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1. INTRODUCTION
The OCEAN 2.0 End-feed applicators are available with either a mechanical terminal feeder or a pneumatic
terminal feeder assembly. Each style of applicator accepts end-feed strip terminals and applies pre-stripped
wires.
NOTE
Dimensions in this instruction sheet are in metric units [with U.S. customary units in brackets]. Figures are not drawn to scale.
NOTE
This instruction sheet, the exploded-view drawing with the associated parts list packaged with the applicator, along with the
applicable customer manual provide all the information required to operate and maintain the applicator and machine.
Following is a list of the terminating machine customer manuals that apply:
409-5128
Basic AMP-O-LECTRIC* machine
409-5207
or
409-5289
Model "G" machine
409-5842
409-10047
AMP 3K* machines 1725950-[ ] and AMP 5K* machines 1725900-[ ]
409-10099
AMP 3K/40* machines 2119683-[ ] and AMP 5K/40* machines 2119684-[ ]
NOTE
Reference Instruction Sheet 408-35008
2. DESCRIPTION
Overview
Main components of the mechanical and air feed applicators are identified in Figures 1 and 2,
respectively.
Indicator Notch/CutOut
Ram Assembly
Insulation Crimp Dial
Stripper
Lead Terminal (Ref)
Anvil
Future Release
1
© 2019 TE Connectivity Ltd. family of companies.
All Rights Reserved.
*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.
OCEAN 2.0 End-Feed Applicators
Model "T" terminating unit
1
for translations of the Safety Warnings specified herein.
Mechanical Feed Applicator
Figure 1
PRODUCT INFORMATION 1-800-522-6752
Wire Crimp Disc
Terminal Feeder Assembly
Applicator Housing
Strip Guide Plate
Strip Guide
Base Plate
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.te.com.
Instruction Sheet
408-35043
Rev C
20 JUN 19
End-Feed Strip-Form
Terminal Strip
Drag Release Lever
1 of 21
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Related Manuals for TE Connectivity OCEAN 2.0
Summary of Contents for TE Connectivity OCEAN 2.0
- Page 1 1 of 21 For latest revision and Regional Customer Service, All Rights Reserved. visit our website at www.te.com. *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.
- Page 2 408-35043 Air Feed Applicator Air Feed Cam Air Supply Connection Lock Nut Retract Speed Control Feed Arm Extend Speed Control Feed Pawl Mounting Screws Figure 2 Each applicator is individually designed for specific terminals. The wire crimp height and insulation crimp height can be adjusted to accommodate different wire sizes and insulation ranges, respectively.
- Page 3 408-35043 The OCEAN applicator can be used in various machines, provided the machine has the proper stroke length and all the necessary equipment. There are two basic applicator design styles, Atlantic and Pacific, to meet the many terminator and leadmaker configurations worldwide (see Figure 4). Basic Applicator Design Styles (Pacific) Atlantic)
- Page 4 408-35043 Though the Atlantic and Pacific ram and base plate interfaces are different, most of the Ocean applicator features and adjustments are the same. The terminal strip must be fed into the applicator, with the wire barrels facing up and first into the applicator, between the strip guide plates.
- Page 5 408-35043 Mounting Mechanical Feed Cam Figure 6 Spare Feed Cam Storage Location Applicator Counter Setscrew Stroke Length Adjustment Screw Feed Mounting Screw (2 Places) Stroke Pivot Stroke Length Applicator Counter Adjustment Lock Screw Fine Feed Adjustment Screw Feed Pawl Holder Fine Feed Adjust Lock Screw Stock Drag Feed Pawl Pin...
- Page 6 408-35043 With this applicator, the mechanical feed system feed cam and its mechanical system of rods, levers, and springs are replaced by an air cylinder module. In the air feed module, the feed action is started when the applicator ram moves. At the beginning of the ram’s downward stroke, the ram-mounted cam pushes the valve inside the air feed housing causing the retract side of the cylinder (closest to the anvil) to be filled, shifting the feed pawl to the rear of the strip guide.
- Page 7 408-35043 B. Removal Turn off, and disconnect, the power to the machine. Unload the applicator as described in Section 4. Remove the hold-down bracket and movable stop, then slide the applicator away from the stop on the base mount until the ram post is clear of the machine ram. Model “T”...
- Page 8 408-35043 If terminals are post-feed, lift the feed pawl and pull the strip back one terminal length. The lead terminal will then be moved over the anvil on the downward stroke of the ram assembly. Hand-cycle the machine several times to make sure the applicator is properly adjusted as described in Section 5.
- Page 9 408-35043 During extensive operation, periodically inspect the terminals as described in Step 4 to make sure the applicator is producing correct terminations. B. Wire Crimp Adjust Lock Position The wire crimp height adjusts can be locked in position by changing the Detent Pin orientation (see Figure 10).
- Page 10 408-35043 Adjust Set to 0 (Zero) Fine Adjust Head Setup Distance Figure 11 Insulation Crimp The insulation crimp is adjustable in increments of 0.19 mm [.0075 in.] by pulling the Insulation Crimp Dial out (see Figure 9) and turning it to line up with the number (1 through 18) that it is shown at the indicator notch on the ram;...
- Page 11 408-35043 Note: There are two adjustments that work in combination to properly position the lead terminal over the anvil and give the proper backstroke position to pick up the next terminal feed hole. Use one or both adjustment types to properly adjust the applicator. If the slug blade does not shear the terminal in the correct position, make note of the position and continue to cycle the applicator to check the backstroke position.
- Page 12 408-35043 The feed stroke is adjustable in a range from 0 to 49.8 mm, depending on the air feed part number, in stepped increments of 0.04 mm [.0016 in.] for the feed forward position and in 0.08-mm [.0031-in.] increments for the rear feed pawl position (backstroke). NOTE For ease of adjustment, the end cap can be removed with a 3-mm wrench, exposing the “tool-less”...
- Page 13 408-35043 e. To adjust the air feed speed, proceed as follows: NOTE The air feed speed has been set at the factory and should therefore require re-adjustment only in exceptional circumstances. NOTE Take extra precautions during adjustments. When the machine is manually cycled, the mechanism will move forward and backwards once during each press stroke unless the air is disconnected.
- Page 14 408-35043 a. Feed Adjustment The feed stroke (terminal pitch), terminal position, and feed speed adjustments are set from the factory. If adjustment is necessary, follow the instructions below: If the pick-up point is the end of the wire barrel, the backstroke over-travel should be approximately equal to the distance between the wire barrel and the mating end of the terminal ...
- Page 15 408-35043 (8) If the slide hits the rear stop adjust screw before the feed pawl is at the backstroke position, the feed screw needs to be adjusted out. Adjust the rear stop adjust screw counter-clockwise until the feed pawl is at the backstroke position. Loosen the Rear Stop Locking Screw.
- Page 16 408-35043 d. Feed Speed Adjustment NOTE The air feed speed has been set at the factory and should therefore require re-adjustment only in exceptional circumstances. NOTE The speed controls should not be fully opened to maximize feed speed. Excessive feed and/or retract speeds can cause inconsistent feeds and/or air feed module damage.
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Page 17: Replacement And Repair
408-35043 Adjusting Strip Guide Lower Terminal Drag Strip Guide Screw Plate (4 Places) Strip Hold-Down Plate (If Present) Drag Spring and Retaining Nut Terminal Strip Aligned (2 Places) with Anvil Lower Strip Guide Figure 17 6. REPLACEMENT AND REPAIR These procedures cover the applicator parts which most often need replacement or repair because of wear. Proceed with the following: NOTE Make sure to order replacements for parts that were used from the spare parts stock so that they will be available when... - Page 18 408-35043 Shear Plate Replacement Lift the stock drag and feed pawl, then pull the section of the terminal strip back so that the lead terminal is between strip guides. Remove the two screws that fasten the shear plates and spacers (if used) to the strip plates. Remove the parts from the applicator.
- Page 19 408-35043 Air Feed Bushings, Piston Rods, and O-Rings Replacement Air feed module rebuild kits PN 2217901-[ ] are available to replace worn air feed bushings, piston rods, and O-rings. Call PRODUCT INFORMATION (1-800-522-6752) for applicable kit. For installation procedure, refer to 408-32121.
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Page 20: Cleaning, Lubrication, And Storage
408-35043 After re-installing the Crimp Head assembly and Detent Pin, rotate the head assembly until the proper set-up dimension is re-established. Turn the Wire Crimp Disc to the stop. 0 (zero) should be indicated on the Number Ring. Torque the (3) M3 flat-head screw to 6-8 lbf-in [0.7-0.9 Nm]. Verify proper crimp height as in Paragraph 5.1.A. - Page 21 408-35043 Part Number-to-Crimper Spacer Thickness Cross-Reference Se = Existing Crimper Spacer Thickness (See Cross-Reference for Part Number-to-Crimper Spacer Thickness) PART THICKNESS NUMBER mm [in.] 455888-1 0.25 [.010] 455888-2 0.30 [.012] 455888-3 0.38 [.015] 455888-4 0.51 [.020] 455888-5 0.66 [.026] Choose Wire Depressor 455888-6 0.79 [.031] Based on Wire Size Range...
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