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408-10390
Air Feed Applicator
Air Feed Cam
Air Supply Connection
Retract Speed Control
Forward Speed Control
Mounting Screw
(2 Places)
Feed Stroke/Feed Forward Position
Adjustment
End Cap
End Cap Bolt
(2 Places)
Feed Pawl
Feed Arm
Figure 2
Detent Screw
(2 Places)
Feed Backstroke/Rear Position
Adjustment
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. The feeder assembly can be removed from the applicator and
replaced with any different style; mechanical, air, or servo feed; depending on the requirements (see Figure 3).
To change to a different feed type, use retro-fit kit PN 2119949 for the mechanical terminal feeder, retro-fit kit
PN 2119950 for the pneumatic terminal feeder, and retro-fit kit PN 2119951 for the servo terminal feeder.
Changing Feeder Assembly
Servo Terminal
Feeder Assembly
Servo Feeder Latch Plate
Push Rod
Bushing
Pneumatic Terminal
Feeder Assembly
Mechanical Terminal
Feeder Assembly
Applicator
Figure 3
Rev S
2
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408-10390
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 many of the terminator and
leadmaker configurations worldwide (see Figure 4).
Though the applicator 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 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 ram post interface is located just below the wire crimp disc, 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 1.50 mm [.059 in.]. By rotating the wire crimp disc, the ram interface raises and lowers
relative to the applicator housing. The indicator notch of the ram points to the numbers on the outer diameter of
the wire crimp disc, indicating a relative crimp height. For proper crimp height, the number on the wire crimp
disc must correspond to the number on the applicator identification tag and log sheet.
The wire crimper is held in a pre-set position by the ram and the crimper bolt. The 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
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.
Basic Applicator Design Styles
(
Atlantic)
Machine Ram
for Ram Post
Adapter
(Pacific)
Machine Ram
for Ram Post
Adapter
Ram Post
Ram Clamp
Wire Crimp
Disc
Bosses
Insulation
Crimp Dial
Applicator
Ram
Crimper Bolt
Terminal
Hold-Down
Insulation Crimper
Wire Crimper
Figure 4
Applicator
Ram
Terminal
Hold-Down
Insulation Crimper
Rev S
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408-10390
2.1. Applicator with Mechanical Feed System
With this applicator, the terminals are fed by the action of the feed cam and a series of rods and levers, which
move the feed pawl. Two feed cams are available and can be mounted in two different mounting holes
depending on machine stroke length and feed type (see Figure 5). The spare feed cam, when not in use, can
be mounted to the applicator housing in the spare feed cam storage location shown in Figure 6.
NOTE
Pacific applicators can only be used with 30-mm stroke machines and, therefore, only have the 30-mm feed cam mounting
positions on the applicator ram.
The
post-feed
feed cam advances the lead terminal over the anvil on the
downward
stroke of the ram
assembly. The post-feed set up is typically used for leadmaker and end-feed bench 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
The recommended setup for end-feed applications is post-feed. The applicator can be configured for pre-feed, but may
encounter problems with some applications. Feed issues or terminal jamming may occur in the pre-feed configuration.
2.2. Applicator with Air Feed System
With this applicator, the mechanical feed system feed cam and its mechanical system of rods, levers, and
springs are replaced by an air cylinder module. In the air feed module, the feed action is started when the
applicator ram moves. At the beginning of the ram’s
downward
stroke, the ram-mounted cam pushes the push
rod. This actuates the valve inside the air feed housing causing the
retract
side of the cylinder (closest to the
anvil) to be filled, shifting the feed pawl to the rear of the strip guide.
NOTE
The air supply connection (shown in Figure 2) must be connected to an air supply line providing continuous pressure of 5.00 to
6.00 bars [72 to 87 psi] at the applicator.
NOTE
NO oil lubrication of air for the OCEAN Air Feed module is required after receiving and use within a production environment.
Mounting Feed Cam
40-mm [1
5
/
8
-in.] Stroke Machine
30-mm [1
1
/
8
-in.] Stroke Machine
Post-Feed
Post-Feed
Pre-Feed
Pre-Feed Feed Cam
Feed Cam
Installed
Post-Feed Feed Cam
Mounting Screw
Mounting Screw
Counter
Magnet
Pre-Feed
Feed Cam
Installed
Figure 5
4
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Rev S
408-10390
Applicator with Mechanical Feed System
Spare Feed Cam
Storage Location
Applicator Counter Setscrew
Stroke Pivot
Feed Pawl Adjustment Screw
Feed Mounting Screw (2 Places)
Applicator Counter
Stroke Length Adjustment Lock Screw
Fine Feed Adjustment Screw
Feed Pawl
Feed Pawl Holder
Fine Feed Adjust Lock Screw
(Far Side)
Stock Drag
Adjustment Nuts
Figure 6
CAUTION
There is a marking (vertical etched line) on the air feed housing (shown in Figure 2) to use as a visual aid to ensure that the
piston assembly is located within the limits of the air cylinder position. The feed pawl holder must be positioned to the right of
the marking. Incorrect feed pawl positioning relative to the marking may contribute to premature failure of the air feed module.
The ram continues downward, completes the crimping action, and starts back up. As it approaches the fully
raised position, the push rod drops off of 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 [1
5
/
8
-in.] stroke or 30 mm [1
1
/
8
-in.] stroke (refer to Figure 5).
Note that the air feed requires a different cam than the mechanical pre-feed or post-feed.
NOTE
The ram collar needs to be installed when changing crimp tooling to prevent the ram from becoming captured. If this does
occur, the air feed assembly will need to be removed to release the applicator ram.
Feed Pawl Pin
2.3. Applicator with Servo Feed System
With this applicator, the wire crimp height and terminal feed are accomplished by the AMP-O-LECTRIC III
servo terminator or any machine that incorporates the TE Connectivity (TE) precision controller. Refer to
409–10073.
NOTE
Some applicators will not work with the standard feed pawl in the feeder. In these cases, the special feed pawl must be used.
If originally ordered with the servo feed, the applicator will be shipped with the special feed pawl mounted to the applicator.
Each servo feed applicator comes equipped with a data chip that is part of the servo feeder latch plate (see
Figure 3). For a complete description of the data chip, refer to
409-10073.
This device allows the storage of key
operating parameters that allow easy setup between terminals and also contains reference data that can be
useful for other machine setups and crimp inspection.
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