408-10390

Rev M1

9 of 18

5. ADJUSTMENTS

5.1. Wire Crimp Adjustment

1. Select an increment number from 0 (largest crimp height) to 150 (smallest crimp height) from the data

plate for the wire size to be used. Each increment represents a change in crimp height of 0.01 mm

[.0004 in.].

2. Turn the wire crimp height adjustment disc clockwise to decrease the crimp height and turn the wire

crimp disc counterclockwise to increase the crimp height.

3. Turn the wire crimp disc to line up with the specified increment number with the indicator notch/cut out

on the front of the ram. This provides the right crimp height for that wire (see Figure 8).

Figure 8

4. 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.

— If the terminations appear normal, measure the crimp height of each termination as described in

instruction sheet 408-7424, packaged with the applicator. The crimp height must agree with the

measurement specified on the applicator log for the wire size being used. Record crimp height

dimensions for reference.

— If the crimp height is incorrect, remove the applicator, and install one that is known to produce

terminations of correct crimp height. Make several test cycles and repeat the inspection. If the

crimp height is incorrect for this applicator, the problem is the machine shut height, and corrective

information can be found in the appropriate machine manual. If the crimp height is correct, the

problem is in the original applicator, and refer to paragraph 6.6, Adjustable Crimp Height Repair,

for corrective measures.

5. During extensive operation, periodically inspection the terminals as described in step 4 to make sure

that the applicator is producing correct terminations.

5.2. Insulation Crimp Adjustment

The insulation crimp is adjustable in increments of 0.19 mm [.0075 in.] by pulling the insulation crimp dial out

(refer to Figure 4) and turning it to line up with the number (1 through 18) so that it is shown at the indicator

notch on the ram: No. 1 makes the loosest crimp and No. 18 makes the tightest crimp. The total range of

adjustment is approximately 3.30 mm [.130 in.]. To find the desired insulation crimp, start with No. 1, make test

crimps, then increase the setting one number at a time until the proper insulation crimp height is achieved.

NOTE

Some applicators may have a special insulation adjustment dial that differs in range and increments than described. Refer to

the marking on the front of the insulation crimp dial for correct increments.

Indicator Notch/Cut Out

Insulation Crimp Dial

Wire Crimp Disc