a1 revisions 0 plc 1 plc 2 plc 3 plc 4 plc angles 00779 of scale sheet rev name size cage code drawing no dimensions: tolerances unless otherwise specified: dwn chk apvd material finish product spec application spec weight p ltr date apvd dwn description loc dist 5 6 7 8 3 4 2 1 d b a a b c c d by tyco electronics corporation. all rights reserved. released for publication c copyright this drawing is unpublished. amp 4805 rev 31mar2000 restricted to this drawing is a controlled document for tyco electronics corporation it is subject to change and the controlling engineering organization should be contacted for the latest revision. 1 2 4 6 7 8 13 14 9 10 11 12 13 customer accessible production drawing te connectivity harrisburg, pa 17105-3608 2151968 bob higman 24may2013 g.bailey 24may2013 m.clifford 24may2013 1:2 1 4 b1 - - - - - mm - 0.5 0.13 0.013 0.0001 - a 66 ocean side feed applicator - - 20 - - 20 b ecr-15-002668 17feb2015 rk gb b1 ecr-16-000025 04jan2016 jh ct item no description part no -1 -2 -5 -6 -7 -77 1 - 1 2-1633738-0 crimper, wire 2-1633738-0 1 1 1 1 1 1 2 - 1 455888-4 spacer, crimper 455888-4 1 1 1 1 1 - 3 - 1 3-1633962-6 crimper, insulation f premium 3-1633962-6 1 1 1 1 1 1 4 - 1 238011-7 block, crimper spacer 238011-7 1 1 1 1 1 - 5 - 1 1-2119780-1 depressor, shear 1-2119780-1 1 1 1 1 1 - 6 .. 1 item_6 - - - - - - - - 7 - 1 3-240641-0 spacer 3-240641-0 1 1 1 1 1 - 8 - 1 1803056-1 anvil, combination 1803056-1 1 1 1 1 1 1 9 - 1 1803095-1 floating shear, front 1803095-1 1 1 1 1 1 - 10 - 1 2119805-1 shear holder, front 2119805-1 1 1 1 1 1 - 11 - 1 1-356885-4 stop, shear 1-356885-4 1 1 1 1 1 - 12 - 1 simp_3-22280-3 spring, compression 3-22280-3 1 1 1 1 1 - 13 - 1 2119806 insert, shear 2119806-1 1 1 1 1 1 - 19 - 1 2119533 stripper, side feed 2119533-1 1 1 1 1 1 - 20 - 1 1-18028-2 washer, flat, reg m4 1-18028-2 1 1 1 1 1 - 21 - 1 2168083-2 scr, skt hd cap, rohs, m4 x 8.0 2168083-2 1 1 1 1 1 - 24 - 1 1320928-2 strip guide 1320928-2 1 1 1 1 1 - 28 - 1 455888-3 spacer, crimper 455888-3 1 1 1 1 1 - 29 - 1 2119959-1 assembly, strip guide 2119959-1 1 1 1 1 1 - 30 - 1 1320908-6 spacer, strip guide 1320908-6 1 1 1 1 1 - 32 - 1 2161328 hex head, flanged, m5 x 8mm long 2161328-1 1 1 1 1 1 - 33 - 2 2079383-5 scr, bhsc, rohs (m4 x 20) 2079383-5 2 2 2 2 2 - 34 - 1 1752356-9 support, terminal 1752356-9 1 1 1 1 1 - 35 - 1 2119092-1 bolt, adjustment 2119092-1 1 1 1 - 1 - 37 - 1 2119085 fa head, atlantic style 2119085-1 1 1 1 1 1 - 38 - 1 2119644-1 ram washer, precision 2119644-1 1 1 1 1 1 - 39 - 1 2119957-1 applicator shim pack 2119957-1 1 1 1 - 1 - 40 - 1 2119645 disc, numbered fa wire adjustment 2119645-1 1 1 1 - 1 - 41 - 1 2079383-7 scr, bhsc, rohs (m8 x 25) 2079383-7 1 1 1 1 1 - 44 - 1 2119370 ram, amp style, side feed 2119370-1 1 1 1 - 1 - 46 - 1 2119656-9 applicator basic assembly, sf 2119656-9 1 1 1 1 1 - 47 - 1 2119653 feed cam, post feed 2119653-1 1 - - - - - 48 - 1 2119652 feed cam, pre feed 2119652-1 1 - - - - - 49 - 3 18023-9 scr, skt hd cap m4 x 6.0 18023-9 2 1 - - - - 50 - 1 690753-2 spacer, tonker 690753-2 1 1 1 1 1 - 51 - 1 811242-5_old bumper, hold down 811242-5 1 1 1 1 1 - 52 - 1 5018030-1 nut, hex, reg, rohs, m3 5018030-1 1 1 1 1 1 - 53 - 2 2168083-8 scr, skt hd cap, rohs, m4 x 16 2168083-8 2 2 2 2 2 - 54 - 4 2168400-1 shcs, low head, rohs, m4 x 12 2168400-1 4 4 4 4 4 - 56 - 1 1338685-1 pawl, feed 1338685-1 1 1 - - - - 58 - 1 21028-2 pin, slotted spring .062 x .250 21028-2 1 1 1 1 1 - 59 - 1 5-18022-5 scr, hex hd cap, m4 x 6.0 5-18022-5 1 1 - - - - 60 - 1 2079383-4 scr, bhsc, rohs (m4 x 8) 2079383-4 1 1 1 1 1 - 62 - 3 992763-5 scr, set, soc, cone point, m3 x 4.0 992763-5 3 3 3 - 3 - 63 - 1 2119793 limiter, adjustment bolt 2119793-1 1 1 1 - 1 - 66 - 2 2168078-1 screw, drive, rh, rohs, 2 x .188 2168078-1 2 2 2 2 2 - 67 - 1 2119740-1 tag,identification 2119740-1 1 1 - - 1 - 71 - 1 2119956-1 documentation package 2119956-1 1 1 1 1 1 - 74 - 1 854769-4 holder, ins 854769-4 1 1 1 1 1 - 77 - 1 simp_5-547505-2 spring, compression 5-547505-2 1 1 1 1 1 - 82 - 1 455888-4 spacer, crimper 455888-4 1 1 1 1 1 - 117 - 1 2119944-1 feed finger assembly,sf 2119944-1 - - ref ref - - 119 - 1 1-18028-2 washer, flat, reg m4 1-18028-2 1 1 1 1 1 - 133 .. 1 1633743-1 servo feed latch asm 1633743-1 - - 1 1 - - 135 - 1 1901689_empty_ocean_sf memory chip, programmed see note 4 - - ref ref - - 136 - 1 2119799 holder,feed finger, af 2119799-1 - 1 - - - - 137 - 1 3-23627-7 pin, retain, grvd, 3/16 x .854 3-23627-7 - 1 - - - - 163 - 1 240638 spring, feed finger 240638-1 - 1 - - - - 164 - 1 counter_994970 counter, magnetic 994970-2 ref ref ref ref ref - 166 - 1 994969-1_gatd magnet, rare earth high energy 994969-1 1 1 1 1 1 - 172 - 2 21045-3 ring, retain, extern, 3/16 crescent 21045-3 - 2 - - - - 198 .. 1 1901094-3 spacer, feeder 1901094-3 - - 1 1 - - 213 - 1 2119740-2 tag,identification 2119740-2 - - 1 1 - - 238 - 1 2063440-1 air feed module 2063440-1 - 1 - - - - 239 - 1 2119580-1 mechanical feed assembly 2119580-1 1 - - - - - 240 - 2 2168400-6 shcs, low head, rohs, m5 x 16 2168400-6 - - 2 2 - - 241 - 1 7-18023-7 scr, skt hd cap m3 x 4.0 7-18023-7 1 1 1 1 1 - 242 - 1 2119083 retainer, insulation dial 2119083-1 1 1 1 1 1 - 243 - 1 2079764 washer, wave spring, crest-to-crest 2079764-1 1 1 1 1 1 - 244 - 1 2119082-3 cam, snail, insulation adjustment 2119082-3 1 1 1 1 1 - 245 - 1 2119758 ram, amp style, side feed, non-adj. 2119758-1 - - - 1 - - 246 - 1 1-22279-3_simp spring, compression 1-22279-3 1 1 1 - 1 - 247 - 1 2119798-1 detent pin 2119798-1 1 1 1 - 1 - item no description part no -1 -2 -5 -6 -7 -77 248 - 1 2119641-1 feed cam, air feed 2119641-1 - 1 - - - - 249 - 1 2079988_gatd bushing, lch5-12, misumi 2079988-1 - 1 - - - - 250 - 1 2119640-1 push rod, air feed 2119640-1 - 1 - - - - 252 - 1 8-21084-0_gatd o-ring, .676 id, .070 dia. mat. 8-21084-0 1 1 1 - 1 - 260 - 1 2119957-2 applicator shim pack 2119957-2 - - - 1 - - atlantic version terminator interface adapter part number revision description feed type applicator style conversion chart convert to part numbers required 2151968 -1 b fine crimp height adjust mechanical pneumatic feed 2119950-1 1338685-1 5-18022-5 2119641-1 2119799-1 2063440-1 servo latch plate 2119951-1 - 8- 2151968 -5 1901094-3 1-1752354-7 2168400-6 (quantity 2) smart applicator 2161326-1 - 8- 2151968 -4 - - - 2151968 -2 b fine crimp height adjust pneumatic mechanical feed 2119949-1 1338685-1 5-18022-5 2119653-1 - - servo latch plate 2119951-1 - 8- 2151968 -5 1901094-3 1-1752354-7 2168400-6 (quantity 2) smart applicator 2161326-1 - 8- 2151968 -4 - - - 2151968 -5 b fine crimp height adjust servo latch plate mechanical feed 2119949-1 1338685-1 5-18022-5 2119653-1 - - pneumatic feed 2119950-1 1338685-1 5-18022-5 2119641-1 2119799-1 2063440-1 2151968 -6 b non-crimp height adjust servo latch plate - - - - - - - - - - - - - - 2151968 -7 b fine crimp height adjust none - - - - - - - 7- 2151968 -7 a crimp tooling kit - - - - - - - - wire size crimp height mm [inch] 0.8 or 18 w1__dwg_wgauge_1 1.020+/-0.050 [.0400+/-.0020] w1__dwg_crimp_ht_1 0.5 or 20 w1__dwg_wgauge_2 0.995+/-0.045 [.0390+/-.0020] w1__dwg_crimp_ht_2 0.35 or 22 w1__dwg_wgauge_3 0.895+/-0.045 [.0350+/-.0020] w1__dwg_crimp_ht_3 0.2 or 24 w1__dwg_wgauge_4 0.830+/-0.040 [.0325+/-.0015] w1__dwg_crimp_ht_4 applicator data crimp size type wire 1.60 mm [.063] f insul 2.00 mm [.079] f applicator instructions 408-10389 terminal data: te terminal molex crimp specification terminal name: amp mcp 2.8k flat type receptacle wire strip length insulation diameter range .171-.186 in [4.34-4.72 mm] n .120-.125 in [3.05-3.18 mm] terminal application specification - - - - - - terminals applied te terminal c3__dwg_pn_1_0 te terminal c3__dwg_pn_2_0 te terminal c3__dwg_pn_3_0 te seal c3__dwg_pn_4_0 67890-1 (c) c3__dwg_pn_1_1 67890-3 (c) c3__dwg_pn_2_1 67890-5 (c) c3__dwg_pn_3_1 67890-7 (c) c3__dwg_pn_4_1 67890-2 (c) c3__dwg_pn_1_2 67890-4 (c) c3__dwg_pn_2_2 67890-6 (c) c3__dwg_pn_3_2 67890-8 (c) c3__dwg_pn_4_2 wire size crimp height mm [inch] crimp height reference setting 7.1 w1__fa_setting_1 7.1 w1__fa_setting_2 8.6 w1__fa_setting_3 9.2 w1__fa_setting_4 crimp height reference setting crimp height reference setting 7.1 w2__fa_setting_1 7.1 w2__fa_setting_2 wire size crimp height mm [inch] 0.8 or 18 w2__dwg_wgauge_1 1.020+/-0.050 [.0400+/-.0020] w2__dwg_crimp_ht_1 0.5 or 20 w2__dwg_wgauge_2 0.995+/-0.045 [.0390+/-.0020] w2__dwg_crimp_ht_2 terminal data: molex terminal molex crimp specification terminal name: mini fit jr overall tin crimp terminal wire strip length insulation diameter range 3.00-3.50 mm [.118-.138 in] n 1.40-1.70 mm [.055-.067 in] terminal application specification molex 63902-3900 rev b - - - - - terminals applied te terminal c2__dwg_pn_1_0 molex terminal c2__dwg_pn_2_0 te terminal c2__dwg_pn_3_0 molex terminal c2__dwg_pn_4_0 2113022-1 c2__dwg_pn_1_1 45750-1211 c2__dwg_pn_2_1 1-2113022-0 c2__dwg_pn_3_1 46083-1121 c2__dwg_pn_4_1 2113022-2 c2__dwg_pn_1_2 45750-1111 c2__dwg_pn_2_2 1-2113022-1 c2__dwg_pn_3_2 46083-1211 c2__dwg_pn_4_2 2113022-3 c2__dwg_pn_1_3 46012-1111 c2__dwg_pn_2_3 1-2113022-2 c2__dwg_pn_3_3 46083-1221 c2__dwg_pn_4_3 2113022-4 c2__dwg_pn_1_4 46018-1541 c2__dwg_pn_2_4 1-2113022-3 c2__dwg_pn_3_4 46134-1111 c2__dwg_pn_4_4 2113022-5 c2__dwg_pn_1_5 46083-1111 c2__dwg_pn_2_5 1-2113022-4 c2__dwg_pn_3_5 46134-1121 c2__dwg_pn_4_5 2113022-6 c2__dwg_pn_1_6 46098-1541 c2__dwg_pn_2_6 286603-9 c2__dwg_pn_3_6 44476-1111 c2__dwg_pn_4_6 2113022-7 c2__dwg_pn_1_7 46012-1141 c2__dwg_pn_2_7 2-286603-7 c2__dwg_pn_3_7 44476-1211 c2__dwg_pn_4_7 2113022-8 c2__dwg_pn_1_8 46012-1211 c2__dwg_pn_2_8 286611-7 c2__dwg_pn_3_8 44478-1111 c2__dwg_pn_4_8 2113022-9 c2__dwg_pn_1_9 46012-1241 c2__dwg_pn_2_9 1-286611-9 c2__dwg_pn_3_9 44478-1211 c2__dwg_pn_4_9 1-2113022-5 46134-1211 1-2113022-6 46134-1221 set up gauge 2119599-1 atlantic version shown on sheets 1 of 4 & 2 of 4 (pacific version shown on sheets 3 of 4 & 4 of 4) applicator data crimp size type wire 1.60 mm [.063] f insul - - applicator instructions 408-10389 atlantic version terminator interface adapter part number revision description feed type applicator style conversion chart convert to part numbers required 2151968 -2 1 fine crimp height adjust pneumatic - - - - - - - servo latch plate 2119951-1 - 8- 2151968 -5 1901094-3 1-1752354-7 2168400-6 (quantity 2) smart applicator 2161326-1 - 8- 2151968 -4 - - - 2151968 -5 1 fine crimp height adjust servo latch plate - - - - - - - pneumatic feed 2119950-1 1338685-1 5-18022-5 2119641-1 2119799-1 2063440-1 2151968 -6 1 non-crimp height adjust servo latch plate - - - - - - - - - - - - - - 2151968 -7 1 fine crimp height adjust none - - - - - - - 7- 2151968 -7 1 crimp tooling kit - - - - - - - - terminal data: molex terminal molex crimp specification terminal name: mini fit jr overall tin crimp terminal wire strip length insulation diameter range 3.00-3.50 mm [.118-.138 in] n 1.40-1.70 mm [.055-.067 in] terminal application specification molex 63902-3900 rev b terminals applied te terminal c1__dwg_pn_1_0 molex terminal c1__dwg_pn_2_0 te terminal c1__dwg_pn_3_0 molex terminal c1__dwg_pn_4_0 286603-1 c1__dwg_pn_1_1 39-00-0038 c1__dwg_pn_2_1 286611-1 c1__dwg_pn_3_1 39-00-0040 c1__dwg_pn_4_1 286603-2 c1__dwg_pn_1_2 39-00-0055 c1__dwg_pn_2_2 286611-2 c1__dwg_pn_3_2 39-00-0061 c1__dwg_pn_4_2 286603-3 c1__dwg_pn_1_3 39-00-0207 c1__dwg_pn_2_3 286611-3 c1__dwg_pn_3_3 39-00-0053 c1__dwg_pn_4_3 286603-4 c1__dwg_pn_1_4 39-00-0163 c1__dwg_pn_2_4 286611-4 c1__dwg_pn_3_4 39-00-0120 c1__dwg_pn_4_4 286603-5 c1__dwg_pn_1_5 39-00-0059 c1__dwg_pn_2_5 286611-5 c1__dwg_pn_3_5 39-00-0126 c1__dwg_pn_4_5 286603-6 c1__dwg_pn_1_6 39-00-0153 c1__dwg_pn_2_6 286611-6 c1__dwg_pn_3_6 39-00-0219 c1__dwg_pn_4_6 286603-7 c1__dwg_pn_1_7 39-00-0181 c1__dwg_pn_2_7 286611-9 c1__dwg_pn_3_7 39-00-0430 c1__dwg_pn_4_7 286603-8 c1__dwg_pn_1_8 39-00-0213 c1__dwg_pn_2_8 1-286611-1 c1__dwg_pn_3_8 39-00-0121 c1__dwg_pn_4_8 1-286603-1 c1__dwg_pn_1_9 39-00-0114 c1__dwg_pn_2_9 1-286611-2 c1__dwg_pn_3_9 39-00-0420 c1__dwg_pn_4_9 1-286603-2 c1__dwg_pn_1_10 39-00-0428 c1__dwg_pn_2_10 1-286611-3 c1__dwg_pn_3_10 39-00-0437 c1__dwg_pn_4_10 1-286603-3 c1__dwg_pn_1_11 39-00-0419 c1__dwg_pn_2_11 1-286611-4 c1__dwg_pn_3_11 39-00-0426 c1__dwg_pn_4_11 1-286603-4 c1__dwg_pn_1_12 39-00-0425 c1__dwg_pn_2_12 1-286611-6 c1__dwg_pn_3_12 39-00-0075 c1__dwg_pn_4_12 1-286603-5 39-00-0436 1-286611-7 39-00-0427 1-286603-6 39-00-0440 1-286611-8 40-13-0853 1-286603-7 39-00-0073 2-286611-0 30490-1002 1-286603-8 39-00-0108 2-286611-1 30490-2002 1-286603-9 39-00-0169 2-286611-2 40-01-0853 2-286603-0 39-00-0175 2-286611-3 98-00-0174 2-286603-1 39-00-0194 2-286611-4 30490-0002 2-286603-2 39-00-0200 2-286603-3 39-00-0405 2-286603-4 39-00-0407 2-286603-5 39-00-0410 2-286603-6 40-13-0851 2-286603-7 44485-1211 2-286603-8 44485-1311 2-286603-9 44485-1411 recommended spare parts grease bearing surfaces lightly 3. lubricate daily per the applicator instruction sheet supplied with the applicator. applicator specific data to be entered into blank memory chip at assembly. see below for part number: mechanical feed with "smart applicator" conversion: 8- 2151968 -4 pneumatic feed with "smart applicator" conversion: 8- 2151968 -4 servo feed with "fine crimp height adjust": 8- 2151968 -5 servo feed with "non-crimp height adjust": 8- 2151968 -6 5. adjustment of the stripper may be required when moving the applicator between bench and leadmaker applications. apply part number 1-23419-5 loctite to threads of item 62. apply part number 2-23419-6 loctite to threads of item 242. for -6 only apply part number 1-23419-5 loctite to threads of item 37. grease threads, groove and o-ring on items 35 & 252. magnet, item 166 must be oriented correctly in order to properly actuate the counter. this applicator applies terminal with a seal. apply torq-seal in allen socket to fill hole after flat hd has been adjusted to correct height at qualification. apply #1-23419-5 loc-tite to threads. *warning on installation, set wire disc, item 40 to largest wire size setting. use of settings below minimum required crimp height setting will cause damage to crimp tooling. cut to length at assembly. this applicator has been designed to apply wires with thin wall (flr) insulation. this applicator has been designed to apply wires with thin wall (flr) insulation. the insulation crimp & applicable insulation range may not conform to parameters listed in the application specification. insulation rangle quoted is that of the terminal. the seal insulation range is #- # [# - # in.] insulation crimp may not conform to that stated in relevant application specification. feed adjustments may be required when switching terminals. sheets 3 & 4 are not required for atlantic version recommended spare parts grease bearing surfaces lightly 3. lubricate daily per the applicator instruction sheet supplied with the applicator. applicator specific data to be entered into blank memory chip at assembly. see below for part number: pneumatic feed with "smart applicator" conversion: 8- 2151968 -4 servo feed with "fine crimp height adjust": 8- 2151968 -5 servo feed with "non-crimp height adjust": 8- 2151968 -6 5. adjustment of the stripper may be required when moving the applicator between bench and leadmaker applications. apply part number 1-23419-5 loctite to threads of items 62, 180 & 242. for -6 only apply part number 1-23419-5 loctite to threads of items 37, 180 & 242. grease threads, groove and o-ring on items 35 & 252. magnet, item 166 must be oriented correctly in order to properly actuate the counter. crimp height reference setting was the setting used when the applicator was qualified at the factory. adjustment may be necessary when running applicator in the field. terminal pitch not compatible with mechanical feed. to convert the applicator to a non-carrier cutting style, remove item 13 and attach to the location on the back side of the housing. refer to instruction sheet for additional information. when assembling a non crimp height adjust applicator (-6) use shims from item 260 to achieve a nominal shim height of 4.78 . crimp height reference setting was the setting used when the applicator was qualified at the factory. adjustment may be necessary when running applicator in the field. spare feed cam storage location refer to instruction sheet for additional information. to convert the applicator to a non-carrier cutting style, remove item 13 and attach to the location on the back side of the housing. refer to instruction sheet for additional information. when assembling a non crimp height adjust applicator (-6) use shims from item 260 to achieve a nominal shim height of 4.78 . cut to length at assembly. 1 1 1 1 1 1 1 2 4 6 7 8 9 10 11 12 1 1 1 1 1 4 4 12 1 9 9 9 10 6 6 6 13
a1 revisions 0 plc 1 plc 2 plc 3 plc 4 plc angles 00779 of scale sheet rev name size cage code drawing no dimensions: tolerances unless otherwise specified: dwn chk apvd material finish product spec application spec weight p ltr date apvd dwn description loc dist 5 6 7 8 3 4 2 1 d b a a b c c d by tyco electronics corporation. all rights reserved. released for publication c copyright this drawing is unpublished. amp 4805 rev 31mar2000 restricted to this drawing is a controlled document for tyco electronics corporation it is subject to change and the controlling engineering organization should be contacted for the latest revision. - see sheet 1 - - - customer accessible production drawing te connectivity harrisburg, pa 17105-3608 2151968 bob higman 28may2013 g.bailey 28may2013 m.clifford 28may2013 1:2 2 4 b1 - - - - - mm - 0.5 0.13 0.013 0.0001 - a 66 ocean side feed applicator - - 20 - - 20 a pneumatic 4.3 0.5 atlantic version shown on sheets 1 of 4 & 2 of 4 (pacific version shown on sheets 3 of 4 & 4 of 4) 4 35 40 37 24 38 242 33 60 41 54 21 28 2 82 30 19 34 67 32 243 244 46 10 241 11 63 3 53 50 44 247 13 12 52 7 74 58 77 5 66 62 246 245 213 1 8 51 20 166 29 252 39 260 54 164 a 119 9 terminal support location 34 8 ref ref 29 30 ref ref feed track position guide by insulation barrel item 30 located at front holes 47 49 feed type 48 49 49 248 239 250 249 238 136 137 163 172 135 240 133 198 117 ref cam positions sheets 3 & 4 are not required for atlantic version cam position 59 56 59 56 11 2 2 2 2 8 2 7 7 2 10 1 1 1 1 1 11 6 6 6 mechanical post feed 30mm stroke 40mm stroke mechanical pre feed 30mm stroke 40mm stroke air feed 30mm stroke 40mm stroke mechanical a 4 2 servo latch plate a servo feeder not included 13
a1 revisions 0 plc 1 plc 2 plc 3 plc 4 plc angles 00779 of scale sheet rev name size cage code drawing no dimensions: tolerances unless otherwise specified: dwn chk apvd material finish product spec application spec weight p ltr date apvd dwn description loc dist 5 6 7 8 3 4 2 1 d b a a b c c d by tyco electronics corporation. all rights reserved. released for publication c copyright this drawing is unpublished. amp 4805 rev 31mar2000 restricted to this drawing is a controlled document for tyco electronics corporation it is subject to change and the controlling engineering organization should be contacted for the latest revision. 6 7 8 12 13 9 10 11 12 - see sheet 1 - - - customer accessible production drawing te connectivity harrisburg, pa 17105-3608 2151968 bob higman 28may2013 g.bailey 28may2013 m.clifford 28may2013 1:2 3 4 b1 - - - - - mm - 0.5 0.13 0.013 0.0001 - a 66 ocean side feed applicator - - 20 - - 20 set up gauge 2119599-1 applicator data crimp size type wire 1.60 mm [.063] f insul 2.00 mm [.079] f applicator instructions 408-10389 terminal data: molex terminal molex crimp specification terminal name: mini fit jr overall tin crimp terminal wire strip length insulation diameter range 3.00-3.50 mm [.118-.138 in] n 1.40-1.70 mm [.055-.067 in] terminal application specification molex 63902-3900 rev b - - - - - terminals applied te terminal c1__dwg_pn_1_0 molex terminal c1__dwg_pn_2_0 te terminal c1__dwg_pn_3_0 molex terminal c1__dwg_pn_4_0 286603-1 c1__dwg_pn_1_1 39-00-0038 c1__dwg_pn_2_1 286611-1 c1__dwg_pn_3_1 39-00-0040 c1__dwg_pn_4_1 286603-2 c1__dwg_pn_1_2 39-00-0055 c1__dwg_pn_2_2 286611-2 c1__dwg_pn_3_2 39-00-0061 c1__dwg_pn_4_2 286603-3 c1__dwg_pn_1_3 39-00-0207 c1__dwg_pn_2_3 286611-3 c1__dwg_pn_3_3 39-00-0053 c1__dwg_pn_4_3 286603-4 c1__dwg_pn_1_4 39-00-0163 c1__dwg_pn_2_4 286611-4 c1__dwg_pn_3_4 39-00-0120 c1__dwg_pn_4_4 286603-5 c1__dwg_pn_1_5 39-00-0059 c1__dwg_pn_2_5 286611-5 c1__dwg_pn_3_5 39-00-0126 c1__dwg_pn_4_5 286603-6 c1__dwg_pn_1_6 39-00-0153 c1__dwg_pn_2_6 286611-6 c1__dwg_pn_3_6 39-00-0219 c1__dwg_pn_4_6 286603-7 c1__dwg_pn_1_7 39-00-0181 c1__dwg_pn_2_7 286611-9 c1__dwg_pn_3_7 39-00-0430 c1__dwg_pn_4_7 286603-8 c1__dwg_pn_1_8 39-00-0213 c1__dwg_pn_2_8 1-286611-1 c1__dwg_pn_3_8 39-00-0121 c1__dwg_pn_4_8 1-286603-1 c1__dwg_pn_1_9 39-00-0114 c1__dwg_pn_2_9 1-286611-2 c1__dwg_pn_3_9 39-00-0420 c1__dwg_pn_4_9 1-286603-2 c1__dwg_pn_1_10 39-00-0428 c1__dwg_pn_2_10 1-286611-3 c1__dwg_pn_3_10 39-00-0437 c1__dwg_pn_4_10 1-286603-3 c1__dwg_pn_1_11 39-00-0419 c1__dwg_pn_2_11 1-286611-4 c1__dwg_pn_3_11 39-00-0426 c1__dwg_pn_4_11 1-286603-4 c1__dwg_pn_1_12 39-00-0425 c1__dwg_pn_2_12 1-286611-6 c1__dwg_pn_3_12 39-00-0075 c1__dwg_pn_4_12 1-286603-5 39-00-0436 1-286611-7 39-00-0427 1-286603-6 39-00-0440 1-286611-8 40-13-0853 1-286603-7 39-00-0073 2-286611-0 30490-1002 1-286603-8 39-00-0108 2-286611-1 30490-2002 1-286603-9 39-00-0169 2-286611-2 40-01-0853 2-286603-0 39-00-0175 2-286611-3 98-00-0174 2-286603-1 39-00-0194 2-286611-4 30490-0002 2-286603-2 39-00-0200 2-286603-3 39-00-0405 2-286603-4 39-00-0407 2-286603-5 39-00-0410 2-286603-6 40-13-0851 2-286603-7 44485-1211 2-286603-8 44485-1311 2-286603-9 44485-1411 wire size crimp height mm [inch] 0.8 or 18 w1__dwg_wgauge_1 1.020+/-0.050 [.0400+/-.0020] w1__dwg_crimp_ht_1 0.5 or 20 w1__dwg_wgauge_2 0.995+/-0.045 [.0390+/-.0020] w1__dwg_crimp_ht_2 0.35 or 22 w1__dwg_wgauge_3 0.895+/-0.045 [.0350+/-.0020] w1__dwg_crimp_ht_3 0.2 or 24 w1__dwg_wgauge_4 0.830+/-0.040 [.0325+/-.0015] w1__dwg_crimp_ht_4 crimp height reference setting 7.1 w1__fa_setting_1 7.1 w1__fa_setting_2 8.6 w1__fa_setting_3 9.2 w1__fa_setting_4 terminal data: molex terminal molex crimp specification terminal name: mini fit jr overall tin crimp terminal wire strip length insulation diameter range 3.00-3.50 mm [.118-.138 in] n 1.40-1.70 mm [.055-.067 in] terminal application specification molex 63902-3900 rev b - - - - - terminals applied te terminal c2__dwg_pn_1_0 molex terminal c2__dwg_pn_2_0 te terminal c2__dwg_pn_3_0 molex terminal c2__dwg_pn_4_0 2113022-1 c2__dwg_pn_1_1 45750-1211 c2__dwg_pn_2_1 1-2113022-0 c2__dwg_pn_3_1 46083-1121 c2__dwg_pn_4_1 2113022-2 c2__dwg_pn_1_2 45750-1111 c2__dwg_pn_2_2 1-2113022-1 c2__dwg_pn_3_2 46083-1211 c2__dwg_pn_4_2 2113022-3 c2__dwg_pn_1_3 46012-1111 c2__dwg_pn_2_3 1-2113022-2 c2__dwg_pn_3_3 46083-1221 c2__dwg_pn_4_3 2113022-4 c2__dwg_pn_1_4 46018-1541 c2__dwg_pn_2_4 1-2113022-3 c2__dwg_pn_3_4 46134-1111 c2__dwg_pn_4_4 2113022-5 c2__dwg_pn_1_5 46083-1111 c2__dwg_pn_2_5 1-2113022-4 c2__dwg_pn_3_5 46134-1121 c2__dwg_pn_4_5 2113022-6 c2__dwg_pn_1_6 46098-1541 c2__dwg_pn_2_6 286603-9 c2__dwg_pn_3_6 44476-1111 c2__dwg_pn_4_6 2113022-7 c2__dwg_pn_1_7 46012-1141 c2__dwg_pn_2_7 2-286603-7 c2__dwg_pn_3_7 44476-1211 c2__dwg_pn_4_7 2113022-8 c2__dwg_pn_1_8 46012-1211 c2__dwg_pn_2_8 286611-7 c2__dwg_pn_3_8 44478-1111 c2__dwg_pn_4_8 2113022-9 c2__dwg_pn_1_9 46012-1241 c2__dwg_pn_2_9 1-286611-9 c2__dwg_pn_3_9 44478-1211 c2__dwg_pn_4_9 1-2113022-5 46134-1211 1-2113022-6 46134-1221 wire size crimp height mm [inch] 0.8 or 18 w2__dwg_wgauge_1 1.020+/-0.050 [.0400+/-.0020] w2__dwg_crimp_ht_1 0.5 or 20 w2__dwg_wgauge_2 0.995+/-0.045 [.0390+/-.0020] w2__dwg_crimp_ht_2 crimp height reference setting 7.1 w2__fa_setting_1 7.1 w2__fa_setting_2 terminal data: te terminal molex crimp specification terminal name: amp mcp 2.8k flat type receptacle wire strip length insulation diameter range .171-.186 in [4.34-4.72 mm] n .120-.125 in [3.05-3.18 mm] terminal application specification - - - - - - terminals applied te terminal c3__dwg_pn_1_0 te terminal c3__dwg_pn_2_0 te terminal c3__dwg_pn_3_0 te seal c3__dwg_pn_4_0 67890-1 (c) c3__dwg_pn_1_1 67890-3 (c) c3__dwg_pn_2_1 67890-5 (c) c3__dwg_pn_3_1 67890-7 (c) c3__dwg_pn_4_1 67890-2 (c) c3__dwg_pn_1_2 67890-4 (c) c3__dwg_pn_2_2 67890-6 (c) c3__dwg_pn_3_2 67890-8 (c) c3__dwg_pn_4_2 wire size crimp height mm [inch] crimp height reference setting pacific version shown on sheets 3 of 4 & 4 of 4 (atlantic version shown on sheets 1 of 4 & 2 of 4) item no description part no -21 -22 -25 -27 -77 1 - 1 2-1633738-0 crimper, wire 2-1633738-0 1 1 1 1 1 2 - 1 455888-4 spacer, crimper 455888-4 1 1 1 1 - 3 - 1 3-1633962-6 crimper, insulation f premium 3-1633962-6 1 1 1 1 1 4 - 1 238011-7 block, crimper spacer 238011-7 1 1 1 1 - 5 - 1 1-2119780-1 depressor, shear 1-2119780-1 1 1 1 1 - 6 .. 1 item_6 - - - - - - - 7 - 1 3-240641-0 spacer 3-240641-0 1 1 1 1 - 8 - 1 1803056-1 anvil, combination 1803056-1 1 1 1 1 1 9 - 1 1803095-1 floating shear, front 1803095-1 1 1 1 1 - 10 - 1 2119805-1 shear holder, front 2119805-1 1 1 1 1 - 11 - 1 1-356885-4 stop, shear 1-356885-4 1 1 1 1 - 12 - 1 simp_3-22280-3 spring, compression 3-22280-3 1 1 1 1 - 13 - 1 2119806 insert, shear 2119806-1 1 1 1 1 - 19 - 1 2119533 stripper, side feed 2119533-1 1 1 1 1 - 20 - 1 1-18028-2 washer, flat, reg m4 1-18028-2 1 1 1 1 - 21 - 1 2168083-2 scr, skt hd cap, rohs, m4 x 8.0 2168083-2 1 1 1 1 - 24 - 1 1320928-2 strip guide 1320928-2 1 1 1 1 - 28 - 1 455888-3 spacer, crimper 455888-3 1 1 1 1 - 29 - 1 2119959-1 assembly, strip guide 2119959-1 1 1 1 1 - 30 - 1 1320908-6 spacer, strip guide 1320908-6 1 1 1 1 - 32 - 1 2161328 hex head, flanged, m5 x 8mm long 2161328-1 1 1 1 1 - 33 - 2 2079383-5 scr, bhsc, rohs (m4 x 20) 2079383-5 2 2 2 2 - 34 - 1 1752356-9 support, terminal 1752356-9 1 1 1 1 - 38 - 1 2119644-1 ram washer, precision 2119644-1 1 1 1 1 - 39 - 1 2119957-1 applicator shim pack 2119957-1 1 1 1 1 - 40 - 1 2119645 disc, numbered fa wire adjustment 2119645-1 1 1 1 1 - 41 - 1 2079383-7 scr, bhsc, rohs (m8 x 25) 2079383-7 1 1 1 1 - 48 - 1 2119652 feed cam, pre feed 2119652-1 1 - - - - 49 - 3 18023-9 scr, skt hd cap m4 x 6.0 18023-9 2 1 - - - 50 - 1 690753-2 spacer, tonker 690753-2 1 1 1 1 - 51 - 1 811242-5_old bumper, hold down 811242-5 1 1 1 1 - 52 - 1 5018030-1 nut, hex, reg, rohs, m3 5018030-1 1 1 1 1 - 53 - 2 2168083-8 scr, skt hd cap, rohs, m4 x 16 2168083-8 2 2 2 2 - 56 - 1 1338685-1 pawl, feed 1338685-1 1 1 - - - 58 - 1 21028-2 pin, slotted spring .062 x .250 21028-2 1 1 1 1 - 59 - 1 5-18022-5 scr, hex hd cap, m4 x 6.0 5-18022-5 1 1 - - - 62 - 3 992763-5 scr, set, soc, cone point, m3 x 4.0 992763-5 3 3 3 3 - 63 - 1 2119793 limiter, adjustment bolt 2119793-1 1 1 1 1 - 66 - 2 2168078-1 screw, drive, rh, rohs, 2 x .188 2168078-1 2 2 2 2 - 67 - 1 2119740-1 tag,identification 2119740-1 1 1 - 1 - 71 - 1 2119956-1 documentation package 2119956-1 1 1 1 1 - 74 - 1 854769-4 holder, ins 854769-4 1 1 1 1 - 77 - 1 simp_5-547505-2 spring, compression 5-547505-2 1 1 1 1 - 82 - 1 455888-4 spacer, crimper 455888-4 1 1 1 1 - 117 - 1 2119944-1 feed finger assembly,sf 2119944-1 - - ref - - 119 - 1 1-18028-2 washer, flat, reg m4 1-18028-2 1 1 1 1 - 133 .. 1 1633743-1 servo feed latch asm 1633743-1 - - 1 - - 135 - 1 1901689_empty_ocean_sf memory chip, programmed see note 4 - - ref - - 136 - 1 2119799 holder,feed finger, af 2119799-1 - 1 - - - 137 - 1 3-23627-7 pin, retain, grvd, 3/16 x .854 3-23627-7 - 1 - - - 139 - 1 2119092-2 bolt, adjustment 2119092-2 1 1 1 1 - 140 - 1 2119650 ram, asian style, side feed 2119650-1 1 1 1 1 - 141 - 1 1-2119656-0 applicator basic assembly, sf 1-2119656-0 1 1 1 1 - 142 - 1 2119653-2 feed cam, post feed 2119653-2 1 - - - - 143 - 4 2168400-5 shcs, low head, rohs, m4 x 20 2168400-5 4 4 4 4 - 144 - 1 2079383-8 scr, bhsc, rohs (m4 x 16) 2079383-8 1 1 1 1 - 145 - 1 2119798-2 detent pin 2119798-2 1 1 1 1 - 151 - 1 2119641-2 feed cam, air feed 2119641-2 - 1 - - - 152 - 1 8-21084-1_gatd o-ring, .801 id, .070 dia. mat. 8-21084-1 1 1 1 1 - 163 - 1 240638 spring, feed finger 240638-1 - 1 - - - 164 - 1 counter_994970 counter, magnetic 994970-2 ref ref ref ref - 166 - 1 994969-1_gatd magnet, rare earth high energy 994969-1 1 1 1 1 - 172 - 2 21045-3 ring, retain, extern, 3/16 crescent 21045-3 - 2 - - - 198 .. 1 1901094-3 spacer, feeder 1901094-3 - - 1 - - 213 - 1 2119740-2 tag,identification 2119740-2 - - 1 - - 238 - 1 2063440-1 air feed module 2063440-1 - 1 - - - 239 - 1 2119580-1 mechanical feed assembly 2119580-1 1 - - - - 240 - 2 2168400-6 shcs, low head, rohs, m5 x 16 2168400-6 - - 2 - - 241 - 1 7-18023-7 scr, skt hd cap m3 x 4.0 7-18023-7 1 1 1 1 - 242 - 1 2119083 retainer, insulation dial 2119083-1 1 1 1 1 - 243 - 1 2079764 washer, wave spring, crest-to-crest 2079764-1 1 1 1 1 - 244 - 1 2119082-3 cam, snail, insulation adjustment 2119082-3 1 1 1 1 - 246 - 1 1-22279-3_simp spring, compression 1-22279-3 1 1 1 1 - item no description part no -21 -22 -25 -27 -77 249 - 1 2079988_gatd bushing, lch5-12, misumi 2079988-1 - 1 - - - 250 - 1 2119640-1 push rod, air feed 2119640-1 - 1 - - - 251 - 1 2119782 fine adjust head asm, pacific style 2119782-1 1 1 1 1 - pacific version terminator interface adapter part number revision description feed type applicator style conversion chart convert to part numbers required 2- 2151968 -1 b fine crimp height adjust mechanical pneumatic feed 2119950-1 1338685-1 5-18022-5 2119641-2 2119799-1 2063440-1 servo latch plate 2119951-1 - 8- 2151968 -5 1901094-3 1-1752354-7 2168400-6 (quantity 2) smart applicator 2161326-1 - 8- 2151968 -4 - - - 2- 2151968 -2 b fine crimp height adjust pneumatic mechanical feed 2119949-1 1338685-1 5-18022-5 2119653-2 - - servo latch plate 2119951-1 - 8- 2151968 -5 1901094-3 1-1752354-7 2168400-6 (quantity 2) smart applicator 2161326-1 - 8- 2151968 -4 - - - 2- 2151968 -5 b fine crimp height adjust servo latch plate mechanical feed 2119949-1 1338685-1 5-18022-5 2119653-2 - - pneumatic feed 2119950-1 1338685-1 5-18022-5 2119641-2 2119799-1 2063440-1 2- 2151968 -7 b fine crimp height adjust none - - - - - - - 7- 2151968 -7 a crimp tooling kit - - - - - - - - applicator data crimp size type wire 1.60 mm [.063] f insul - - applicator instructions 408-10389 pacific version terminator interface adapter part number revision description feed type applicator style conversion chart convert to part numbers required 2- 2151968 -2 1 fine crimp height adjust pneumatic - - - - - - - servo latch plate 2119951-1 - 8- 2151968 -5 1901094-3 1-1752354-7 2168400-6 (quantity 2) smart applicator 2161326-1 - 8- 2151968 -4 - - - 2- 2151968 -5 1 fine crimp height adjust servo latch plate - - - - - - - pneumatic feed 2119950-1 1338685-1 5-18022-5 2119641-2 2119799-1 2063440-1 2- 2151968 -7 1 fine crimp height adjust none - - - - - - - 7- 2151968 -7 1 crimp tooling kit - - - - - - - - recommended spare parts grease bearing surfaces lightly 3. lubricate daily per the applicator instruction sheet supplied with the applicator. applicator specific data to be entered into blank memory chip at assembly. see below for part number: mechanical feed with "smart applicator" conversion: 8- 2151968 -4 pneumatic feed with "smart applicator" conversion: 8- 2151968 -4 servo feed with "fine crimp height adjust": 8- 2151968 -5 5. adjustment of the stripper may be required when moving the applicator between bench and leadmaker applications. apply part number 1-23419-5 loctite to threads of item 62. apply part number 2-23419-6 loctite to threads of item 242. grease threads, groove and o-ring on items 139 & 152. magnet must be oriented correctly in order to properly actuate the counter. this applicator applies terminal with a seal. apply torq-seal in allen socket to fill hole after flat hd has been adjusted to correct height at qualification. apply #1-23419-5 loc-tite to threads. *warning on installation, set wire disc, item 40 to largest wire size setting. use of settings below minimum required crimp height setting will cause damage to crimp tooling. cut to length at assembly. this applicator has been designed to apply wires with thin wall (flr) insulation. this applicator has been designed to apply wires with thin wall (flr) insulation. the insulation crimp & applicable insulation range may not conform to parameters listed in the application specification. insulation rangle quoted is that of the terminal. the seal insulation range is #- # [# - # in.] insulation crimp may not conform to that stated in relevant application specification. feed adjustments may be required when switching terminals. sheets 1 & 2 are not required for pacific version recommended spare parts grease bearing surfaces lightly 3. lubricate daily per the applicator instruction sheet supplied with the applicator. applicator specific data to be entered into blank memory chip at assembly. see below for part number: pneumatic feed with "smart applicator" conversion: 8- 2151968 -4 servo feed with "fine crimp height adjust": 8- 2151968 -5 5. adjustment of the stripper may be required when moving the applicator between bench and leadmaker applications. apply part number 1-23419-5 loctite to threads of items 62, 180 & 242. grease threads, groove and o-ring on items 139 & 152. magnet must be oriented correctly in order to properly actuate the counter. crimp height reference setting was the setting used when the applicator was qualified at the factory. adjustment may be necessary when running applicator in the field. terminal pitch not compatible with mechanical feed. to convert the applicator to a non-carrier cutting style, remove item 13 and attach to the location on back side of the housing. refer to instruction sheet for additional information. crimp height reference setting was the setting used when the applicator was qualified at the factory. adjustment may be necessary when running applicator in the field. spare feed cam storage location refer to instruction sheet for additional information. to convert the applicator to a non-carrier cutting style, remove item 13 and attach to the location on back side of the housing. refer to instruction sheet for additional information. cut to length at assembly. 1 2 4 1 1 1 1 1 1 1 2 4 6 7 8 9 10 11 9 9 9 1 1 1 1 1 1 4 10 6 6 12
a1 revisions 0 plc 1 plc 2 plc 3 plc 4 plc angles 00779 of scale sheet rev name size cage code drawing no dimensions: tolerances unless otherwise specified: dwn chk apvd material finish product spec application spec weight p ltr date apvd dwn description loc dist 5 6 7 8 3 4 2 1 d b a a b c c d by tyco electronics corporation. all rights reserved. released for publication c copyright this drawing is unpublished. amp 4805 rev 31mar2000 restricted to this drawing is a controlled document for tyco electronics corporation it is subject to change and the controlling engineering organization should be contacted for the latest revision. - see sheet 1 - - - customer accessible production drawing te connectivity harrisburg, pa 17105-3608 2151968 bob higman 28may2013 g.bailey 28may2013 m.clifford 28may2013 1:2 4 4 b1 - - - - - mm - 0.5 0.13 0.013 0.0001 - a 66 ocean side feed applicator - - 20 - - 20 a pneumatic 4.3 0.5 pacific version shown on sheets 3 of 4 & 4 of 4 (atlantic version shown on sheets 1 of 4 & 2 of 4) 142 49 feed type 48 49 49 151 239 250 249 238 136 137 163 172 135 240 133 198 117 ref cam positions sheets 1 & 2 are not required for pacific version cam position 1 2 3 4 5 7 8 10 11 12 13 19 20 21 24 28 29 30 32 33 34 139 38 39 40 41 140 141 50 51 52 53 143 58 144 62 63 66 67 74 77 82 166 213 241 242 243 244 246 145 251 152 143 164 a 119 9 feed track position guide by insulation barrel item 30 located at front holes 29 30 ref ref ref ref terminal support location 34 8 56 59 59 56 mechanical a 4 2 servo latch plate a servo feeder not included mechanical post feed 30mm stroke mechanical pre feed 30mm stroke 30mm stroke air feed 12 7 7 8 2 2 2 2 2 11 10 1 1 1 1 1 11 6 6
|
