Etco IP-Mini Instruction Manual

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Old Values, New Ideas

Instruction Manual

IP-Mini Rear Feed Applicator

Thank you for purchasing
an ETCO product!

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should still be the rule.

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The founders of ETCO had very basic values based on integrity.
Today we still live by those values. Please feel free to call us if
you have a question;
I promise you a human will answer.

David Dunn

Chairman

ETCO Incorporated, Tel: [phone] Fax: [phone] Web: www.etco.com

Instruction
Manual

ETCO IP-Mini
Rear Feed
Applicator

INSTALL AND SET-UP INSTRUCTIONS

CRIMP INSPECTION AND MEASUREMENT

MAINTENANCE SCHEDULES

TROUBLESHOOTING GUIDES

ASSEMBLY DRAWING and BILL OF MATERIALS

See pocket on the inside back cover of this manual.

TO CONTACT ETCO TECHNICAL SUPPORT.

TEL: [phone]
FAX: [phone]
EMAIL: [email protected]
WEB: www.etco.com

Hours 8 am – 5 pm, Monday – Friday, Eastern US Time Zone

ETCO IP Mini Rear Feed Rev. 2

2

4

3

1

4

5

1

ALWAYS REMEMBER TO REPLACE

BOTH PRESS SAFETY GUARD AND

APPLICATOR SAFETY GUARD

BEFORE OPERATING PRESS.

(NOTE: THIS ALSO ACTIVATES

SAFETY INTERLOCK SYSTEM.)

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11

SECTION 1

INSTALL AND SET-UP INSTRUCTIONS

ETCO IP MINI REAR FEED APPLICATOR – page 1

BEFORE INSTALLING APPLICATOR

1 Remove press Safety Guard.

Clean base plate on press.

2 Be sure press has Mini Die

Adapter Base Plate connected.

3 Be sure press has T-Slot

Connector installed.

Note: Contact

ETCO if Base Plate

or

T- Slot Connector are not

installed on your press.

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SECTION 1

UNPACK, INSTALL AND SET-UP INSTRUCTIONS

ETCO IP MINI REAR FEED APPLICATOR – page 2

1

BEFORE INSTALLING APPLICATOR
CONTINUED

4 Using wrench on crankshaft

end, rotate crankshaft clockwise
to bottom dead center.

5 Measure shut height from

surface of Mini Die Adapter
Base Plate to pads on T-Slot
Connector. Shut height should
measure

5.346”.

6 If necessary, adjust shut height

by loosening the TWO locking
nuts (a, c) and rotating the ram
adjustment bolt (b) until proper
dimension is achieved.
Retighten the TWO locking
nuts.

Note: Turning ram adjustment bolt

(b) to the right will lower, and
turning it to the left will raise,
the shut height.

a
b
c

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SECTION 1

INSTALL AND SET-UP INSTRUCTIONS

ETCO IP MINI REAR FEED APPLICATOR – page 3

INSTALL APPLICATOR

7 Using wrench on crankshaft

end, rotate crankshaft clockwise
to top dead center.

8 Adjust position of Reel Arm

and Stock Chute.

9 Loosen Clamp Knob by

rotating counterclockwise.

1

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11

INSTALL APPLICATOR CONTINUED

10 Remove applicator Safety Guard.

11 Slide Mounting Post on

Applicator into T-Slot from
left side of press.

12 With Mounting Post fully engaged

into T-Slot, pull Applicator body
down until Applicator Base Plate
is flat against Mini Die Adapter
Base Plate

SECTION 1

INSTALL AND SET-UP INSTRUCTIONS

ETCO IP MINI REAR FEED APPLICATOR – page 4

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1

INSTALL APPLICATOR CONTINUED

13 Slide Applicator left until

Applicator Base Plate is
fully engaged in clamps.

14 Tighten right clamp by rotating

knob clockwise.

15 Using wrench on crankshaft,

cycle over by hand, one complete
revolution.

SECTION 1

INSTALL AND SET-UP INSTRUCTIONS

ETCO IP MINI REAR FEED APPLICATOR – page 5

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11

INSTALL APPLICATOR CONTINUED

16 Tag shows ETCO recommended

Wire Settings (top dial letters).
Adjust Insulation Dial (bottom
dial numbers) according to your
insulation thickness.

Note: The dial settings are also

located on the back of each
applicator.

17 Load reel of terminals onto

arbor of reel arm and install
locking collar. Remove inside
clamp for traverse wind.

18 Lift Brake Shoe on Applicator

by rotating Arm 90 degrees
clockwise or counterclockwise.

SECTION 1

INSTALL AND SET-UP INSTRUCTIONS

ETCO IP MINI REAR FEED APPLICATOR – page 6

PLACE TAG HERE.

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11

INSTALL APPLICATOR CONTINUED

19 Thread terminals around Stock

Chute and into Feed Plate.

20 Push strip of terminals through

Feed Plate until crimp ears are
just short of cut off die edge.

21 Lower Brake Shoe by returning

Arm to 6 o’clock position.

SECTION 1

INSTALL AND SET-UP INSTRUCTIONS

ETCO IP MINI REAR FEED APPLICATOR – page 7

ALWAYS REMEMBER TO REPLACE

BOTH PRESS SAFETY GUARD AND

APPLICATOR SAFETY GUARD

BEFORE OPERATING PRESS.

(NOTE: THIS ALSO ACTIVATES

SAFETY INTERLOCK SYSTEM.)

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11

INSTALL APPLICATOR CONTINUED

22 Replace Applicator

Safety Guard.

23 Replace Press

Safety Guard.

(Note: This also activates
Safety Interlock System.)

SECTION 1

INSTALL AND SET-UP INSTRUCTIONS

ETCO IP MINI REAR FEED APPLICATOR – page 8

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11

INSTALL APPLICATOR CONTINUED

24 Rotate Power Switch to

ON position and then press
RESET button.

Note: You must press RESET button

each time you turn on the press.

25 Press yellow JOG button until

press makes ONE complete
revolution. While press is
jogging, observe Applicator for
proper functions – part feeding,
crimping, cut-off, etc.

26 Insert wire over anvil just

touching cut-off pad. Depress
foot pedal once to cycle press
under power.

Note: Repeat steps 25 and 26,

three to six times.
– Inspect sample terminations
for proper crimping and cut-off.

SECTION 1

INSTALL AND SET-UP INSTRUCTIONS

ETCO IP MINI REAR FEED APPLICATOR – page 9

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1

AIR ATTACHMENT

27 Attach all air tubing to their

corresponding numbers.

Connect Mead Pilot Valve
(

T-connection) to your air

supply using 1/4” tubing.

Adjust air pressure to 80-90 lbs.

Should air lines become
disconnected, match
number marked on airlines
with corresponding number
on air fittings.

PRESS AND APPLICATOR ARE
NOW READY FOR PRODUCTION

SECTION 1

INSTALL AND SET-UP INSTRUCTIONS

ETCO IP MINI REAR FEED APPLICATOR – page 11

2

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SECTION 2

CRIMP INSPECTION AND MEASUREMENT

ETCO MX MINI REAR FEED APPLICATOR - page 1

CRIMP INSPECTION

1 Wire strands should protrude a minimum of 1/64” from

the end of the crimp.

2 Bellmouth should be clearly visible.

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SECTION 2

CRIMP INSPECTION AND MEASUREMENT

ETCO MX MINI REAR FEED APPLICATOR - page 2

2

3 Crimp should be of an acceptable configuration.

UNACCEPTABLE TERMINATION

4 All wire strands must be captured in the crimp ears during

termination. Stray wire strands are not acceptable.

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SECTION 2

CRIMP INSPECTION AND MEASUREMENT

ETCO MX MINI REAR FEED APPLICATOR - page 3

2

5 Wire insulation must not be caught in the wire crimp

ears, this will result in a poor electrical connection.

MEASURING CRIMP HEIGHT

6 Crimp height must be measured with the spindle and

anvil, of a micrometer, centered against the bottom and
the top of the crimp respectively and between the ribs on
the bottom of the crimp, if applicable.

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SECTION 2

CRIMP INSPECTION AND MEASUREMENT

ETCO MX MINI REAR FEED APPLICATOR - page 4

7 Measure crimp height as shown.

TERMINAL CROSS-SECTION

8 Cross-sections shall be made between ribs on crimp form.

2

USE ONLY ETCO TOOLINGUSE ONLY ETCO TOOLING

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SECTION 2

CRIMP INSPECTION AND MEASUREMENT

ETCO MX MINI REAR FEED APPLICATOR - page 5

2

TERMINAL CRIMP CRITERIA

9 • All wire strands should be enveloped by the crimp wings.

• All wire strands should be uniformly deformed and evenly
distributed on both sides of the crimp.

• The wire strand honeycomb-like structure shall have
minimal cavities/voids.

• Barrel shape shall be relatively symmetrical and the seam
shall be closed.

• The crimp should not cut any wire strands due to
over-crimping or inadequate bellmouth.

• The crimp should have minimal excess material extrusion.

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SECTION 4

TROUBLESHOOTING GUIDE

ETCO IP MINI REAR FEED APPLICATOR – page 1

44

SYMPTOM CAUSE REMEDY

INCORRECT CRIMP HEIGHT. WRONG CRIMP DIAL PAD SETTING. CONSULT TAG ON BACK OF

APPLICATOR FOR CORRECT
SETTING.
ADJUST DIAL ACCORDINGLY.

DEBRIS UNDER BASEPLATE. REMOVE APPLICATOR

FROM PRESS AND CLEAN.

PRESS SHUT HEIGHT INCORRECT. ADJUST SHUT HEIGHT UNTIL

SATISFACTORY.
TOOLING IMPROPERLY INSTALLED. SEE SECTION 5, BACK POCKET.
WORN ROLLING TOOLS AND ANVILS. REPLACE.
MOUNTING POST LOOSE. ADJUST POST AND TIGHTEN

SET SCREWS.

BELLMOUTH OF THE CRIMP WRONG TOOLING FOR TERMINAL. SEE SECTION 5, BACK POCKET
OFF LOCATION. TOOLING IMPROPERLY INSTALLED. SEE SECTION 5, BACK POCKET

FEED ADJUSTMENT OFF. ADJUST FEED.

WIRE BENT AFTER PROCESSING WIRE PRESENTATION ADJUST PRESS HEIGHT.
BEHIND INSULATOR BLOCK. TOO LOW/HIGH.
“GOOSE NECK” TONK (PISTON) HEIGHT TOO HIGH. ADJUST TONK.

WIRE BENT TO THE SIDE AUTOMATIC MACHINE IS PULLING SHOULD RUN IN CLOSED
OR INSULATOR IS WIRE AWAY BEFORE INSULATION CRIMP AT 3200 PIECES/HR.
DAMAGED. IS PROPERLY INSTALLED. INCREASE DWELL TIME

BEFORE CONTACT IS

PULLED OUT OF PRESS.

EXCESSIVE BURR IN WORN OR CHIPPED CUT-OFF REPLACE.
CUT-OFF AREA. DIE/PUNCH.

HEAVY BURR ON UNDERSIDE CHIPPED OR WORN ANVIL. REPLACE.
OF CRIMPED WIRE EAR. WORN ROLLING TOOL. REPLACE.

STRAY WIRE STANDS. CHIPPED OR WORN TOOLING. REPLACE.

WIRE PRESENTATION TOO FAR LEFT ADJUST AS NEEDED TO

OR RIGHT. CENTER WIRE OVER EAR.

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SECTION 4

TROUBLESHOOTING GUIDE

ETCO IP MINI REAR FEED APPLICATOR – page 2

44

SYMPTOM CAUSE REMEDY

TERMINAL STICKING WORN ROLLING TOOL. REPLACE.
IN ROLLING TOOL. BRASS BUILDUP IN ROLLING TOOL. POLISH OR REPLACE.

WORN OR MISSING EJECTOR OR REPLACE.

EJECTOR SPRING.

INSERT SLIDE STAYS AIR VALVES ARE PLUMBED SEE AIR ATTACHMENT
DIAGRAMAT ITS FULL STROKE INCORRECTLY. SECTION 1, PAGE 10.
UPON INSERTION.

INSULATOR WILL NOT AIR CYLINDER LOOSE ON BASE PLATE TIGHTEN SCREWS.
FULLY INSERT. AIR CYLINDER BINDING OR REPLACE AIR CYLINDER.

LEAKING AIR.

AIR SUPPLY IS NOT 80 TO 90 PSI ADJUST AS NEEDED.

OR 6 BARS APP.
INCONSISTENT AIR VOLUME. ADJUST AS NEEDED.
TUBING IS BENT RESTRICTING REPLACE TUBING.

AIR VOLUME.
INCORRECT INSULATION PUSHER. SEE SECTION 4, PAGE 4.
OBSTRUCTION BETWEEN INSULATION CLEAR OBSTRUCTION.

PUSHER AND DIE HOLDER.
PRESS SPEED IS TOO FAST. SHOULD BE 3200/HR. MAX.
WIRE CUTTER HEAD/TUBE MACHINE SETTINGS

NOT HOLDING POSITION FOR FULL ARE INCORRECT.

TERMINATION STROKE. ADD DWELL.

CYLINDER DOES NOT FIRE. MX338 CAM LOOSE ON RAM. TIGHTEN CAM.

CRIMPED AIR TUBE. REPLACE TUBING.
AIR PRESSURE TOO LOW. CHECK AIR PRESSURE.

SHOULD BE 80 TO 90 PSI.

AIR LEAK FROM NOVA VALVE. NOVA VALVE O-RINGS REPLACE VALVE.

WORN OR BROKEN.
TUBING INCORRECTLY INSTALLED. SEE AIR ATTACHMENT

DIAGRAM SECTION 1,
PAGE 10.

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SYMPTOM CAUSE REMEDY

TERMINAL WILL NOT FEED PICK-UP POSITION INCORRECT. ADJUST.
FORWARD WHEN PRESS
IS CYCLED. PIVOT SHEAR PIN BROKEN. REPLACE. SPARES ARE

LOCATED ON TOP OF
APPLICATOR.

MISSING CAM ROLLER. REPLACE.

FEED FINGER ADJUSTMENT TIGHTEN.

SCREW LOOSE.

BROKEN FEED FINGER SPRING. REPLACE.

TERMINAL OVER FEEDS FEED SETTING INCORRECT. ADJUST.
WHEN PRESS IS CYCLED.

BRAKE LEVER IN OFF SWING LEVER DOWN TO

POSITION. ON POSITION.

BRAKE TENSION SET TOO LIGHT. TURN CLOCKWISE TO

INCREASE PRESSURE.

FEED FINGER PICKUP LOCATION ADJUST.

INCORRECT.

TERMINAL UNDER FEEDS FEED SETTING INCORRECT. ADJUST.
WHEN PRESS IS CYCLED.

INCORRECT CAM INSTALLED. SEE SECTION 5, BACK

POCKET FOR PROPER CAM.

BRAKE TENSION SET TOO HEAVY. TURN COUNTERCLOCKWISE

TO DECREASE PRESSURE.

FEED FINGER PICKUP LOCATION ADJUST.

INCORRECT.

TERMINAL TANGLED ON REEL. CONTACT ETCO QUALITY

CONTROL DEPARTMENT.

INTERMITTENT FEED CHANGES. BRAKE LEVER IN OFF POSITION. SWING LEVER DOWN TO

ON POSITION.

DEBRIS UNDER BRAKE. REMOVE STRIP FROM FEED

TRACK AND CLEAN.

FEED ARM PIVOT PINS LOOSE. TIGHTEN SET SCREWS.

SECTION 4

TROUBLESHOOTING GUIDE

ETCO IP MINI REAR FEED APPLICATOR – page 3

4

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SECTION 4

TOOLING AND COMPONENT QUICK REFERENCE LIST

ETCO IP INSULATED REAR FEED APPLICATORS – page 4

TERMINAL WIRE ROLL INSULATION WIRE ANVIL INSULATION

TOOL ROLL TOOL ANVIL

PDF224 13-5001 14-5001 9-5001 9A-5001
PDF225 13-5002 14-5002 9-5002 9A-5002
PDF124/126 13-5003 14-5001 9-5001 9A-5001
PDF125/127 13-5004 14-5002 9-5002 9A-5002

BACKING DOG CUT-OFF DIE CUT-OFF PAD CUT-OFF

PAD DRIVER

PDF224 15-5001 8-5002 12-5002 15-5003
PDF225 15-5002 8-5002 12-5002 15-5003
PDF124/126 15-5005 8-5003 12-5003 15-5003
PDF125/127 15-5004 8-5003 12-5003 15-5003

LEFT GUIDE LEFT ANVIL SLIDE COVER CAM SPACER
RAIL GUIDE

PDF224 MX405-ITD-R MX409-ITD-R MX414-ITD-R NOT REQUIRED
PDF225 MX405-ITD-R MX409-ITD-R MX414-ITD-R NOT REQUIRED
PDF124/126 MX405-1-ITD-R MX409-1-ITD-R MX414-1-ITD-R MX421-ITD-R
PDF125/127 MX405-1-ITD-R MX409-1-ITD-R MX414-1-ITD-R MX421-ITD-R

TERMINAL GUIDE BLOCK POSITION INSULATION
BLOCK TOWARD TERMINAL PUSHER

PDF224 MX411-ITD-R (REV “A”) SHORT SIDE MX401-ITD-R
PDF225 MX411-ITD-R (REV “A”) SHORT SIDE MX401-ITD-R
PDF124/126 MX411-ITD-R (REV “A”) LONG SIDE MX401-ITD-R
PDF125/127 MX411-ITD-R (REV “A”) LONG SIDE MX401-ITD-R

4

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USE ONL

Y ETCO TOOLING

SECTION 4

DESCRIPTION

ETCO IP MINI REAR FEED APPLICATOR – page 6

A HEIGHT ADJUSTING DIAL/WIRE

ROLLING TOOL ONLY:
Set at appropriate letter pad setting.

Number and letter pad settings
located on Assembly Drawing in
pocket on inside back cover of this
manual.

B HEIGHT ADJUSTING DIAL/

INSULATION ROLLING TOOL ONLY:
Set at appropriate number pad setting.

C BRAKE CAM:

Rotate 90 degrees to brake in relief posi­tion.

D FEED FINGER ARM ROUGH ADJUST:

Used to adjust approximate feeding
distance. Loosen locking screw on feed
finger to change position of finger.
Tighten locking screw.

E BRAKE TENSION ADJUSTMENT:

Tighten knob clockwise to increase
brake tension, counter-clockwise to
decrease tension. Optimum position is
to have screw bottomed out.

F-G FEED ADJUSTING SCREW/

LOCKING SCREW:
To adjust final feeding distance, loosen

locking screw G. Turning screw F
clockwise increases feeding distance,
counter-clockwise decreases feeding
distance. Tighten locking screw G when
adjustment is complete.

H SAFETY PIVOT PIN:

If replacement is needed for safety pivot
pin, use spare pins on top of frame.

I CRIMP TOOL HOLDING SCREW:

When replacing crimp tools, note that
all tools, spacers and washers are in
position before operating.

F

E

C

H G

D

I

A
B

4