Instruction Sheet
408-8011
Applicator Instructions for
Hinge Bar Applicators
20 JUL 05
Rev A
Reel Support Arm
Reel of Terminals
Holding
Ram Retaining
Screws (4)
Plate
Wire Barrel
Insulation
Tab
Barrel
Flow of Terminals
Stock Guide
Identification
Plate
Strip
Locking
Length
Base Mount
Lances
Figure 1
1. INTRODUCTION
4. INSPECTING THE APPLICATOR
This applicator instruction sheet covers a basic
applicator design, and provides general instructions
for applicators of this design.
Every applicator is aligned and tested before
shipment. If the applicator was damaged during
shipment, file a claim against the carrier and notify
Tyco Electronics immediately.
Refer to the applicator drawings shipped with this
machine, as well as Customer Manual 409–5128 (for
the AMP–O–LECTRIC* Machine) for further
information.
If you received a terminating machine with the
applicator already installed, proceed to Section 6,
SET–UP PROCEDURE.
5. INSTALLING THE APPLICATOR IN THE MACHINE
2. DESCRIPTION
5.1. Removing the Old Applicator
Figure 1 illustrates many of the machine components.
A. Removing the Feed Finger
The applicator’s identification plate (Figure 1) shows
the serial number, as well as the applicator number.
The serial number identifies a particular applicator.
The applicator number identifies the applicator as one
that can crimp terminals appearing on the parts list.
1. Disconnect electrical and air power from the
AMP–O–LECTRIC machine.
2. Remove the air feed assembly from the
applicator by removing the holding screws on the
back of of the base mount (Figure 1). If the
machine has mechanical feed, remove the feed
arm from the feed arm drive shaft.
3. WIRE STRIPPING
3. Remove the cotter pins from the clevis pin. See
Figure 2.
Strip the insulation to the length shown on the parts
list shipped with the applicator.
4. Loosen the screw on the tension adjustment
plate (provided the feed finger is so equipped).
E
2005 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
AMP and Tyco are trademarks.
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,
*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
Applicator Instructions for Hinge Bar Applicators
408-8011
B. Removing the Upper and Lower Tooling
Clevis
1. Remove the ram retaining plate by removing the
four holding screws shown in Figure 1.
Clevis
Pin
Feed Finger
Tension Spring
2. Loosen the two base mount holding screws and
turn the crimp height adjustment screw “down” until
the base mount is at it’s lowest point. See Figure 3.
3. Remove the base mount holding screws.
4. Swing the the upper and lower tooling toward
you.
5. When the lower tooling has cleared the
machine, pull it away from the upper tooling and
set it aside.
Feed
Finger
Cotter
Pin
Feed Finger
Holder
Figure 2
Be SURE to capture the feed finger tension
spring.
6. Remove the feed finger holder with the attached
feed finger.
Upper
Tooling
7. Hand–cycle the machine according to the
procedures in the AMP–O–LECTRIC machine
manual. Hand–cycle the machine until the ram
reaches it’s lowest point.
8. Loosen the socket set screw shown in Figure 4.
9. Pull the ram toward you.
5. Remove the clevis pin from the clevis.
NOTE
6. Push the ram back into place.
10. Remove the ram link pin and ram with the
attached tooling.
5.2. Installing the New Applicator
1. Attach the ram to the toggle link by inserting the
ram link pin. See Figure 4.
Ram
Toggle
Lever
Shear
Pick-Up
Hook
Toggle
Link
Lower
Tooling
Ram
Ram Link
Pin
Socket
Set Screw
Base Mount
Holding Screws
Crimp Height
Adjustment Screw
Figure 3
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Figure 4
Rev A
Applicator Instructions for Hinge Bar Applicators
2. Tighten the socket set screw on the ram.
3. Turn the machine flywheel forward until the
machine is in the “rest” (TDC) position.
4. Pull the ram toward you and place the shear
pick up hook under the shear blade. Refer to
Figure 3.
5. Swing the upper and lower tooling into the
machine.
6. Insert and tighten the two base mount holding
screws.
7. Replace the ram retaining plate.
8. Attach the the spring to the shear pick–up hook
holder and bracket. See Figure 5.
Hook
Holder
Cam Follower
Spring
408-8011
6. Turn the crimp height adjustment screw until the
anvil begins to show through the anvil insert.
7. Fully tighten the two base mount holding
screws.
8. Manually turn the machine flywheel until the
machine returns to the rest position.
5.4. Installing the Feed Finger
1. Place the new feed finger holder (with the
attached feed finger) in the clevis. See Figure 2.
2. Insert the clevis pin through the first hole in the
clevis and the first hole in the feed finger holder.
3. Insert the feed finger tension spring and push
the clevis pin through it’s opening.
4. Push the pin through the remaining two holes
and insert the cotter pin.
5. Attach the feed assembly to the feed arm drive
shaft according to the instructions in the Tyco
Electronics’ customer machine manual.
6. Refer to the parts list shipped with the applicator
for the proper feed point. Using this feed point,
refer to the machine manual for instructions on
feed–cycle adjustment. Adjust the feed.
6. SET-UP PROCEDURES
Your applicator has been thoroughly adjusted prior to
shipment. However, these adjustments should be
checked prior to placing the machine in operation.
Be sure to check these items after extended machine
operation AND after replacing worn or damaged
parts.
Spring
Bracket
Figure 5
5.3. Raising the Base Mount
1. Remove the small strip of terminals from the
applicator.
2. Slowly hand–cycle the machine until the ram is
at it’s lowest position.
CAUTION
Be sure there is no interference between the
upper and lower tooling.
3. Loosen the two base mount holding screws.
Refer to Figure 3.
4. Push “in” on the base mount.
5. Finger tighten the base mount holding screws.
Rev A
6.1. Checking the Wire Crimper/Anvil Alignment
Slowly hand–cycle the machine according to the
procedure in the appropriate customer machine
manual.
DANGER
To avoid personal injury, be sure power is turned
off" and disconnected before checking the
crimper/anvil alignment.
The anvil should protrude from the anvil insert slot
and center in the arc of the wire crimper. See
Figure 6. If necessary, adjust as follows:
1. Loosen the two wire crimper holding screws.
See Figure 6.
2. Place the wire crimper at it’s correct position
over the anvil.
3. Tighten the two wire crimper holding screws.
4. Hand–cycle the machine to check the
adjustment.
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408-8011
Applicator Instructions for Hinge Bar Applicators
Slowly hand–cycle the machine and observe while a
terminal is crimped. If the wire barrel passes through
the slot (see Figure 8), proceed to Paragraph 6.4, Tab
Engagement. If the tab misses the slot, adjust as
follows:
Wire Crimper
Holding Screws
A. Tab Too Far to the Left or Too Far to the Right
Insulation Crimper
Holding Screws
DANGER
Wire
Insulation
off" and disconnected before making tab
adjustments.
Crimper
Crimper
To avoid personal injury, be sure power is turned
1. Loosen the holding screws and locking nuts on
the adjusting screws from the front strip guide. See
Figure 7.
2. Turn the adjustment screw clockwise and
counterclockwise and observe the positioning.
Adjust the position appropriately.
3. Tighten the locking nuts.
4. Hand–cycle the the machine to check the
adjustment.
Anvil
Figure 6
6.2. Loading Terminals
1. Place the reel of terminals on the reel support
bar so they will enter the applicator with their wire
barrels ”upright.” See Figure 1.
2. Pull the terminal strip from the reel and around
the stock guide.
3. Release the stock drag by depressing the stock
drag handle, and feed the terminal strip between
the strip guides.
4. Push the terminal strip forward until the shear
blade can rest between the first and second
terminal. See Figure 7.
NOTE
If the shear blade does not return to the terminal
strip at the end of each cycle, the limit switch will
B. Tab Too Far to the Front or Back
Adjust the feed distances according to the the
procedures in the customer machine manual.
6.4. Tab Engagement
NOTE
The Tab Placement procedures and Tab
Engagement procedures involve precise
adjustments that may require repetition until the
desired results are achieved.
Inspect a crimped terminal. The tab should have
engaged one or both locking lances. Refer to Figure
8,A. If this condition does not exist, adjust as follows:
DANGER
To avoid personal injury, be sure power is turned
off" and disconnected before making tab
adjustments.
cut off power to the operator's pedal, and the
terminating unit cannot be cycled. When this
occurs, properly position the shear blade and
hand-cycle the machine. If it occurs again, adjust
the terminal feed distance according to the
procedure in the customer machine manual.
5. The feed finger should rest at the feed point
called out on the parts shipped with the applicator.
If necessary, refer to the customer machine
manual for instructions on feed cycle adjustment.
Adjust the feed.
6.3. Tab Placement
NOTE
The Tab Placement procedures and Tab
Engagement procedures involve precise
adjustments that may require repetition until the
desired results are achieved.
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A. Tab Fails to Reach Locking Lances (Figure 8,B.)
1. Loosen the holding screws and locking nuts on
the adjustment screws for the front strip guide. See
Figure 7.
2. Turn the adjustment screws clockwise.
3. Tighten the holding screws.
4. Hand–cycle the machine and check the
adjustment.
B. Tab Fails to Engage Locking Lances
(Figure 8,C.)
Make a fine adjustment of the feed distance
according to the procedures in the machine manual.
Rev
A
408-8011
Applicator Instructions for Hinge Bar Applicators
Limit Switch
Strip Guide
Holding Screw
Shear
Blade
Strip Guide
Holding Screw
Strip
Hold
Down
Locking Nut
Locking Nut
Adjustment
Screw
Hold Down
Holding Screws
Stock
Drag
Handle
Adjustment
Screw
Figure 7
Tab Engaging Both Lances
B
Tab Engaging One Lance
And Against the Other
C
A
Figure 8
Rev A
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Applicator Instructions for Hinge Bar Applicators
6.5. Setting the Wire Crimp Height
NOTE
408-8011
Note 1
Changes to the crimp height may affect terminal
feed. When adjusting the crimp height, always
make sure the feed finger has fed the terminal
Note 1
properly. If it has not, manually center the
terminal over the anvil and then adjust the feed
after you obtain the proper crimp height.
Find the recommended crimp height setting in the
parts list shipped with the applicator. Check this with
the information written on the sample pack of
terminals. Check the crimp height and adjust, if
necessary, according to the instructions in the
machine manual.
6.6. Inspecting the Crimped Terminals
DANGER
BE SURE all the guards are on the machine
before operating the machine under power.
1. Connect the power and turn the machine “on.”
Bare Wire and Insulation
Must Be Visible Here
Notes:
1. Cut-Off Tabs Must Not Interfere with the Function of
the Receptacle or Be Bent Up Enough to Abrade
the Wire Insulation.
2. The Receptacle MUST Be Straight When Viewd
from the Top and Side and Must Not Be Deforrmed.
2. Crimp several terminals on the wire and inspect
the crimps as follows:
S Both bare wire and insulation should be visible
in the slot between the insulation barrel and the
wire barrel. See Figure 9.
S The bare wire should protrude slightly from the
front of the wire barrel.
S Terminals should be straight and not deformed.
To assure optimum results from the crimped
terminals, make sure they meet with the requirements
outlined in the applicable customer documents.
NOTE
The list of documents in Figure NO TAG is NOT
complete. It is merely a sampling of documents.
7. OPERATING PROCEDURES
Insert a stripped wire beneath the inverted “V“ of the
crimpers at a slight angle against the shear blade,
which also serves as a wire stop. Depress and
release the operator’s pedal.
The machine will cycle, the terminal will be crimped
and sheared from the strip, and the next terminal will
be positioned over the anvil.
Refer to the Tyco Electronics machine manual for
optimum operating efficiency.
8. PERIODIC CHECKS
8.1. Checking Crimped Terminals
At the beginning of each eight hour shift of operation,
crimp several terminals onto wire under power and
check the following:
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Bare Wire Should
NOT Extend More Than
0.254 mm [.010 In.] Beyond
the Cut-off Tab Here
Figure 9
A. Wire Placement
Be sure your wire is stripped to the correct strip
length. The strip length of the wire and the angle of
the wire placement against the shear blade will
determine the amount of bare wire that extends past
the crimped wire barrel.
To assure optimum results from the crimped
terminals, make sure they meet the requirements
outlined in specification 114–2078.
B. Wire Crimp Height
Check the crimp height of the samples. Refer to the
appropriate customer machine manual for crimp
height setting procedures.
C. Insulation Crimp
The insulation barrel should be just tight enough to
support the wire insulation. The main purpose of the
insulation support of the terminal is to keep the bare
wire from flexing against the edge of the wire crimp.
See Paragraph 9.1 for Insulation Support
Adjustments.
D. Tab Placement and Tab Adjustment
The wire barrel tab should pass through the slot and
engage one or both of the locking lances. See
Paragraph 6.3 and Paragraph 6.4 for adjustments.
8.2. Checking Terminal Feed
A. Feed Point
Check the applicator parts list for the proper feed
point. With a terminal centered over the anvil, the tip
Rev A
Applicator Instructions for Hinge Bar Applicators
of the feed finger should fall directly behind the wire
barrel of a specific terminal.
408-8011
4. Turn “on” the machine and connect the power, if
necessary.
B. Over Feed
9.3. Strip Hold Down Adjustment
If the feed finger positions the terminal too far over
the anvil, a feed adjustment or stock drag tension
adjustment may be necessary. Refer to the machine
manual for the feed adjustment, and Paragraph 9.5
for the stock drag tension adjustment.
The strip hold down rests on the edge of the terminal
carrier strip, as shown in Figure 7. If adjustment is
necessary,simply loosen the holding screws, position
the strip hold down and tighten the holding screws.
C. Under Feed
If the terminal is not positioned far enough over the
anvil, a feed adjustment may be necessary. Refer to
the instructions in the machine manual to adjust the
feed.
9. OPERATING ADJUSTMENTS
9.1. Insulation Crimp Adjustment
DANGER
To prevent personal injury, be sure power to the
machine is turned off" and disconnected if
making this adjustment while the applicator is
installed in the machine.
9.4. Ram Retainer Plate Adjustment
DANGER
To prevent personal injury, be sure power to the
machine is turned off" and disconnected if
making this adjustment while the applicator is
installed in the machine.
If play develops in the ram, proceed as follows:
1. Tighten the two wear plate adjusting screws until
the ram cannot be moved when the machine is
hand–cycled. Refer to Figure 10.
2. Back off each screw approximately 1/8 turn.
3. Hand–cycle the machine.
4. Turn “on” the machine and connect the power, if
necessary.
1. While holding the insulation crimper at it’s
present position. Loosen the the two insulation
crimper holding screws. See Figure 6.
2. Move the insulation crimper to a new position
and tighten the insulation crimper holding screws.
CAUTION
Ram Retaining
Plate
Wear Plate
BE SURE the bottom of the insulation crimper is
not lower than the bottom of the wire crimper.
3. Hand–cycle the machine to check the
adjustment.
4. Reconnect power, if necessary.
9.2. Shear Depressor Adjustment
DANGER
To prevent personal injury, be sure power to the
machine is turned off" and disconnected if
making this adjustment while the applicator is
installed in the machine.
The shear depressor should depress the shear blade
slightly beyond the shearing point. If it does not,
proceed as follows:
1. Loosen the nut on the shear depressor screw.
2. Tighten the depressor screw to raise it; loosen
the screw to lower it.
3. Tighten the jam nut and hand–cycle the
machine.
Rev A
Wear Plate Adjusting Screws
Figure 10
9.5. Stock Drag Tension Adjustment
Adjust the stock drag tension by loosening or
tightening the screws that compress the stock drag
springs.
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Applicator Instructions for Hinge Bar Applicators
10. MAINTENANCE
10.1.Preventive Maintenance
Preventive maintenance should be performed on a
regular basis to keep the applicator in optimum
running condition.
408-8011
should center in the arc of the wire crimper as
shown in Figure 6.
8. Continue hand–cycling the machine until it
returns to the rest position.
Preventive maintenance consists primarily of
lubrication and cleaning.
9. Replace the insulation crimper and insulation
crimper holding screws. Check the wire crimp
height according to the procedures in the machine
manual.
A. Lubrication
10. Check the insulation crimp height.
From time to time (on a regular basis) apply a small
amount of machine oil between: (1) the inner surfaces
of the hinge bar assembly and the front stabilizing bar
and; (2) the hinge block and the stabilizer.
11. Turn “on” the machine and connect the power,
if necessary.
B. Cleaning
Frequently clean the dirt and metal chips from the
machine with a small brush or a clean, lint–free rag.
10.2.Replacement Parts
Refer to the parts list shipped with the applicator for
spare parts. Certain parts are designated “wearable”
parts. These items are the one most like to require
replacement. It is recommended that these parts be
kept on hand for immediate replacement.
B. Anvil Replacement
Refer to the parts list (and exploded view drawing)
shipped with the applicator and replace the anvil as
described below.
DANGER
To prevent personal injury, be sure power to the
machine is turned off" and disconnected if this
replacement procedure is performed while the
applicator is installed in the machine.
1. Remove the two anvil holder screws.
2. Slide the anvil holder toward the stock drag.
3. Tilt the anvil holder and remove it.
10.3.Replacing Worn or Broken Parts
4. Remove the anvil.
A. Wire Crimper Replacement
5. Insert a new anvil in the anvil insert slot.
Refer to the parts list (and exploded view drawing)
shipped with the applicator and replace the wire
crimper as described below.
DANGER
To prevent personal injury, be sure power to the
machine is turned off" and disconnected if this
replacement procedure is performed while the
applicator is installed in the machine.
1. Note the insulation crimper location. Then
remove the two insulation crimper holding screws
and the insulation crimper.
2. Remove the two wire crimper holding screws
and the wire crimper.
3. Place a new wire crimper against the ram and
make the two holding screws finger tight.
4. Hand–cycle the machine, so that the bottom
surface of the wire crimper touches the anvil insert.
5. Pull the wire crimper toward you, until it’s
crimping surface almost touches the anvil insert.
6. Securely tighten the wire crimper holding
screws.
7. Continue hand–cycling the machine until the
protrudes from the anvil insert slot. The anvil
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6. While holding the anvil in place, insert the anvil
holder into the anvil insert.
7. Move the anvil holder away from the stock drag,
so that it’s slot engages the anvil’s pin.
8. Move the anvil holder up and down to be sure
the anvil is engaged and moves freely.
9. Hand–cycle the machine until the ram reaches
it’s lowest point.
10. Move the anvil holder away from the stock
drag as far as it will go, making sure the anvil
holder is parallel to the base plate.
11. Securely tighten the two anvil holder screws.
12. Continue hand–cycling the machine while
observing the crimper/anvil alignment. If
necessary, align the crimpers to the anvil.
13. Turn “on” the machine and connect the power,
if necessary.
11.REVISION SUMMARY
S Replaced “Form IC–9” with 114–2078
S Updated format to current corporate
requirements
Rev A
