All roll dies have stamped on their flat sides the normal size of the cable with which they are designed to be used.
Select the matched pair of roll dies marked with the normal size of the cable on which you wish to swage a straight shank terminal. Install the roll dies on the shaft of the machine so that the word "UPPER" stamped on the flat side of the roll die on the upper shaft, and the word "LOWER" stamped on the flat side of the roll die on the lower shaft are visible as shown below. This is necessary in order to be sure that the grooves in the working faces of the two roll dies are properly lined up with one another.
The single key in the shafts and keyways in the roll dies will automatically position the two roll dies in the proper index relationship to each other. When the keys and keyways are lined up, push the roll dies all the way onto the shafts and secure them with the special flat washer and socket head bolts shown in Figure 1. Do not use tools to force the roll dies onto the shafts. This should not be necessary.
Figure 1 FEED GUIDE
The function of this component of the Type II Swaging Machine is to hold the cable and terminal in the proper position relative to the roll dies at the start of the swaging operation. It guides the movement of the cable toward the roll dies during the operation. It is a steel bar that slides in a slot in the roll side frame of the machine. It carries a spring clip that engages the cable, a socket engages the head of the terminal, and a screw-adjusted stop. This stop is used when the operator wishes to swage a run of several identical cable and terminal combinations. It enables the customer to set the feed guide carrying the cable and terminal at the same location relative to the roll dies each time the operator starts a new swaging operation. The adjustable stop is simply a 3/8 x 16 screw threaded into the crossbar. A knurled capstan nut is welded to the outboard end of the screw to serve as a convenient handle. A second knurled capstan nut is threaded onto the screw and bears on the crossbar to lock the screw in position. The inboard end on the screw strikes on the machine frame to stop the motion of the feed guide at the point of the swaging operation.
The feed guide assembly is shown, installed in the machine in Figure 2. To Remove feed assembly from the machine, detach the spring clip from the right hand end of the bar and slip the bar to the left until it comes out of the slot in the machine frame. (The spring clip is detached by removing the two Allen head screws on the back of the bar.) The socket at the left hand end of the bar is designed to accept terminal heads for cables larger than 3/16" diameter. With terminal heads for cable 3/16" and smaller, the auxiliary adapter (Figure 2) must be used. To install the adapter, use an Allen wrench to back out the 1/4" bolt located at the bottom of the socket. (This bolt holds the adjustable stop crossbar and cylindrical spacer to the socket.) [Note: The outer hole in the crossbar is tapped 1/4"x 20, while the inner hole is drilled 1/4" and is not threaded.] Pass the 1/4" x 28 hex head bolt through the inner hole of the crossbar, the cylindrical spacer, and the bottom of the original feed guide socket and screw it into the auxiliary adapter.
It is essential that the cable and the terminal you select to swage onto it are both the same size. Check the cable diameter with a micrometer and, using the gauge (included in the kit Figure 3) check the outside diameter of the terminal shank to be sure it corresponds to the size of the cable. Complete dimensional data on cable and terminals that can be assembled successfully by the LOCOLOC®-Kearney Type II Swaging Machine are specified in the operator's manual.
Push the cable into the fitting until the end of the cable reaches the bottom of the bore. Mark the cable at point (A) as shown in Figure 4.
Place the cable beside the fitting shank and have mark (A) placed flush with the bottom of the shank. Mark the shank at point (B) using the end of the cable as shown in Figure 5.
Place the cable next to the mark (B) and mark the shank at point (C) as shown in Figure 6. (one cable diameter)
Push the cable back into the fitting until mark (A) is flush with the bottom of the shank again. Start your swaging at mark (C) on the shank as shown in Figure 7 .
Insert the cable to approximately half the depth of the bore and holding the cable close to the end of the terminal, bend it sharply enough to set a bend into the cable as shown in Figure 7 . This is to help ensure that the terminal will not move on the cable while they are being inserted in the swaging machine. On Fork Shank Terminals sizes 1/16 to 5/16, push the cable into the terminal until the end of the cable reaches the end of the bore. Pull the cable back 1/8" to 1/4"short of the end of the bore. The cable-terminal assembly is now ready to be swaged. Support cable from back of swage to help eliminate the shank from bending from the curve in hanging cable
The operating lever of the Type II Swaging Machine is similar to a large conventional ratchet wrench. A handle is attached to the outer end by a bolt to form a crank. To reverse the direction of the rotation of the roll dies flip the ratchet lever at the base of the handle then disengage the internal reverse latch of the machine by pulling and holding out the wire loop that extends from the right side of the machine behind and above the Feed Guide.
When swaging the larger size terminals, more leverage is needed to operate the machine, remove the crank handle and slip the handle extension (part no. 84-80) over the end of the operating lever to double its length. The motor of the power-driven machine is reversible simply by reversing the throw of the hand switch. To cause the machine to turn the roll die in the normal direction for swaging - upper roll die clockwise -flip the hand switch lever to forward position and press the foot switch; to reverse flip the hand switch lever to the reverse position and press down on the foot switch. Be careful to allow the drive motor to come to a full stop before switching directions. (The internal reverse latch is not installed in the power-driven machines.) With either machine, rotate the roll dies until their clearance arcs are opposite as shown in Figure 1. Place the assembled cable and terminal in the clearance space with the head of the terminal engaged with the terminal adapter as shown in Figure 10. Press the cable into the spring clip on the right hand end of the feed guide. Inch the roll die around until they are just touching, but not squeezing the terminal shank. Move the Feed Guide to the right until the roll dies are contacting at the proper location on the terminal shank to be swaged. As noted above in preparing the cable and terminal, if you are about to swage a number of identical cable-terminal assemblies, set the adjustable stop of the Feed Guide Assembly, as discussed in Feed Guide Assembly, so that you can repeatedly move the Feed Guide to this position relative to the dies.
Rotate the roll dies until they have passed over the terminal shank. When the first pass has been completed, a longitudinal fin or "flash" on two diametrically opposite sides of the terminal will be noticeable on the swaged portion of the shank. To eliminate the longitudinal fin, rotate the terminal 90 degrees from the first swaging position and pass it through the rolls as outlined in preceding instructions. After the second pass the terminal shank will appear smooth and round .
Finished sleeve should look like this. Be sure sleeves have been compressed the proper number of times
Measure the diameter of the terminal shank with the gauge. The shank should now slide through the slot from one end of the swaged portion of the other except for the slight flash which will be left after the second pass. The diameter over flash should not exceed the shank diameter after swaging by more than 0.010 inch. The gauge is made to pass a terminal which has been reduced to the proper diameter as specified in applicable MS drawings except over flash. If the terminal has not been sufficiently reduced, an additional pass may be necessary to reduce it to the required diameter. Rotate the terminal 45 degrees for the 3rd pass to make the terminal more uniform.
Over-swaging will only cause work hardening, or may lead to embrittlement which may induce terminal cracking. For this reason, we advise that you never use more than four passes. If four passes are required on any job, and after the fourth pass the diameter on the sleeve has not been reduced to the proper size, survey the equipment and recheck instructions in order to determine what is causing the problem.