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1. INTRODUCTION
The OCEAN 2.0 side-feed applicators are available with either a mechanical terminal feeder or a pneumatic
terminal feeder assembly. Each style of applicator accepts side-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
Model "T" Terminating Unit
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
Refer to Instruction Sheet 408-35005
2. DESCRIPTION
Overview
1. Main components of the mechanical and air feed applicators are identified in Figures 1 and 2,
respectively.
Mounting Screw (2 Places)
Side-Feed Strip-Form
Terminals
Rear Strip Guide Plate
1
Future Release
© 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 Side-Feed Applicators
1
for translations of the Safety Warnings specified herein.
Mechanical Feed Applicator
Mechanical Terminal
Feeder Assembly
Front Strip Guide Plate
Feed Pawl
PRODUCT INFORMATION 1-800-522-6752
Figure 1
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.te.com.
Instruction Sheet
408-35042
Rev C
08 APR 19
Ram Assembly
Applicator Housing
Base Plate
1 of 26
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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 26 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 2 408-35042 Air Feed Applicator Vertical Etched Line Ram Assembly Air Supply Connection Forward Speed Control Applicator Retract Speed Control Housing Mounting Screw (2 Places) Feed Pawl Pneumatic Terminal Base Plate Feeder Assembly Rear Strip Guide Plate Feed Arm Front Strip Guide Plate Figure 2 2.
- Page 3 408-35042 3. 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).
- Page 4 4. Though the Atlantic and Pacific applicator ram and base plate interfaces are different, most of the OCEAN 2.0 features and adjustments are the same. The terminal strip must be fed into the applicator with the wire barrels facing out; between the Front (outer) and Rear (inner) Strip Guides.
- Page 5 408-35042 5. Lubrication 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. ...
- Page 6 408-35042 Spare Feed Cam Storage Location Figure 8 Applicator with Air Feed System 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.
- Page 7 This machine must be equipped with Machine Conversion Kit PN 690675-2 to adapt it for use with the OCEAN 2.0 applicators. The kit includes applicator Instruction Sheet 408-8022, which explains how an applicator with mechanical feed is installed and removed from the machine.
- Page 8 408-35042 Other Terminating Machines For installation and removal procedures for the basic AMP-O-LECTRIC machine, Model “G” machine, AMP 3K and AMP 5K machines, and AMP 3K/40 and AMP 5K/40 machines, refer to the appropriate 409 Series Customer Manual specified in Section 1. For installation and removal procedures for terminating machines not listed, refer to the customer documentation supplied with the machine.
- Page 9 408-35042 7. 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). 8. Turn the Drag Release Lever downward to lower the Stock Drag. 9.
- Page 10 408-35042 5. Make the insulation crimp adjustment described in Paragraph 5.2, then make several test cycles and inspect the terminations closely. Look for rough or sharp edges around the 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.
- Page 11 408-35042 Detent Pin Ring Stop DETAIL DETAIL Pin in DETENT Orientation Pin in LOCK orientation Figure 12 Adjust Set to 0 (Zero) Fine Adjust Head Setup Distance Figure 13 11 of 26 Rev C...
- Page 12 408-35042 Insulation Crimp The insulation crimp is adjustable in increments of 0.19 mm [.0075 in.] by pulling the Insulation Crimp Dial out (see Figure 11) and turning it to line up with the number (1 through 18) that it is shown at the indicator notch on the ram;...
- Page 13 408-35042 Stroke Length Adjustment Screw Stroke Pivot Stroke Length Adjustment Lock Screw Fine Feed Adjustment Screw Feed Pawl Fine Feed Adjust Lock Screw Feed Pawl Holder Strip Guide Adjusting Screw Strip Guide Locking Screw Figure 14 5. Turn the Stroke Length Adjustment Screw counterclockwise to reduce the stroke length or clockwise to increase the stroke length.
- Page 14 408-35042 Terminal Strip Feed – Air Feed Applicator OCEAN applicators equipped with Air Feed Module PN 2063440-1, -2 or -3: Refer to Section 5.4.A. OCEAN applicators equipped with Air Feed Module PN 2844940-1 or -2: Refer to Section 5.4.B. A.
- Page 15 408-35042 Using the feed-forward adjustment knob, change the feed-forward position based on the direction and amount noted in step 4.d. The adjustments are in 0.04 mm [.0016-in.] increments or 15 degrees and can be felt as clicks during the feed-stroke adjustment knob rotation. Turning the feed forward adjustment knob clockwise moves the feed pawl away from the anvil and turning it counter-clockwise moves the feed pawl toward the anvil.
- Page 16 408-35042 The feed mechanism is actuated by a constant supply of compressed air (see Figure 2). DANGER To avoid personal injury, this applicator should be used only in an appropriate terminating machine. The pressurized air supply should only be connected after the applicator is properly installed in the terminating machine. DANGER Take extra precautions during adjustments.
- Page 17 408-35042 Feed Pawl to Rear of Terminal Feed Hole Figure 16 (8) If the feed pawl is at the rear edge of the feed hole before the slide hits the rear stop adjust screw, turn the rear stop adjust screw clockwise until the screw meets the slide, as follows: Clockwise Rear Stop Locking Screw Rear Stop Adjust Screw...
- Page 18 408-35042 Feed Position (terminal position over the anvil) (1) Remove the air supply from the module. (2) Manually feed the terminal by fully extending the feed and then fully retracting the feed until a terminal is over the anvil. (3) If the terminal position is left of the anvil (under-fed), turn the Fine Feed Adjust Screw clockwise to move the terminal to the right of the anvil (see Figure 18).
- Page 19 408-35042 Figure 19 Strip Guide Plate and Feed Pawl 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. NOTE Getting the adjustment of the Feed Pawl to match any change in the position of the Front Strip Guide is also described here.
- Page 20 408-35042 Strip Guide This adjustment is only needed when the Rear Strip Guide is not parallel to the Strip Guide Plate, the Front and Rear Strip Guides are not parallel to each other, or there is a variation in strip width. NOTE The Front and Rear Strip Guides are correctly positioned on the Strip Guide Plate when the applicator is built and normally does not need adjustment.
- Page 21 408-35042 4. Depress the Floating Shear, and check for proper shearing action and proper cutoff tab. 5. If necessary, repeat Steps 1 through 4, or check for worn or damaged tooling. Carrier Strip Cut or No-Cut Setup The Shear Holder can be set for the carrier strip to be cut or not. If it is set for the cut orientation (Figure 21; Top Detail), check that the cutting blade is present and in the proper orientation on the Shear Holder.
- Page 22 408-35042 Applicator Hold-Down Setup For proper terminal hold-down setup, refer to Instruction Sheet 408-35001. 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 used from the spare parts stock so more will be available when needed. Preparation 1.
- Page 23 408-35042 Feed Pawl Replacement 1. Remove the hex head cap screw that holds the Feed Pawl to the Feed Pawl Holder. 2. Replace the Feed Pawl using the reverse procedure. Note: If a new Feed Pawl is installed, verify the part number agrees with the number on the applicator parts list.
- Page 24 408-35042 8. Re-assemble, keeping the (3) M3 screws loose to allow the disc to rotate on the head. Figure 23 9. Apply grease to the Detent Plate to lubricate the Detent Pin contact surface. 10. After re-installing the Crimp Head assembly and Detent Pin, rotate the head assembly until the proper set-up dimension is re-established.
- Page 25 408-35042 Counter Magnet Orientation The applicator counter magnet will properly actuate the applicator counter only if it is installed with the correct side facing out from the ram. If for any reason the magnet is removed, it will need to be determined before re- installing the magnet in the ram which side of the magnet actuates the counter.
- Page 26 408-35042 7. CLEANING, LUBRICATION, AND STORAGE For best performance and minimum downtime, the applicator should be cleaned daily and monthly, and inspected, lubricated, and stored as indicated in Instruction Sheet 408-8059. 8. REVISION SUMMARY Revised Section 5.4 and added Air Feed Modules PN 2844940-1 and PN 2844940-2 (Section 5.4.B.) ...
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