TE Connectivity AMP 5k/40 CE Instruction Sheet

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Page 1

Tool Holder

Guard

Applicator Base

Tool Holder

Applicator Base

Guards on the applicator may differ from the guards shown in the illustrations.

End-Feed Through-Splice Applicator for ThroughSplice Applications in AMP 5K/40 CE Terminators

Side-Feed Through-Splice Applicator for Through-

Splice Applications in AMP 5K/40 CE Terminators

End-Feed and Side-Feed

DANGER

STOP

CAUTION

NOTE

Applicators for AMP 5K/40* CE Through-Splice Terminators

Instruction Sheet

408-32027

08 FEB 12 Rev A

ORIGINAL INSTRUCTIONS

1. INTRODUCTION

Side-Feed and End-Feed Through-Splice Applicators (Figure 1) for AMP 5K/40 CE Through-Splice Terminators apply 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. The terminal listed on the applicator data plate is the one that was specified when the applicator was ordered. Some terminals have two carrier strips, others just one.

Additionally, these instructions cover the differences b

etween the AMP 5K/40 CE through-splice terminator for through-splice terminals (Figure 1) and the  AMP 5K/40 CE Terminator 2161500-[ ] for end of wire a

pplications. Refer to customer manual 409-10204 for general

chine information about the AMP 5K/40 CE

Terminating Machines.

Figure 1

This instruction sheet, the parts list and the exploded view dra

wing packaged with the applicator and 

409-10204 provide all the information required to op

erate and maintain the applicator and machine

When reading this document, pay particular attention to DANGER, CAUTION, and NOTE statements.

Denotes an imminent hazard which may result in moderate or severe injury.

Denotes a condition which may result in product or equipment damage.

Highlights special or important information.

*Trademark TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners.

TOOLING ASSISTANCE CENTER PRODUCT INFORMATION

1-800-522-6752

1-800-722-1111



This controlled document is subject to change. For latest revision and Regional Customer Service, visit our website at www.te.com

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LOC B

Page 2

NOTE

Applicator Guard Safety Switch

Hinged Guard Door

Applicator Guard

AMP 5K/40 CE TERMINATOR

TERMINATOR PART

NUMBER

2161300-1 Machine (Base) 2161300-2 Machine w/ CQM II

DESCRIPTION

408-32027

Figure 2

Dimensions in this document are in metric units [with U.S. customary units in brackets

2. DESCRIPTION

2.1. Terminator Description

The AMP 5K/40 CE Through-Splice Terminator (Figure 2) was designed to be used as a stand alone semi-automatic bench machine. The modifications d

escribed below allow application of through-splice terminals and other terminals that require access to both sides of the wire crimper.

The guards of the standard AMP 5K/40 CE Terminator ha

ve been modified to allow access to both sides of the crimper for through-splice type applications. Refer to Figure 3. These guards work together with the applicator guards to protect the operator. The left and r

ight guards are deeper to allow for the long air feed end feed applicators. Attached to the right guard is a hinged metal guard. A safety switch is mounted on the hinged guard that is actuated by a magnetically encoded switch actuator mounted on the applicator guard. The terminator will not cycle without the applicator guard in place.

Rev A

Figure 3

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408-32027

NOTE

Locating Pins

Tool Holder

Crimp Height Adjustment Wheel

Hold-Down Bracket

Shear Blade

Crimper Bolt

Wire Crimper

Front Shear Depressor

Crimp Height Adjustment Wheel

Wire Crimper

Crimper Bolt

The front guard has been modified to remove the guard insert. The front guard works together with the applicator guarding to protect the operator. The front guard retains its keyed interlock to actuate the guard safety switch when closed.

The modified guards on the AMP 5K/40 CE throughslice terminator will work with side-feed and end-feed CE through-splice applicators.

2.2. Applicator Description

End-Feed and Side-Feed applicators used with AMP 5K/40 CE through-splice terminators are two-piece applicators consisting of a tool holder and applicator base.

The tool holder is secured to the ram of the AMP  5K’/40 Through-Splice Terminating Machine with screws. The tool holder contains locating pins  (Figure 4) to facilitate it's location on the ram. The locating pins allow an easier tooling cha

ngeover.

The wire crimper , insulation crimper, and the front sh

ear depressor are located in a pocket in the tool holder, and are secured by a crimper bolt. The front shear depressor pushes the front floating shear down to cut the crimped terminal from the strip.

terminator

two

The wire crimp is easily adjusted, providing an array of dif

ferent wire crimp sizes.

All AMP 5K/40 CE Through-Splice Terminators are equipped with a "precision adjust" feature.



The hold-down bracket (see Figure 4) is attached to the ram and, with bracket attached, holds the terminal in p

lace during the crimping and shearing process.

The applicator's mounting surface is it The base plate attaches to the base of the terminator. The anvil, shear tooling and strip guide plates are all located on the base plate.

Since the upper tooling is p lower tooling can be adjusted to the correct position and locked (screwed) into place.

End-Feed and Side-Feed Through-Splice Applicators can

withstand the high crimping pressures required to apply terminals to the larger CMA ranges (up to approximately 17,000 CMA ). Although these applicators accept only certain terminals, they provide valuable application flexibility. The design optimizes accessibility which aids in more precise wire placement, and increased production throughout.

ermanently located, the

s base plate.

Rev A

Figure 4

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408-32027

NOTE

Feed Cylinder

Front Strip Guide

Strip Guide Plate

Strip Guide Adjusting Block

Terminal Drag

Shear Retaining Screw

Anvil

Applicator Base Plate

Feed Finger

Feed Bracket

Stripper

Anvil

Applicator Base Plate

Strip Guide Plate

Front Strip Guide

Rear Strip Guide

Floating Shear

Feed Finger

Feed Cylinder

Terminal strip is fed into the applicator with the barrel (wire) end first, between the front (outer) and rear (inner) strip guides. It passes the stock drag, and the LEAD terminal is positioned over the anvil. The feed pawl feeds one terminal during each cycle of the machine. The terminals are fed by the action of the air cylinder that is controlled by a valve on the terminator.

Some applicators have a solid metal hold-down that may require adjustment when changing the wire size and/or crimp height.

Terminals with dual-carrier strips require a shear d

epressor, spacer, and terminal holder. These parts are also attached to the tool holder assembly. The rear shear depressor pushes the rear floating sh ea r do wn

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 anvil, the front shear holder, the rear shear holder (

if used), the terminal support, and the strip guide adjustment block are mounted on the base plate, as well as the rear floating shear and rear shear holder.

The strip guide plate (Figure 5) is fastened to the strip guide adjustment block. The stock drag, the s tri p gu

ide cover plate, and the front and rear strip guides

are mounted on the strip guide plate. The applicators used for the through-splice application

e PRE-FEED Applicators. This means that the lead

terminal is over the anvil when the machine is at rest.

Rev A

Figure 5

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408-32027

CAUTION

DANGER

STOP

DANGER

STOP

NOTE

DANGER

STOP

DANGER

STOP

3. APPLICATOR INSTALLATION AND REMOVAL

With the applicator in the machine, NEVER attempt to cycle machine under power WITHOUT terminals properly loa

ded, as described in Section 4;

otherwise, the tooling may be damaged.

3.1. Applicator Installation

To avoid personal injury , be SURE the terminator is turned off and power to the machine is disconnected BEFORE installing or removing the applicator

A. Tool Holder Installation

To properly install Through-Splice Applicator first install the tool holder.

1. Position the tool holder on the bottom of the ter

minator ram using the two locating pins shown in

Figure 4.

2. Secure the the tool holder into position with two cap screw

B. Applicator Base (Lower Tooling) Installation

Align the applicator base to the terminator and the tool holder and secure the base plate to the terminator base as follows:

1. Align the lower tooling to the upper tooling (tool ho

lder with the crimper installed) In the side-to-side

direction.

To avoid personal injury , be SURE the terminator is turned off and power to the machine is disconnected BEFORE installing or removing the applicator cord from the back of the terminator. Insert a hex wrench into back of the gearbox and turn the drive sprocket.

a. Place the base plate of the app base portion of the terminator and loosely install two 6mm screws.

b. Double a piece of paper over the anvil and lo

wer the terminator ram and tool holder so that

the crimper engages with the anvil. c. Try to rotate the lower portion of the applicator .

It sh

ould not have any movement. If side-to-side movement is present, lower the ram and crimper until the base plate does not move.

If the ram is at the bottom-dead-center position and there is be adjusted. Refer to Paragraph 5.1, Crimp Height Adjustment.

If the lower portion has no mo properly located side to side.

2. Align the lower tooling to the upper tooling (tool holder with back direction.

. Lower the ram by removing the power

licator onto the

still movement, the crimper must

vement then it is

the crimper installed) In the front-to-

The lower tooling on the base plate is located properly when the bellmouth on the product is within the specified ra

nge.

3. Tighten two 6mm screws securing the applicator base

to the terminator base.

4. IInstall the wrap-around guard to the applicator with two mounting s

crews.

5. Be sure the appropriate plexi-glass guard is inst

alled on the terminator.

Refer to customer manual 409-10204 for hand-cycling instruc

tions.

3.2. Applicator Removal

To avoid personal injury, Be SURE power to the machine is turned "off" (or power cord is disconnected) BE

FORE installing or removing the

applicator.

1. Turn machine "off" and disconnect power cord.

2. Remove the wrap-around guard by removing the tw

o mounting screws. Refer to Figure 6.

3. Remove the product strip from the applicator.

4. Remove two 6mm screws that secure the ap

plicator base to the terminator.

5. Slide the applicator base clear .

6. Remove two screws that secure the tool holder to th

e terminator ram.

7. To store the applicator

, refer to Section 8,

APPLICATOR STORAGE.

4. APPLICATOR LOADING AND UNLOADING

To avoid personal injury , be SURE the terminator is turned off and power to the machine is disconnected BEFORE

loading or unloading the

applicator.

4.1. Terminal Strip Loading

Before loading terminal strip in applicator, be SURE the installed applicator is the right one for terminal to be applied. Compare terminal number on reel with numbers listed on applicator parts list.

1. Turn "off" and disconnect power to the terminator.

2. Be sure ram assembly is all the way up. If ne

cessary, hand-cycle machine to raise the ram. (Refer to customer manual 409-10204 for handcycling instructions.)

3. Open the guard doors of the terminator.

4. Raise stock drag by turning terminal drag (drag re

lease lever) upward.

Rev A

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Page 6

Wrap-Around Guard

Wrap-Around Guard Mounting Screw(s)

Terminating Machine Base (Ref)

Wrap-Around Guard

Wrap-Around Guard Mounting Screw(s)

Terminating Machine Base (Ref)

NOTE

408-32027

5. With reel of terminals installed on reel support, feed terminal strip into applicator between strip guides.

Be SURE terminal strip enters strip guides with barrel (wire) end toward the stock drag and the open side up.

Figure 6

7. Turn terminal drag downward to lower the stock dr

ag.

8. Be sure tip of feed pawl is in feed hole in carrier str

ip. Note that some carrier strips have additional holes which are not used for feed purposes.

9. Close the terminator guard doors.

6. Raise feed pawl and continue to feed terminal strip

until LEAD terminal is over anvil and feed pawl

engages hole in carrier strip.

Rev A

4.2. Terminal Strip Unloading

1. Turn "off" an d disconnect power to the term inator.

2. Be sure ram assembly is all the way up. If

cessary, hand-cycle machine to raise the ram.

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408-32027

NOTE

CAUTION

NOTE

DANGER

STOP

CAUTION

DANGER

STOP

(Refer to customer manual 409-10204 for handcycling instructions.)

3. Open the guard doors of the terminator.

4. Raise stock drag by turning terminal drag (drag elease lever) upward. Remove length of terminal

r strip left in applicator by grasping terminals at the strip guide entry, raising the feed pawl, and pulling strip straight out of applicator.

5. Turn terminal drag down ward to lower the stock

ag.

6. Close the guard doors of the terminator.

5. ADJUSTMENTS

Refer to the exploded view drawing and parts list packaged with the applicator for identification of parts.

Before setting-up any applicator , set the manual adjust of

the terminator to the "zero" position. Then refer to the applicator log sheet for the correct crimp height setting.

This setting will get you close to the range to properly crimp a particular terminal. It is highly recommended that you refer to the ap for the crimp height setting, or tooling damage may result.

plicator log

A. Minor Crimp Height Adjustments

Minor adjustments can be made using the manual adjust that is on the terminator. The total adjustment range using this feature is approximately .018 inches. Refer to the customer manual 409-10204 for details concerning this procedure.

B. Major Crimp Height Adjustment

Before making this adjustment, first try to adjust the minor crimp height adjustment. If does not get you the specified crimp height move this adjustment back to the "zero " setting. This will insure that the tooling isn't damaged while making this adjustment. To avoid personal injury, Be SURE power to the terminator is turned "off" and the power cord is disconnected BEFORE adjustment.

1. Turn machine "off" and disconnect power cord.

2. Open the guard doors of the terminator.

3. Remove the wrap around guard (Figure 6).

4. Loosen the crimper bolt (Figure 7).

5. Rotate the crimp height adjustment wheel  (Figure 7) one position. If a smaller crimp height is required, decrease the number on the adjustment whe

el. If a bigger crimp height is desired, increase

the number on the adjustment wheel.

making the crimp height

this adjustment

The crimp height range is from 1 to 7, with the smallest crim

p height on the "1" setting.

There is an optional adjustment wheel (for purchase) containing settings from 8 through 1 This adjustment wheel is for the crimp heights above .125 in.

5.1. Crimp Height Adjustments

Make several test cycles and inspect terminations CLOSELY.

•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 6, REPAIR AND REPLACEMENT OF PARTS.

•If terminations appear normal, measure crimp

height of each termination as described in  408-7424, packaged with the applicator. Crimp h

eight must agree with measurement specified on parts list for wire size being used. Record crimp height dimensions for reference.

•If crimp height is INCORRECT then a crimp height

adjustment is necessary. This is accomplished with the following procedure.

If necessary, make minor or major crimp height adjustment

s as follows.

Do not move the adjustment feature more then one position or tooling damage may result.

6. Apply upward pressure to the crimper so that the top e

dge of the crimper is tight against the adjustment wheel. Continue to apply this pressure and secure the crimper bolt.

7. Install the wrap around guard and close the guard do

ors.

8. Crimp additional product and inspect. If the crimp he

ight is not correct repeat the directions in the

Paragraphs 5.1,A and 5.1,B.

5.2. Terminal Strip Feed Adjustment

Part of the Terminal Strip Feed Adjustment is made with the pneumatic power "on." T injury , BE SURE to exercise caution around moving machine parts with the machine "on" and the guards open.

1. Turn electrical power off to the terminator. Keep the p

neumatic power “on”.

2. Open the terminator guards and remove the ap

plicator guard.

3. Raise the terminal drag. Feed in a strip of terminals feed hole on side feed applicators or behind the terminal on end feed applicators.

until the feed finger drops into the first

o avoid personal

Rev A

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Page 8

Crimp Height Adjustment Wheel

Wire Crimper

Tool Holder

Crimper Bolt

Manual Precision Adjustment Mechanism on the Terminator

Figure 7

Manual Over-Ride Button

Adjustment Locking Screw

Adjustment Screw

Stroke Clamp

NOTE

DANGER

STOP

4. Lower the terminal drag.

5. Depress and release the manual over-ride button n the air feed valve located on the back of the

o terminator until the terminal is located above the anvil. See Figure 8.

6. Determine the direction of adjustment required to

nter the terminal over the anvil.

7. Loosen the adjustment locking screw.

8. Turn the adjustment screw to make an

justment. See Figure 9.

Figure 8

Rev A

408-32027

Figure 9

9. Tighten the adjustment locking screw.

For side feed applicators: Turning the adjustment screw clockwise will move the terminal to the left on the next feed stroke. For end Turning the adjustment screw clockwise will move the terminal toward the rear of the anvil on the next feed stroke.

10. Raise the terminal drag, lif pull the terminal strip back and repeat steps 3 through 7 until the terminal is centered over the anvil.

11. If the feed finger stroke is incorrect, loosen the st

roke clamp (Figure 9) and move the clamp closer to the air cylinder for less str cylinder for more stroke.

12. Tighten the clamp and check the feed.

oke and further from the

feed applicators:

t the feed finger, and

5.3. Strip Guide Plate and Feed Pawl Adjustments (Side-

Feed Through-Splice Applicators Only)

This procedure moves the plate on which the strip guides are mounted. Since the terminal strip is fed into the applicator between the strip guides, it is moved front and back over the anvil as the strip guides are moved.

The adjustment of the feed pawl to match any change in the

position of the front strip guide is also described

here.

To avoid personal injury, be SURE power to the terminator is turned "off" and the power cord is disconnected before removing the applicato

1. With the power to the terminator "of power cord disconnected, open the terminator

f," and the

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408-32027

NOTE

DANGER

STOP

NOTE

DANGER

STOP

NOTE

DANGER

STOP

guard doors and remove the applicator as described in Paragraph 3.2.

2. From bottom side of strip guide plate, loosen the screw that holds the strip guide adjustment block to the strip guide plate.

3. With the LEAD terminal centered over anvil, lift a

nd hold (or block) the feed pawl up to clear the

front strip guide.

4. Turn strip guide plate adjustment screw CLOCKWISE to REAR, or COUNTERCLOCKWISE to move it TOWARD FRONT. The insulation barrel of the lead terminal should be as close as possible to the floating shear.

5. Tighten screw to hold st r

6. Loosen screw holding feed pawl to feed finger eed pawl holder). Move feed pawl until its tip drops

(f into slot in front strip guide. Retighten screw.

7. Hand-cycle terminating unit, checking for proper

ter

minal feed and strip guide plate alignment.

Refer to customer manual 409-10204 for handcycling instructions.

move strip guide plate TOWARD

ip guide plate in position.

5.4. Strip Guide Adjustment

This adjustment is not used very often, because it is only needed when the rear strip guide is not parall el to the strip guide plate, the strip guides are not parallel to each other, or there is a variation in strip width.

The strip guides are correctly positioned on the strip guide plate when the applicator is built, and normally do NOT need adjustment. DO NOT use this procedure for front-to-rear positioning of strip refer to Paragraph 5.4, Strip Guide Plate and Feed Pawl Adjustments.

To avoid personal injury, be SURE power to the terminator is turned "off" and the power cord is disconnected before making adju guard doors open.

1. With the power to the terminator "off," and the

ower cord disconnected, open the terminator

guard doors.

2. Lift and hold (or block) the feed pawl up to clear

the

front strip guide, and loosen screws holding strip

guides to strip guide plate.

3. Move the rear strip guide in the desired direction,

making sure it is p then retighten the holding screws.

4. Align the front strip guide with the holes in the

rminal carrier strip, but be sure the strip guides are parallel, and that the terminal strip can move freely with a minimum of side clearance. Retighten the screws.

arallel to the strip guide plate, and



stments with the

If feed pawl is not aligned with the front strip guide, refer to Paragraph 5.3, Step 4.

5. Hand-cycle terminating unit, checking for proper ter

minal feed and strip guide alignments.

5.5. Adjustment of Shear(s) and Shear Holder(s) (Side-

Feed Through-Splice Applicators Only)

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.

The lower portion of the applicator must be removed from the terminating unit for this procedure. See removal procedure under Parag

raph 3.2.

A. Front Shear Adjustment

To avoid personal injury, be SURE power to the terminator is turned "off" and the power cord is disconnected before removing the applicato

1. With the power to the terminator "of power cord disconnected, open the terminator guard doors and remove the applicator as described in Paragraph 3.2.

2. From the bottom of the base plate, loosen the two sc

rews that secure the shear holder to the base

plate.

3. Move the shear holder and floating shear in the de

sired direction, and retighten the screws.

There should be minimal clearance (.002 in.) between the floating shear and the anvil; the shear must move up and down freely square to the back of the anvil.

4. Reinstall and re-align the applicator base plate to the ter

minator base and load it with product so that a terminal is centered over the anvil. Check that the floating shear correctly cuts the terminal from the carrier strip. If shearing action is not correct, repeat Step s 1 and 2 or check for worn or dama ged tooling.

f," and the

, and must be

B. Rear Shear Adjustment (Dual Carrier Strip 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 .

To avoid personal injury, be SURE power to the terminator is turned "off" and the power cord is disconnected before removing the applicato

1. With the power to the terminator "of power cord disconnected, open the terminator guard doors and remove the applicator as described in Paragraph 3.2.

f," and the

Rev A

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408-32027

NOTE

DANGER

STOP

NOTE

DANGER

STOP

DANGER

STOP

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 te

rminal, and then tighten the holding screws.

5. Depress the floating shear and check for proper she

aring action and proper cutoff tab.

6. If necessary, repeat Steps 2 through 5 or check for

worn or damaged tooling.

6. REPAIR AND REPLACEMENT OF PARTS

These procedures cover the applicator parts which most often need repair or replacement because of wear. Remove the a pplicato r from th e ma chine be fo re doing any maintenance work. Refer to the exploded view drawing and parts list packaged with the applicator for identification of parts. Be sure to order replacements for parts used from sp are parts stock, so that they will be available when needed.

Wipe parts with a clean, dry cloth as they are removed from the applicator. Then, when putting them

back into applicator, wipe mating surfaces with your fingers to make sure that all lint and other foreign matter have been removed.

6.1. Anvil Replacement

To avoid personal injury, be SURE power to the terminator is turned "off" and the power cord is disconnected before removing the app

1. With the power to the terminator "off," and the p

ower cord disconnected, open the terminator guard doors and remove the applicator as described in Paragraph 3.2.

2. Raise the terminal drag, raise feed pawl, and pull str

ip back so lead terminal is between strip guides.

3. From bottom of base plate, remove screw that h

olds anvil to base plate.

4. Remove anvil from groove in top of base plate.

5. Install anvil using reversed procedure. If a new a

nvil is needed, be sure the part n umber o f the new anvil agrees with the number on the applicator p arts list.

When the anvil is replaced, the front shear and holder must be re-aligned. See Paragraph 5.6,A.

licator.



6.2. Floating Shear Replacement (Side-Feed Through-Splice

Applicators Only)

It is not necessary to remove shear holder(s) to replace floating shear(s). Before removing floating shear(s), note orientation fo floating shears are spring-loaded, so be careful during removal.

To avoid personal injury, be SURE power to the terminator is turned "off" and the power cord is disconnected before removing the applicato

1. With the power to the terminator "of power cord disconnected, open the terminator guard doors and remove the applicator as described in Paragraph 3.2.

2. Raise the terminal drag , raise feed pawl, and pull st

rip back so lead terminal is between strip guides.

3. Push down on the floating shear, then remove sh

ear retaining screw from side of shear holder.

4. Slowly release pressure on floating shear. Compres

5. After removing floating shear, lift compression spr

6. Inspect spring for damage and replace it if necess

7. Re-install floating shear(s) using reversed procedure. number agrees with the number on the parts list.

8. Raise feed pawl and move lead terminal over the an

9. Check shear holder adjustment as described in Par Holder(s).

sion spring will push it out of shear holder.

ing out of shear holder.

ary. Refer to parts list for correct number.

If installing new shear, be sure part

vil. Lower thew terminal drag to lower stock drag.

agraph 5.6, Adjustment of Shear(s) and Shear



r re-installation. The

f," and the

6.3. Crimper Replacement

To avoid personal injury, be sure power to the machine is turned "off" and the power cord is disconnected BEFORE the machine. The machine ram should be in the raised position.

1. Turn off th e terminator and disconnect power.

2. Open the guard doors to gain access to the ap

plicator.

3. Remove crimper bolt that holds the front shear de

pressor, front shear depressor spacer, tubular spacer, insulation crimper, crimper spacer, and wire crimper in place on the ram assembly. Note position of of parts for purposes of re-installation.

4. Replace parts.

taking the applicator out of

6. Re-align crimpers.

Rev A

5. Re-install parts in reversed order of removal.

10 of 11

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NOTE

408-32027

NOTE

DANGER

STOP

DANGER

STOP

NOTE

CAUTION

DANGER

STOP

CAUTION

The upper end of the wire crimper must be up against the adjustment wheel on the tool holder.

6. Tighten the crimper bolt ONLY finger tight.

Insulation crimpers with legs of equal length, that are identical front and back, may 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.

7. Lift feed pawl and pull te lead terminal is between strip guides.

8. Form a piece of heavy paper over anvil, then slowly hand-c 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.

ycle machine while watching

rminal strip back until

be positioned with

6.4. Feed Pawl Replacement

To avoid personal injury, be SURE power to the terminator is turned "off" and the power cord is disconnected before making repla guard doors open.

1. With the power to the terminator "off," and the p

ower cord disconnected, open the terminator

guard doors.

2. Remove the adjustment screw which holds the fe

ed pawl to the feed finger (feed pawl holder).

3. Replace feed pawl using reversed procedure. If new p

awl is installed, be SURE the part number

agrees with the number on the parts list.

4. Adjust feed pawl as described in Paragraph 5.4.

cements with the

7. CLEANING AND LUBRICATION

For best performance and minimum downtime, applicator should be cleaned, inspected, and lubricated after each eight hours of operation, and each time it is removed from machine to be placed in storage.

7.1. Cleaning

To avoid personal injury, be SURE power to the terminator is turned "off" and the power cord is disconnected before removing the app

licator.

2. Using a clean, dry cloth, remove dirt, chips, etc., fro

m applicator. The entire applicator may be immersed in a suitable commercial solvent (one that won't affect paint or plastic) once a month to flush out chips.

3. Lubricate applicator as described in Paragraph

7.2 b

efore re-assembling.

7.2. Lubrication

Lubricate applicator each eight hours at the following points with SAE 20 motor oil (nondetergent), or where specified, light grease.

DON'T use too much oil or grease on applicator. Any excess lubricant MUST be wiped of placing applicator back in service. Don't put lubricants between wire and insulation discs.

To avoid personal injury, be SURE power to the terminator is turned "off" and the power cord is disconnected before removing the applicato

1. With the power to the terminator "of power cord disconnected, open the terminator guard doors and remove the applicator as described in Paragraph 3.2.

2. Carefully lay applicator on its side and put one dr

op of oil on feed finger pin. Wipe feed finger pin to

remove excess oil.

3. Put a drop or two of oil on the floating shear(s) in th

e shear holder(s).

f before

f," and the

8. APPLICATOR STORAGE

When storing applicator, or taking it out of machine for any reason, be sure to avoid damage to the toolin

g by preventing the bottoming of the upper

tooling on the applicator base.

1. Remove the terminal strip as described in Par

agraph 4.2.

2. Remove the applicator as described in Paragraph

3.2.

3. Clean and lubricate the applicator as described in Section 7, CLEANING AND LUBRIC

4. Store the a pplicator in an area where it cannot be d

amaged.

ATION.

1. With the power to the terminator "off," and the p

ower cord disconnected, open the terminator guard doors and remove the applicator as described in Paragraph 3.2.

It is NOT necessary to remove section of terminal strip to clean applicator.

Rev A

9. REVISION SUMMARY

This document supersedes 408-127000. New release of 408-32027.

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