DCM00044 REV. 14 71
7.1.3.2 Ultrasonic Stack Assembly
1. Clean Horn, Converter, Booster and diaphragm surfaces with solvent to remove all contaminants
and previously used paste.
2. Apply an even, light coat of Molykote G-n paste (about equal in size to half a paper match head)
to the mating surfaces of the Converter, Booster and Horn. Do NOT apply paste to threaded
opening or to stud threads or to diaphragm. Do NOT use silicone grease.
3. Place the Rear Diaphragm Spring (Item 3 – 0.500” diameter center hole) and Clamp Ring (Item
1) onto the studded end of the Booster (Item 7). Then thread the Booster into the Converter. Be
careful to center the Diaphragm Spring on the Booster and then torque Booster and Converter to
55 ft/lbs (74.6 N-m) using two spanner wrenches. Do not clamp on the Converter.
4. Slide the Booster/Converter subassembly in through the rear of the Polar Shell. Assemble the
twelve M5 SHCS’s to fasten in an alternating pattern the Clamp Ring to the rear of the Polar
Shell.
5. Place a Clamp Ring and the Front Diaphragm Spring (Item 2 – 0.750" diameter center hole) onto
the studded end of the Horn (Item 6). Then thread the Horn into the Booster. Assemble the
twelve M5 SHCS’s to fasten in an alternating pattern the Clamp Ring to the front of the Polar
Shell. Be careful to center the Diaphragm Spring on the Horn and then torque Booster and Horn
to 80 ft/lbs (108.5 N-m).
6. Replace the Tip and loosely thread on the Tip Nut. (applicable to replaceable Tip Horns only) The
Tip (or Horn blade) will have to be made square and parallel to the Anvil prior to welding.
7.1.3.3 Reconditioning Tip and Nut Clamping Surfaces (Replaceable Tip Horns Only)
After prolonged use, burrs may form on the clamping surfaces of the tooling. These burrs
may be removed from the Tip and Tip Nut by polishing with 600 grit emery paper placed
on a flat surface. With light pressure, polish the clamp faces in a Figure 7.3
pattern.
The burrs on the horn clamping surface must be removed by machining back the Horn
clamp surface. The least amount of material should be removed, but in no case should
more than .020” be removed. The undercut at this clamping surface must also be re-cut
NOTICE
See Figure 7.2 for item listings.
CAUTION General Warning
Do not operate ultrasonics while the tip is loose.
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