slot in front strip guide. Retighten screw.
5. Hand–cycle terminating unit, checking for proper
terminal feed and strip guide plate alignment.
5.6. Strip Guide Adjustment
NOTE
At the end of its backstroke, the feed pawl should
be at the back edge of the feed hole to be used.
i
The backstroke must not be longer than this, or
the feed pawl might not drop into the feed hole.
6. If feed pawl stroke length is satisfactory, feed
adjustments are complete. If not, continue with
Step 7.
7. Loosen slightly the 19mm hex nut, on side of
applicator, to allow the bushing to move in slot (see
Figure 2).
This adjustment is not used very often, because it is
only needed when the rear strip guide is not parallel
to the strip guide plate, the strip guides are not
parallel to each other, or there is a variation in strip
width.
CAUTION
pry the terminal strip out of the guides with a
!
NOTE
8. Move the bushing (in small increments) upward
to lengthen the stroke and downward to shorten
the stroke.
screwdriver or similar tool.
The strip guides are correctly positioned on the
strip guide plate when the applicator is built, and
i
normally do NOT need adjustment. Do not use
this procedure for front-to-rear positioning of
strip Ċ refer to Paragraph 5.5, Strip Guide Plate
9. Tighten the 19mm hex nut. Repeat Step 5 to
check stroke length.
10. Repeat Steps 7 through 9 until stroke length is
correct.
To avoid damage to the rear strip guide, do NOT
and Feed Pawl Adjustments.
DANGER
To avoid personal injury, turn off" the power to
the terminating unit and disconnect the power
cord before removing the applicator.
5.5. Strip Guide Plate and Feed Pawl Adjustments
This adjustment is made to change the terminal
bellmouth and rear cut–off tab, a necessary feature
for proper termination. Refer to the appropriate
terminal application specification for terminal
bellmouth.
1. Remove the applicator as described in
Section 3, INSTALLATION and REMOVAL.
This procedure moves the block on which the strip
guides are mounted. Since the terminal strip is fed
into the applicator through the strip guide assembly, it
is moved front and back over the anvil as the strip
guide is moved.
3. With a section of terminal strip in place, move
the rear strip guide in the desired direction. The
strip should slide smoothly but have no
“front–to–back” play. Tighten the screws.
The adjustment of the feed pawl to match any change
in the position of the front strip guide is also described
here.
1. From bottom side of strip guide plate, use a
3mm hex wrench to loosen the screw that holds
the strip guide assembly lockscrew. See Figure 2.
2. With the lead terminal centered over anvil, lift
and hold (or block) the feed pawl up to clear the
front strip guide.
3. Turn strip guide assembly adjustment screw
clockwise to move strip guide assembly toward
front, or counterclockwise to move it toward rear.
It is necessary to push the assembly back until the
adjustment screw touches the applicator frame.
Tighten screw to hold strip guide assembly in
position.
Rev C
2. Lift and hold (or block) the feed pawl to clear the
front strip guide, and loosen screws holding rear
strip guide to strip guide plate.
4. Loosen screws securing the front strip guide;
align the front strip guide with the holes in the
terminal carrier strip; and tighten screws.
5. Lower the feed pawl into the slot and carefully
move the feed linkage through its motion. The feed
pawl should be centered in the slot throughout its
range of motion.
NOTE
If feed pawl is not aligned with the front strip
guide, refer to Paragraph 5.5, Step 4.
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5.7. Adjustment of Shear(s) and Shear Holder(s)
With lead terminal centered over anvil, check to see if
floating shear(s) cuts the terminal from the carrier
strip(s) correctly. If necessary, make the following
adjustments.
Tyco Electronics Corporation
7
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408-8322
Heavy Duty Industrial (HD-I) Side-Feed Type Applicator
NOTE
The applicator must be removed from the
6. PREVENTIVE MAINTENANCE
terminating unit for this procedure. Remove the
i
DANGER
applicator ram before proceeding.
To avoid personal injury, be sure power to the
terminating unit is turned off" and the power cord
is disconnected before removing the applicator
for preventive maintenance. The machine ram
DANGER
To avoid personal injury, turn off" the power to
should be in the raised position.
the terminating unit and disconnect the power
cord before removing the applicator.
NOTE
Do not remove terminal strip during cleaning or
lubrication.
i
A. Front Shear Adjustment
1. Remove the applicator as described in
Section 3, INSTALLATION and REMOVAL.
2. From the bottom of the base plate, loosen the
two screws that secure the shear holder to the
base plate.
3. Position the shear holder so that the shear is
against the anvil.
4. Tighten the screws loosened in Step 2. The
shears should freely move up and down with
minimal clearance to the anvil. A 0.025mm shim
can be used between the shear and the anvil for
proper positioning.
5. 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 shearing action is not correct, check
for worn or damaged tooling.
6.1. Daily Cleaning
Applicators must be cleaned and lubricated after
every eight hours of operation, or when removed from
terminating unit to be stored.
DANGER
terminating unit is turned off" and the power cord
is disconnected.
1. Remove the applicator as described in
Section 3, INSTALLATION and REMOVAL.
2. Remove applicator ram from applicator by
pulling upward. It may be necessary to move feed
finger to release ram assembly. Do not remove
tooling from ram.
3. Wipe complete ram assembly with a clean, dry
cloth to remove old grease and dirt.
CAUTION
!
Product Only)
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. Remove the applicator as described in
Section 3, INSTALLATION and REMOVAL.
2. From the bottom of the base plate, loosen two
screws that hold the rear shear holder to the base
plate.
3. With the terminal strip inserted into applicator,
and the lead terminal centered over the anvil,
move the rear shear holder in the direction required
to obtain the proper cutoff tab.
4. Check that the shear is square to the end of the
terminal, and then tighten the holding screws.
5. Depress the floating shear and check for proper
shearing action and proper cutoff tab.
4. Check crimpers, anvil, and shear for excessive
wear or damage. If necessary, replace parts as
described in Section 7, REPAIR AND
REPLACEMENT OF PARTS.
5. Check alignment of terminal stripper and
tightness of stripper, anvil, and crimper mounting
bolts.
6. Clean applicator body. Make sure all chips, dirt,
and grease are removed. Lubricate pivot points as
described in Paragraph 6.3.
7. Lubricate ram as described in Paragraph 6.3.
8. Replace ram in applicator.
6.2. Monthly Cleaning
Applicators must be cleaned completely every thirty
days to remove all grease, oil, and dirt.
DANGER
6. If necessary, repeat Steps 2 through 5 or check
for worn or damaged tooling.
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DO NOT CLEAN APPLICATOR WITH AIR
HOSE.
B. Rear Shear Adjustment (Dual Carrier Strip
8
To avoid personal injury, be sure power to the
Tyco Electronics Corporation
To avoid personal injury, be sure power to the
terminating unit is turned off" and the power cord
is disconnected.
Rev C
408-8322
Heavy Duty Industrial (HD-I) Side-Feed Type Applicator
1. Remove the applicator as described in
Section 3, INSTALLATION and REMOVAL.
2. Remove ram from applicator. Do not remove
tooling from ram.
3. Submerge the applicator (ram assembly and
applicator body) in a cleaning solution that will not
attack plastic or cast metal.
CAUTION
view drawing and parts list packaged with the
applicator for identification of parts. Be sure to order
replacements for parts used from spare parts stock,
so that they will be available when needed.
DANGER
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.
DO NOT CLEAN IN VAPOR DEGREASER.
NOTE
!
To avoid personal injury, be sure power to
Wipe parts with a clean, dry cloth as they are
removed from the applicator. Then, when putting
i
4. Air dry the applicator.
them back into applicator, wipe mating surfaces
with your fingers to make sure that all lint and
other foreign matter have been removed.
5. Lubricate ram as described in Paragraph 6.3.
6. Lubricate pivot points as described in Paragraph
6.3.
7.1. Anvil Replacement
DANGER
7. Replace ram in applicator.
To avoid personal injury, be sure power to
machine is turned off" and the power cord is
disconnected before taking the applicator out of
the machine.
6.3. Lubrication
Don’t use too much oil or grease on applicator. Any
excess lubricant must be wiped off before placing
applicator back in service. Don’t put lubricants
between wire and insulation crimp disks.
DANGER
To avoid personal injury, be sure power to the
terminating unit is turned off" and the power cord
is disconnected.
1. Remove the applicator as described in
Section 3, INSTALLATION and REMOVAL.
2. Take ram assembly out of applicator, clean ram
and feed cam, and apply a thin coat of a good
grade grease to each corner of ram and to feed
cam.
3. Carefully lay applicator on its side and put one
drop of a good grade oil on feed finger pin. Wipe
feed finger pin to remove excess oil.
4. Set the applicator upright and put a drop of a
good grade oil on each of the following: the
stroke forward limit adjustment screw, the feed rod
(into which this screw is turned), and the bushing
inside the 19mm hex nut. Wipe off excess oil.
5. Put ram assembly back into applicator, and wipe
off excess oil or grease.
1. Remove the applicator as described in
Section 3, INSTALLATION and REMOVAL.
2. From bottom of base plate, remove screw that
holds anvil to base plate.
3. Turn drag release lever upward, raise feed pawl,
and pull strip back using long–nose pliers so lead
terminal is between strip guides.
4. Remove anvil from groove in top of base plate.
5. Install anvil using reversed 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.
NOTE
holder must be re-aligned. See Paragraph 5.7,A.
i
6. Re–align crimpers as described in
Paragraph 7.3.
7.2. Floating Shear Replacement
DANGER
cord is disconnected.
NOTE
Rev C
To avoid personal injury, be sure power to the
terminating machine is turned off" and the power
7. REPAIR AND REPLACEMENT OF PARTS
These procedures cover the applicator parts which
most often need repair or replacement because of
wear. Remove the applicator from the machine before
doing any maintenance work. Refer to the exploded
When the anvil is replaced, the front shear and
It is not necessary to remove shear holder(s) to
replace floating shear(s). Before removing
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Tyco Electronics Corporation
floating shear(s), note orientation for
re-installation. The floating shears are
spring-loaded, so be careful during removal.
9
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408-8322
Heavy Duty Industrial (HD-I) Side-Feed Type Applicator
1. Turn drag release lever upward, raise feed pawl,
and pull strip back using long–nose pliers so lead
terminal is between strip guides.
2. Push down on the floating shear, then remove
shear retaining screw from side of shear holder.
3. Slowly release pressure on floating shear.
Compression spring will push it out of shear holder.
4. After removing floating shear, lift compression
spring out of shear holder.
5. Inspect spring for damage and replace it if
necessary. Refer to parts list for correct number.
6. Re–install floating shear(s) using reversed
procedure. If installing new shear, be sure part
number agrees with the number on the parts list.
7. Raise feed pawl and move lead terminal over
the anvil. Turn drag release lever down to lower
stock drag.
8. Check shear holder adjustment as described in
Paragraph 5.7, Adjustment of Shear(s) and Shear
Holder(s).
5. Put ram assembly back into applicator, and
install applicator in machine.
6. Lift feed pawl and pull terminal strip back until
lead terminal is between strip guides.
7. Form a piece of heavy paper over anvil, then
slowly hand–cycle machine while watching
alignment of crimpers with anvil. When ram
assembly has reached bottom of stroke, carefully
tighten crimper bolt. Crimpers MUST move freely
over anvil after paper is removed.
7.4. Feed Pawl Replacement
DANGER
To avoid personal injury, be sure power to the
terminating machine is turned off" and the power
cord is disconnected.
1. Remove the adjustment screw which holds the
feed pawl to the feed finger (feed pawl holder).
2. Replace feed pawl using reversed procedure. If
new pawl is installed, be SURE the part number
agrees with the number on the parts list.
3. Adjust feed pawl as described in Paragraph 5.5.
7.3. Crimper Replacement
7.5. Adjustable Crimp Height Repair
DANGER
To avoid personal injury, be sure power to
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 as described in
Section 3, INSTALLATION and REMOVAL.
2. Loosen the crimper bolt slightly and remove ram
assembly from applicator by pulling upward. It may
be necessary to move the feed finger forward to
release the ram assembly.
3. Remove crimper bolt which 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.
4. Re–install parts using reversed procedure. The
upper end of the wire crimper must be up against
the pins on 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
with either side out. All other insulation crimpers
must be positioned with part number facing the
direction noted during removal. If new parts are
used, be sure part numbers agree with numbers
on parts list.
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DANGER
To avoid personal injury, be sure power to the
machine is turned off" and the power cord is
disconnected BEFORE removing the applicator.
1. Remove the applicator as described in
Section 3, INSTALLATION and REMOVAL.
2. Subtract specified nominal crimp height from
average crimp height recorded as a part of
Paragraph 5.2, Wire Crimp Adjustment. This
difference will be the thickness of washer(s)
(PN 690125–1) to be added under the insulation
crimp disk.
NOTE
Washer 690125-1 is a set of four steel shim
washers that are 0.05mm, 0.076mm, 0.127mm,
i
and 0.254mm thick.
Insulation crimpers with legs of equal length, that
are identical front and back, may be positioned
i
Under the insulation crimp disk is a laminated washer
which may break or compress after extensive use.
This could cause the applicator to produce
terminations with a different crimp height than
specified. To correct this problem, use the following
procedure.
3. Remove ram assembly from applicator, and
loosen ram post locking screw in the side of
applicator ram (see Figure 1).
4. Hold ram assembly with ram post pointing
down, and unscrew ram from ram post, leaving
Tyco Electronics Corporation
Rev C
408-8322
Heavy Duty Industrial (HD-I) Side-Feed Type Applicator
wire disk and insulation crimp disk in place. If
necessary, the end of the ram post may be placed
in a vise to free both hands for turning ram.
DANGER
To avoid personal injury be sure power to
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
CAUTION
disk from ram post. Detent ball and spring will
!
raised position.
DO NOT REMOVE wire disk and insulation crimp
pop out and may become lost if disks are
removed.
1. Remove the applicator as described in
Section 3, INSTALLATION and REMOVAL.
2. Remove the ram assembly from the applicator.
5. Place washer(s) of thickness determined in Step
2 on ram post. If old washer is broken and must be
replaced, measure thickness of broken washer
with a micrometer. Add this measurement to
amount to be added (determined in Step 2), and
select new washer(s) of this thickness. Place new
washer(s) on ram post.
3. Loosen the setscrew on the side of the ram to
unlock the ram post. See Figure 5.
4. Remove (as a unit) the ram post, wire
adjustment disk, and insulation crimp adjustment
disk.
NOTE
6. Hold ram with hole facing downward, screw ram
post into ram, and tighten by hand until snug.
7. Be sure letters on wire disk and numbers on
insulation crimp disk line up properly over the top
of the insulation crimper. disks are held in position
by detents. If necessary, turn ram post back
slightly until numbers and letters line up, then
tighten ram post locking screw to hold ram post in
position.
NOTE
Do not allow the insulation crimp disk to slide off
the ram post until you have completed Step 5.
i
5. Holding the ram post and insulation adjustment
disks as a unit in your hands, remove the screw
from the side of the insulation crimp disk and
carefully remove the spring and ball. See Figure 6.
Ram Post
Turn wire disk and insulation crimp disk to other
Wave Washer
positions. When the click" of the detent ball is
i
heard, check for centering of letter or number
over insulation crimper.
Wire Disk
Insulation
Crimp Disk
8. Put ram assembly back into applicator.
9. Install applicator in machine and make some
test crimps. Measure crimp height and check it
against crimp height specified on applicator parts
list. If crimp height is within specified tolerances,
applicator may be placed in service. If not, repeat
this procedure, starting with Step 1.
Shim
Spacer
Ram Post
Locking
Setscrew
7.6. Wire Disk Pin Removal and Installation
The upper crimp height disk (Figure 5) consists of a
plastic carrier and up to eight hardened pins which
engage the post adapter on the termination machine
ram. When the carrier is rotated, the pins are indexed
into position as required to change the final applicator
crimp height.
Removal and replacement of the pins in the carrier is
rarely required. However, in some cases, it is
necessary, such as when the applicator is asked to
perform additional crimp heights not included in the
original four as shipped with the applicator. To remove
and replace these pins, proceed as follows.
Rev C
Tyco Electronics Corporation
Figure 5
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408-8322
Heavy Duty Industrial (HD-I) Side-Feed Type Applicator
then back it out until a letter pad on the wire disk
aligns with the position of the crimper.
9. Insert the new pins from the top and push them
“in” until you hear and feel them snap into position.
10. Tighten the setscrew in the side of the ram to
lock the ram post in position.
Ball
Spring
11. Insert the ball, spring, and screw back into the
side of the insulation crimp disk. Tighten the screw.
12. Replace the ram assembly in the applicator
and re–install the applicator in the terminating
machine.
Insulation
Crimp Disk
Screw
13. Slowly hand–cycle the terminating machine
several times to make sure there is no binding or
tooling interference.
Figure 6
14. Make several test crimps and measure the
crimp height of the finished terminal. If necessary,
correct any problem.
Inspect the spring for damage and replace if
necessary.
8. APPLICATOR STORAGE
6. Remove the wire and insulation crimp disks
from the ram post.
7. Remove the “snap–fitted” pins from the wire disk
by pushing them from the top. See Figure 7. The
chamfers on the pins and in the holes of the plastic
carrier insure that they can move in only one
direction. Remove pins that you need to replace,
being careful to note the position of the A, B, C, or
D legend molded into the plastic outer edge.
CAUTION
When storing applicator, or taking it out of
machine for any reason, use the following
!
procedure to keep tooling from being damaged
by bottoming of ram assembly.
1. Cut terminal strip one or two terminals from end
of applicator.
2. Take applicator out of machine as described in
Section 3, INSTALLATION and REMOVAL. Clean
and lubricate as presented in Section 7.
3. Lower ram assembly to hold lead terminal
between crimpers and anvil. This will also identify
type of terminal to be used when applicator is put
back in service.
9. APPLICATOR ASSEMBLY AND SUBASSEMBLY
Pin
Figure 8 shows the basic Side–Feed Applicator
Subassembly. Figure 9 contains the HD–I Side–Feed
Applicator Assembly.
Wire Disk
These illustrations, which contain parts descriptions
and identifying item numbers, are intended to be used
with the drawings shipped with the applicator to
determine the appropriate item part numbers.
Figure 7
8. Replace the disks, washers, and spacers, on
the ram post and install them as a unit into the hole
on top of the ram. Thread the post in until it is tight;
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10. REVISION SUMMARY
Since the previous release of this instruction sheet,
the logo was updated.
Tyco Electronics Corporation
Rev C
408-8322
Heavy Duty Industrial (HD-I) Side-Feed Type Applicator
HD-I Side-Feed Applicator
Basic Subassembly
Description (Translation)
Description
Item
No.
Figure 8
Rev C
Tyco Electronics Corporation
13 of 15
Heavy Duty Industrial (HD-I) Side-Feed Type Applicator
408-8322
HD-I Side-Feed Applicator
Figure 9 (Sheet 1 of 2)
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Tyco Electronics Corporation
Rev C
408-8322
Heavy Duty Industrial (HD-I) Side-Feed Type Applicator
HD-I Side-Feed Applicator
Description (Translation)
Description
Item
No.
Figure 9 (Sheet 2 of 2)
Rev C
Tyco Electronics Corporation
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