User’s Manual: WERI Mini Applicator
User’s Manual This document is only valid on the date of printing: 2016-10-26 Page 1 of 15 WERI Mini Applicator Table of Content 1 Document revision history ............................................................................. 2 2 Important warnings ......................................................................................... 3 3 Symbols ........................................................................................................... 4 4 Identification ...............
User’s Manual This document is only valid on the date of printing: 2016-10-26 Page 2 of 15 WERI Mini Applicator 1 Document revision history Rev. Page 1.0 1.1 All 13 Change Description Creation Recommended grease Issued by Checked by Date BBu BBu JC / CH FAEs 2016-05-17 2016-10-26 I:\Specs\eiCan\WERI\ConTOOLC\Datasheet\User's Manual_WERI Mini Applicator.
User’s Manual This document is only valid on the date of printing: 2016-10-26 Page 3 of 15 WERI Mini Applicator 2 Important warnings Verify the press shut height setting by means of a shut height gauge: 135.8 mm at bottom dead center. Verify that the press and the mini applicator’s axis are perfectly in line. Set the top ring of the continuous adjusting head in accordance with the data on the identification plate.
User’s Manual This document is only valid on the date of printing: 2016-10-26 Page 4 of 15 WERI Mini Applicator 3 Symbols WARNING: this symbol identifies any portion of this manual that should be carefully read and understood. STOP: this symbol identifies all the situations where the operator is supposed to stop and proceed to the suggested checks before resuming the operation. Ignoring it would mean causing damages to the equipment.
User’s Manual This document is only valid on the date of printing: 2016-10-26 Page 5 of 15 WERI Mini Applicator 4 Identification TER.: terminal part number. MOD.: mini applicator part number. AWG: cross-sectional area of wire conductor (American Wire Gauge). INDEX: position of the top adjusting ring in order to obtain the corresponding conductor crimping height (CHR). CHR: conductor crimping height. The mini applicator serial number is to be found on its core body. 5 Technical data Shut height: 135.
User’s Manual This document is only valid on the date of printing: 2016-10-26 Page 6 of 15 WERI Mini Applicator 6 Installation (trained operator) 6.1 Installing the mini applicator inside the press Make sure to turn off the press before performing the following steps. Mini applicators are delivered with a rubber spacer inserted between the continuous adjusting head and the body for protection during transportation. Remove it when installing the applicator.
User’s Manual This document is only valid on the date of printing: 2016-10-26 6.2 Page 7 of 15 WERI Mini Applicator Inserting the terminals into the mini applicator With reference to the identification plate, position the top ring of the continuous adjusting head according to the settings related to the maximum wire cross section allowed.
User’s Manual This document is only valid on the date of printing: 2016-10-26 Page 8 of 15 WERI Mini Applicator If, while manually cycling the press, something obstructs the movement, stop immediately and make sure that: - the mini applicator is correctly mated to the press; - the press is correctly set at the standard 135.8 mm shut height; - the adjusting rings are not set too low (too small crimping height).
User’s Manual This document is only valid on the date of printing: 2016-10-26 Page 9 of 15 WERI Mini Applicator 7 Adjustments Any adjustment must be performed after having made sure that the press is turned off. 7.1 Crimping heights (trained operator) Both A (top) and B (bottom) adjusting rings must be set with reference to the C mark. 7.1.1 Conductor crimping height The A adjusting ring has a setting range of 2.7 mm with a resolution of 0.01 mm, and an INDEX of 1.40 corresponds to 14 on the ring.
User’s Manual This document is only valid on the date of printing: 2016-10-26 7.2 Page 10 of 15 WERI Mini Applicator Feeding (qualified technician only) For adapting the pawl B to the pitch of the terminals, in order to have a new terminal correctly placed on the anvil for each cycle of the press: loosen the nut A and move the screw up for a greater pitch or down for a shorter one. Then tighten the nut again.
User’s Manual This document is only valid on the date of printing: 2016-10-26 7.3 Page 11 of 15 WERI Mini Applicator Crimping axis (qualified technician only) This adjustment serves to perfectly align the terminal on the anvils and punches axis. Manually cycle the press by means of a spanner until the terminal is positioned on the anvil. Loosen the nut A and turn the screw clockwise or counter-clockwise to determine the correct position.
User’s Manual This document is only valid on the date of printing: 2016-10-26 Page 12 of 15 WERI Mini Applicator 8 Stroke setting (qualified technician only) The mini applicator is mounted by default with a 40 mm stroke, but it can be lowered to 30 mm by changing the cam position. The cam for feeding the terminal in "pre-feed” or “manual” configuration is attached to the rear edge of the mini applicator. By default, the mounted cam is the “post-feed” or “automatic” one.
User’s Manual This document is only valid on the date of printing: 2016-10-26 Page 13 of 15 WERI Mini Applicator 9 Maintenance (trained operator) 9.1 Cleaning and lubrication The mini applicator must be cleaned and lubricated every time it is removed from the press or every 8 working hours. Suggested lubricating grease: DIN 51502 KP 2 K-30. Remove the mini applicator from the press. Remove the ram from the mini applicator. Using a clean cloth, remove any grease or contamination from the ram.
User’s Manual This document is only valid on the date of printing: 2016-10-26 Page 14 of 15 WERI Mini Applicator 10 Troubleshooting Problem Cause The mini applicator is not The mating surfaces are not correctly mated to the press’ clean and smooth baseplate The mini applicator is not correctly centered under the press While cycling manually the The press has not been set press with the spanner, to the correct shut height of something is blocking and 135.
User’s Manual This document is only valid on the date of printing: 2016-10-26 Problem The crimping acceptable WERI Mini Applicator Cause is Page 15 of 15 Solution not The crimping height is wrong Make sure the adjusting head is correctly set with reference to the applicator plate and check the crimping height obtained The terminal is not correctly Verify the correct positioning positioned with reference to of the terminal over the anvil the anvils and punches axis and, if needed, adjust Anvils and / o
