Instruction Sheet
408-8053
LOC B
1
of 3
E
2007 Tyco Electronics Corporation, Harrisburg, PA
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*Trademark. Other products, logos, and company names used are the property of their respective owners.
TOOLING ASSISTANCE CENTER 1-800-722-1111
PRODUCT INFORMATION 1-800-522-6752 This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at
www.tycoelectronics.com
07 JUN 07 Rev G
Miniature (Mini) Quick-Change Applicators
1. INTRODUCTION
This instruction sheet has been prepared to serve as
an applicator conversion guide and, in the process,
promote a better understanding of the typical
differences between semi–automatic (bench) and
automatic versions of miniature and heavy duty (HD)
miniature quick–change applicators. Applicator setup
personnel and those responsible for production
scheduling should find this of particular value—
especially in operations where miniature
quick–change applicators are used in both
semi–automatic (bench) and automatic machines.
Dimensions in this instruction sheet are in
millimeters [with inches in brackets].
CONVERSION
PART SEMI-AUTOMATIC (BENCH) MACHINE AUTOMATIC MACHINE
With 41.3-mm [15/8-in.] Stroke
Stripper
(Side Feed)
Fixed Floating
Shaft Collar 22292-2
Pin 464661-1
Feed and Eject Sides of Machine
690472-2
Stripper
(End Feed)
Thick
Spacer
Note:
Thicker stripper spacer required
for semi-automatic machine.
Note:
Different stripper spacer requirement than
bench machine (thinner or none).
Thin
Spacer Wire Drops
Straight Down
(End Feed)
Note:
Same thick spacer as bench machine.
Wire is Moved
Straight Down
Thick
Spacer
Terminal
FdC
Machine with 28.6-mm [11/8-in.] Stroke
Pre Feed
Mini 690602-2
HD Mini 690602-5
Post Feed
Mini 690501-1
HD Mini 690501-3
Long Post Feed
Mini 238015-1
HD Mini 690501-4
Feed Cam
(Also See Figure 2) Machine with 41.3-mm [15/8-in.] Stroke
Long Pre Feed
Mini 690602-6
HD Mini 690602-6
Long Post Feed
Mini 238015-1
HD Mini 690501-4
Strip Guide
Cover Plate Not Used Eject Side of Machine
(Side Feed Only) 454877-[ ]
Front Chip Guard
Sometimes Used on Semi-Automatic and Automatic Machines (Side Feed Only)
691667-[ ]
Figure 1
NOTE
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408-8053
Miniature (Mini) Quick-Change Applicators
Rev
G2
of 3 Tyco Electronics Corporation
The question that most frequently arises is:
“If l have a bench machine applicator for Terminal ‘A,’
can l use that applicator to apply that terminal in one
of my automatic machines (and vice versa)?” The
answer is: “Yes . . . BUT only after obtaining and
interchanging the parts required for conversion.”
Reasons for reissue of this instruction sheet are
provided in Section 4, REVISION SUMMARY.
2. DESCRIPTION
Basic differences (typically) between automatic and
semi–automatic applicator versions are illustrated in
Figure 1. Several typical strippers are shown to
indicate that there is quite a difference in side feed
stripper requirements between semi–automatic and
automatic terminating equipment. Note that the end
feed stripper spacer requirement normally differs as
well. Figure 1 also indicates that the machines in
which the applicators are used have different stroke
lengths, and therefore the applicators require different
cams. These are the parts normally involved when a
conversion is made.
To convert an applicator (or applicators), contact your
local representative, and provide the following
information:
Convert APPLICATOR NO. ____________________
for TERMINAL NO. ___________________________
TERMINAL FEED CAM
PRE FEED POST FEED LONG POST FEED
Operation
The terminal is fed over the anvil on
the upstroke of the ram. A terminal is
in position
before
the operator places
the wire into the target area.
The terminal is fed over the anvil on
the downstroke of the ram. There is
no terminal in position over the anvil
until
after
the operator places the wire
in the target area and depresses the
foot switch.
The terminal is fed over the anvil on
the downstroke of the ram. There is
no terminal in position until
after
the
machine places the wire in the target
area and activates the terminating
machine.
Application
The pre-feed cam is used in
semi-automatic application tooling.
This cam can be used with all
side-feed mini applicators, and with
end-feed applicators using wire size
26 AWG or smaller.
The post-feed cam is used in
semi-automatic application tooling.
This cam can be used with all
end-feed mini applicators,
except
those using wire size 26 AWG or
smaller.
The long post-feed cam is used in
automatic application tooling. This
cams is used in all end-feed and
side-feed mini applicators.
Advantage
The pre-feed cam is used with
end-feed mini applicators when
running wire size 26 AWG or smaller.
With small wire, the applicator wire
stop cannot be used for wire
positioning, and the terminal must be
used for wire placement. The
pre-feed cam must be used on all
side-feed applicators.
Use of the post-feed cam with
end-feed mini applicators tends to
eliminate terminal jamsĊincreasing
production.
The post-feed cam is not used with
side-feed mini applicators for bench
applications.
The long post-feed cam must be
used because of the automatic
placement of wire into the applicator.
In addition, this cam is used to
accommodate the longer stroke of the
terminating machine.
Disadvantage
Using the pre-feed cam in end-feed
mini applicators can cause terminal
jams. In addition, production is
decreased because of the need for
the operator to lay the wire in the
terminal. There are no disadvantages
when using the pre-feed cam with
side-feed applicators.
When using the post-feed cam with
end-feed applicators, running small
wire can be a problem. The operator
cannot feel the wire stop. There are
no disadvantages to using the
post-feed cam with end-feed
applicators when running wire size
24 AWG or larger.
The post-feed cam is not used with
side-feed mini applicators for bench
applications.
None
Figure 2
408-8053
Miniature (Mini) Quick-Change Applicators
3
of 3Rev
G
Tyco Electronics Corporation
3. CONVERSION
3.1. To Semi-Automatic (Bench) Machines
With a 41.3-mm [15/8-in.] Stroke
— Applicator guards designed for semi–automatic
(bench) machines are not required for machines
with a 41.3–mm [15/8–in.] stroke. Unless otherwise
specified, Guard Insert 679532–1 can be used.
— Air–feed applicators require Fitting 23238–1 to
properly connect to the air line.
— Quick–Exhaust Valve 22374–7 is required, and
should replace any valve, if the present valve
length or width exceeds 51 mm [2 in.].
— Some applicators may require rotation of the air
feed cylinder end cap by 90
_
to avoid interference
with the drive motor.
— The air feed valve is not required. The air feed
assembly has a flow control valve on the
normally–open port to control the air flow into the
air cylinder. The four–way air feed valve can be
used to control double–acting cylinders.
3.2. To Automatic Machines
With a 41.3-mm [15/8-in.] Stroke
— Applicator guards designed for automatic
machines are not required for machines with a
41.3–mm [15/8–in.] stroke. Unless otherwise
specified, Guard Insert 904291–1 can be used.
— Quick–Exhaust Valve 22374–7 may be required,
and should replace any valve, if the present valve
length or width exceeds 51 mm [2 in.].
— Air–feed applicators require Air Feed Kit
904890–1.
4. REVISION SUMMARY
Revisions to this instruction sheet include:
S
Replaced specific machine names with
semi–automatic and automatic
