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TE Ocean 2.0 Instruction Sheet

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1. INTRODUCTION
Ocean 2.0 end-feed applicators are available with a mechanical terminal feeder or a pneumatic terminal feeder
assembly. Each applicator accepts the end-feed strip-form of terminals identified on the applicator drawing to
apply to pre-stripped wires.
NOTE
Dimensions in this instruction sheet are in millimeters with [inches in brackets]. Figures are for reference only and are not
drawn to scale.
This instruction sheet, along with the parts list, exploded-view drawing (packaged with applicator), and
applicable terminating machine manual (Table 1), provide all the information required to operate and maintain
the applicator and machine.
NOTE
Refer to instruction sheet
© 2022 TE Connectivity Ltd. family of companies.
All Rights Reserved.
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
Figure 1: Ocean 2.0 end-feed applicators
Table 1: Terminating machine manuals
Machine
Basic AMP-O-LECTRIC™
Model T
Model G
AMP 3K™ 1725950-[ ]
AMP 5K™ 1725900-[ ]
AMP 3K/40™ 2119683-[ ]
AMP 5K/40™ 2119684-[ ]
408-35005
for translations of the safety warnings specified herein.
PRODUCT INFORMATION 1-800-522-6752
Manual
409-5128
409-5207
409-5289
409-5842
409-10047
409-10099
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
13 OCT 2022 Rev D
1 of 30

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Summary of Contents for TE Ocean 2.0

  • Page 1 1 of 30 For latest revision and Regional Customer Service, All Rights Reserved. visit our website at www.te.com. 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 2. DESCRIPTION Figure 2 shows the main components of the mechanical feed applicator. Figure 3 shows the main components of the air feed applicator. 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.
  • Page 3 408-35043 Figure 3: Air-feed applicator 1 Air feed cam Extend speed control 2 Air supply connection Feed arm 3 Locking nut Feed pawl 4 Retract speed control Mounting screws 3 of 30 Rev D...
  • Page 4 408-35043 The applicator is also designed to accept modular feed assemblies (Figure 4). Figure 4: Feeder assemblies 1 Pneumatic terminal feeder assembly 2 Mechanical terminal feeder assembly The Ocean applicator can be used in various machines, provided the machine has the proper stroke length and all the necessary equipment.
  • Page 5 The question of whether a lubricant is required depends on the final use of the crimped terminal. To determine whether your applications warrant the use of a terminal lubricant, contact your TE representative. (See section 6Error! Reference source n ot found. for contact information.) If your application warrants the use of a terminal lubricant, use Stoner Terminal Lubricant E807 from Stoner, Inc.
  • Page 6 408-35043 2.2. Applicator with mechanical feed system With this applicator (Figure 6), the terminals are fed by the action of the feed cam and a series of rods and levers that move the feed pawl. Figure 6: Applicator with mechanical feed system 1 Feed mounting screw (2 places) Fine feed adjustment lock screw (far side) 2 Stroke length adjustment screw...
  • Page 7 408-35043 Two feed cams (Figure 7) can be used with the mechanical feed applicator.  The pre-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.
  • Page 8 408-35043 Figure 9: Mounting a feed cam on 30-mm [1⅛-in.] stroke machine 1 Mechanical pre-feed cam 2 Mechanical post-feed cam 3 Air-feed pre- or post-feed cam 4 Mounting screw NOTE Pacific applicators can only be used with 30-mm stroke machines. They have only the 30-mm feed cam mounting positions on the applicator ram.
  • Page 9 408-35043 2.3. Applicator with air feed system With an air feed applicator (Figure 3), the terminals are fed by the action of an air feed module using a constant air supply that moves the feed pawl. The speed control valves control the speed of the feed and retract strokes. Two feed cams (Figure 10) can be used with the air feed applicator.
  • Page 10 408-35043 2.4. Applicator with Pacific head The Pacific applicator works only if the machine’s ram falls within the envelope shown in Figure 11. (Dimensions are in millimeters, with inches in brackets.) Figure 11: Ram dimensions for use with Pacific applicator 3.
  • Page 11 408-35043 3.1. AMP-O-LECTRIC and Model K machines (with mini-applicator conversion) Installation This machine must be equipped with machine conversion kit PN 690675-2 to adapt it for use with miniature applicators. The kit includes applicator instruction sheet 408-8022, which explains how to install and remove an applicator with a mechanical feed.
  • Page 12 408-35043 4. LOADING AND UNLOADING THE TERMINAL STRIP 4.1. Loading the terminal strip 1. Make sure that the installed applicator is the right one for the terminal to be applied. Compare the terminal part number on the reel with the numbers listed on the applicator parts list. 2.
  • Page 13 408-35043 5. ADJUSTMENTS 5.1. Adjusting the wire crimp height 1. Select an increment number from the data plate for the wire size to be used.  Values range from 0 (the largest crimp height) to 150 (the smallest).  Each increment represents a change in crimp height of 0.01 mm [.0004 in.]. 2.
  • Page 14 408-35043 5.2. Locking the wire crimp position The wire crimp height adjustment can be locked in position by inverting the detent pin (see Figure 13). Figure 13: Location of detent pin 1 Ring stop 2 Detent pin 1. Verify the fine adjustment head setup distance (the distance from the crimper seating feature on the ram to the top of the crimp height adjustment head).
  • Page 15 408-35043 2. While holding down the spring-loaded detent pin, turn the adjustment head clockwise until the detent pin can be removed. DANGER The spring-loaded pin can injure you if released unexpectedly. 3. Invert the pin so that the locking end contacts the detent plate (Figure 15). Figure 15: Inverting the detent pin 1 Detent orientation 2 Lock orientation...
  • Page 16 408-35043 5.3. Adjusting the insulation crimp The insulation crimp is adjustable in increments of 0.19 mm [.0075 in.]. Pull the insulation crimp dial out (refer to Figure 5) and turn it to line up with a number (1 through 18) so that it is shown at the indicator notch on the ram.
  • Page 17 408-35043 4. 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. If the lead terminal is not slugged out correctly and the backstroke position is incorrect, both the stroke length and the fine feed position must be adjusted.
  • Page 18 408-35043 Adjusting the feed The feed stroke (terminal pitch), terminal position, and feed speed adjustments are set at 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 (Figure 16) should be approximately equal to the distance between the wire barrel and the mating end of the terminal.
  • Page 19 408-35043 7. If the feed pawl reaches the backstroke position before the slide hits the rear stop adjustment screw, adjust the rear stop adjustment screw. a. Loosen the rear stop locking screw (Figure 19). b. Turn the rear stop adjustment screw clockwise until it meets the slide. c.
  • Page 20 408-35043 Adjusting the feed position NOTE It is not necessary to remove air pressure from the air feed module before making a feed adjustment. 1. Extend the feed fully. 2. Retract the feed fully. The terminal should be positioned over the anvil. 3.
  • Page 21 408-35043 Adjusting the feed speed NOTE The air feed speed is set at the factory. It requires readjustment only in exceptional circumstances. CAUTION Do not fully open the speed controls to maximize feed speed. Excessive feed or retract speeds can damage the air feed module or cause inconsistent feeds.
  • Page 22 408-35043 5.6. Adjusting the front and rear strip guides Disconnect electrical power when performing maintenance or repair on this equipment. 1. Turn off the machine. 2. Disconnect the power cord. 3. Raise the ram. 4. Remove the applicator from the machine as described in section 3, INSTALLING AND REMOVING THE APPLICATOR.

  • Page 23: Replacement And Repair

    These procedures cover the applicator parts that most often need replacement or repair due to wear. Stock and control a complete inventory to prevent lost time when replacement of parts is necessary. Order replacement parts through your TE representative. You can also order parts by any of the following methods: ...
  • Page 24 408-35043 6.3. Replacing shear plates 1. Lift the stock drag and feed pawl. 2. Pull the section of the terminal strip back so that the lead terminal is between strip guides. 3. Remove the two screws that fasten the shear plates and spacers (if used) to the strip plates. 4.
  • Page 25 408-35043 6.4. Replacing the crimper 1. If you are installing new parts, verify that the part numbers match the numbers on the applicator parts list. 2. Loosen the crimper bolt slightly 3. Remove the ram assembly from applicator by pulling upward. If necessary, move the feed pawl forward to release the ram assembly.
  • Page 26 408-35043 6.6. Repairing the adjustable crimp height Replacing the detent plate Under severe long-term use, the detent plate can become worn. This makes it difficult to feel the increments of adjustment. To replace the detent plate, complete the following steps. 1.
  • Page 27 Each applicator is properly aligned at the factory, and the base plate bolts are sealed. However, it is possible to misalign the applicator housing from the base plate by mishandling or dropping the applicator. If the applicator becomes misaligned, contact a TE field service representative or order an end-feed applicator alignment gage (part number 2161422-3).
  • Page 28 408-35043 6.8. Orienting the counter magnet The applicator counter magnet (Figure 22) properly actuates the applicator counter only if it is installed with the correct side facing out from the ram. If the magnet is removed for any reason, you must determine which side of the magnet actuates the counter before reinstalling the magnet.
  • Page 29 408-35043 6.9. Wire depressor accessory If this accessory was not installed on the applicator at the factory, use Figure 23 to identify the parts you need in order to add it. NOTE To add a wire depressor to an existing applicator, the existing crimper spacer must be at least 0.64 mm [.025 in.] thick. Figure 23: Wire depressor accessory parts 1 Existing crimper spacer 2 Replacement crimper spacer...

  • Page 30: Cleaning, Lubrication, And Storage

    408-35043 2. Use Table 2 to determine which crimper spacers you need to achieve the required thickness. Table 2: Crimper spacers, by thickness Thickness Crimper spacer Thickness Crimper spacer Thickness Crimper spacer mm [in.] part number mm [in.] part number mm [in.] part number 0.25 [.010]...