Tyco Electronics 1338600 Series Reference guide

409-10016
Customer Manual
Entry Level Terminator
1 of 34
L C B
E 2008 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. ther products, logos, and company names used are the property of their respective owners.
T LING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.tycoelectronics.com
21 AUG 08 Rev H
(ELT) Machine 1338600-[ ]
EAD THIS FI ST ! 2..........................
SAFETY PRECAUTIONS
1. INT ODUCTION 3....................................................
2. DESC IPTION 4......................................................
2.1. Functional Description 5.............................................
2.2. Electrical Description 6..............................................
2.3. Machine Guard 9..................................................
3. ECEIVING INSPECTION AND INSTALLATION 9.............................
3.1. Receiving Inspection 9..............................................
3.2. Installation 9.....................................................
3.3. Considerations Affecting the Placement of Bench Machines 10.................
4. OPE ATION 11......................................................
4.1. Control Panel peration 11..........................................
4.2. Applicator Installation 11............................................
4.3. Setup 14........................................................
4.4. Mode Selection and peration 14......................................
4.5. Crimp Height Adjustment 16..........................................
4.6. End-Feed/Side-Feed Applicator Conversion 16...........................
5. P EVENTIVE MAINTENANCE 17........................................
5.1. Cleaning 17.....................................................
5.2. Lubrication 17....................................................
6. ADJUSTMENTS 18....................................................
6.1. Measuring the Shut Height 18........................................
6.2. Shut-Height Adjustment 18..........................................
6.3. Crimp Height Adjustment Using Precision Adjustment Mechanism (If Equipped) 19..
6.4. Guard Insert Adjustment 21..........................................
7. MACHINE OPTIONS AND INSTALLATION 23................................
7.1. Installation of Work Light Assembly Kit 1424264-1 23.......................
7.2. Installation of Work Light Assembly Kit 1424264-1 (Inside the Guard) 25..........
7.3. Installation of Batch Counter Kit 1424267-1 29............................
7.4. Installation of Air Feed Kit 1424266-1 32.................................
7.5 Installation of Precision Adjustment Kit 1424208-1 34.......................
8. T OUBLESHOOTING 34...............................................
9. EVISION SUMMA Y 34...............................................

409-10016
ELT Machine 1338600-[
Rev H2 of 34 Tyco Electronics Corporation
SAFETY PRECAUTIONS AVOID INJURY
Safeguards are designed into this application equipment to protect operators and maintenance personnel from
most hazards during equipment operation. However, certain safety precautions must be taken by the operator
and repair personnel to avoid personal injury, as well as damage to the equipment. For best results, application
equipment must be operated in a dry, dust–free environment. Do not operate equipment in a gaseous or
hazardous environment.
Carefully observe the following safety precautions before and during operation of the equipment:
D ALWAYS wear appropriate ear protection.
D ALWAYS wear approved eye protection when operating powered equipment.
D ALWAYS keep guard(s) in place during normal operation.
D ALWAYS insert power plug into a properly grounded receptacle to avoid electrical shock.
D ALWAYS turn off the main power switch and disconnect electrical cord from the power source when
performing maintenance on the equipment.
D NEVER wear loose clothing or jewelry that may catch in moving parts of the application equipment.
D NEVER insert hands into installed application equipment.
D NEVER alter, modify, or misuse the application equipment.
TOOLING ASSISTANCE CENTER
CALL TOLL FREE 1-800-722-1111 (CONTINENTAL UNITED STATES AND PUERTO RICO ONLY)
The Tooling Assistance Center offers a means of providing technical assistance when required.
In addition, Field Service Specialists are available to provide assistance in the adjustment or repair of the
application equipment when problems arise which your maintenance personnel are unable to correct.
INFORMATION REQUIRED WHEN CONTACTING THE TOOLING ASSISTANCE CENTER
When calling the Tooling Assistance Center regarding service to equipment, it is suggested that a person
familiar with the device be present with a copy of the manual (and drawings) to receive instructions. Many
difficulties can be avoided in this manner.
When calling the Tooling Assistance Center, be ready with the following information:
01. Customer name
02. Customer address
03. Person to contact (name, title, telephone number, and extension)
04. Person calling
05. Equipment number (and serial number if applicable)
06. Product part number (and serial number if applicable)
07. Urgency of request
08. Nature of problem
09. Description of inoperative component(s)
10. Additional information/comments that may be helpful
DANGER

409-10016
ELT Machin 1338600-[ ]
Rev H 3 of 34
Tyco Electronics Corporation
PART NUMBER DESCRIPTION SUPSD BY
1338600-1 ELT Machine with 40-mm [15/8-in.] Stroke 1725950-1
1338600-2 ELT Machine with 40-mm [15/8-in.] Stroke, Tool-less Precision Crimp Adjust 1725950-2
1338600-3 ELT Machine with 30-mm [11/8-in.] Stroke, Tool-less Precision Crimp Adjust
[
1725950-3
1338600-4 ELT Machine with 30-mm [11/8-in.] Stroke, Tool-less Precision Crimp Adjust, No Safety Interlock
[
1725950-4
1338600-5 ELT Machine with 40-mm [15/8-in.] Stroke, CE ersion 1725950-5
1338600-6 ELT Machine with 40-mm [15/8-in.] Stroke, CE ersion, Tool-less Precision Crimp Adjust 1725950-6
1338600-7 ELT Machine with 40-mm [15/8-in.] Stroke, Tool-less Precision Crimp Adjust, Crimp Quality Monitor
(CQM) Sensors 1725950-7
1338600-8 ELT Machine with 30-mm [11/8-in.] Stroke, Tool-less Precision Crimp Adjust, CQM Sensors 1725950-8
1338600-9 ELT Machine with 40-mm [15/8-in.] Stroke, Tool-less Precision Crimp Adjust, CQM Sensors, CE Filter 1725950-9
[ This machine is restricted to the Asia/Pacific market. Base plate on the machine does not contain quick-release feature.
Figure 1
1. INTRODUCTION
This manual contains information on operation, preventive maintenance, and adjustments of the Entry Level
Terminator (ELT) Machine 1338600–[ ]. See Figure 1. Descriptions in this manual pertain to the controls and
adjustments on the ELT machine only .
The various applicators that can be used in the ELT machine are covered in applicator instruction sheets
packaged with each applicator. Applicator instruction sheets provide information on applicator installation, care,
and adjustment.
Figure 2 contains specifications and requirements for the ELT machine.

409-10016
ELT Ma hine 1338600-[
Rev H4 of 34 Tyco Electronics Corporation
Capa ity: 13,345 Newtons [3,000 lb] Maximum Crimp Force
Defle tion: 0.13 mm [.0046 in.] Maximum per 4,448 Newtons [1,000 lb] Crimp Force
Noise: Less than 76 dBa Typical at operator position with standard mechanical feed applicator
Weight: 68.86 Kilograms [143 lb]
Height: 510 mm [20 in.] without reel supports
Ele tri al: 100-240 Vac, 50/60 Hz, ingle-Phase Current
Air: 620-760 kPa [90-100 psi], 2.83 liters/sec (6 scfm) When required for use with air-feed applicators
Figure 2
Physi al Environment: Temperature: 4.4 ° -40 ° C [40 ° -104 ° F]
Altitude: Not Applicable
Relative Humidity: Less than 95% (non-condensing)
Transportation and torage: tore in a clean, dry environment after coating all surfaces lightly with
a rust preventing oil.
When reading this manual, pay particular attention to DANGER, CAUTION, and NOTE statements.
Denote an imminent hazard which may re ult in moderate or evere injury.
Denote a condition which may re ult in product or equipment damage.
Highlight pecial or important information.
Reasons for reissue are in Section 9, REVISION SUMMARY.
2. DESCRIPTION
The ELT machine was designed to be used as a stand–alone semi–automatic bench unit. It is assembled with
metric hardware.
Mea urement are in metric unit [followed by U.S. cu tomary unit in bracket ]. Some commercial item may
contain non-metric hardware.
The ELT machine accepts a wide variety of miniature (mini) quick–change applicators, with minor adjustments,
thus providing a great selection of terminals for many applications. Figure 3 lists changeover cams required to
run 11/8–in. stroke cams (for AMP–O–LECTRIC Model “K” terminating machines) and 15/8–in. stroke cams (for
Model “T” and Model “G” terminating machines) in the ELT machine.
Some heavy-duty mini applicator require pecial cam that are not li ted in Figure 3. Refer to the applicator log
hipped with the applicator for additional information.
DANGER
CAUTION
!
NOTE
i
NOTE
i
NOTE
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409-10016
ELT Machine 1338600- ]
Rev H 5 of 34
Tyco Electronics Corporation
Quick–Disconnect Coupling 23238–1 is required to run air–feed applicators.
End–feed and side–feed miniature applicators are easily installed and removed without repositioning the
applicator mounting plate on the machine. An optional precision adjustment feature is available for the machine
to provide quick and accurate crimp height adjustments.
Refer to Section 7, MACHINE OPTIONS for more ELT machine options.
ORIGINAL APPLICATOR
FEED TYPE
CHANGEOVER CAMS FOR ELT MACHINE
ORIGINAL APPLICATOR
FEED TYPE
1338600-1, -2, -5, and -6 1338600-3, -4
1
1
/
8
-in. Stroke A
pp
licator for Pre-Feed 690602-6 Ċ
/8pp
Model K" Terminating Machine Post-Feed 690501-4 Ċ
1
5
/8-in. Stroke Applicator for
Model

T
"
and Model

G
"
Terminating
Pre-Feed Ċ 690602-5
M
o
d
e
l T"
an
dM
o
d
e
l G" T
erm
i
na
ti
ng
Machines Post-Feed Ċ 690501-3
Heavy-Duty Industrial (HD-I) Applicator Pre-Feed/Post-Feed Refer to the HD-I Applicator customer drawing for part num ers.
Figure 3
2.1. Functional Description
The ELT machine provides the force required to crimp terminals in the applicator. A terminal is attached to the
wire by placing the wire in the crimp area and pressing the foot switch. The machine consists of four functional
areas:
1. The motor group includes a dc motor which drives a crankshaft. The motor is activated each cycle
and rotates the crankshaft one full revolution. A motor access cover, located on the end of the motor,
covers a hex key which allows the motor to be cycled manually. See Figure 4.
Figure 4
DC Motor
Crankshaft
Motor Access Cover

409-10016
ELT Machine 1338600-[
Rev H6 f34 Tyc Electr nics C rp rati n
2. The crankshaft–ram group covers the motor rotational force to the up–and–down action of the ram
for driving the applicator during the crimping cycle.
3. The
base plate provides the mounting surface on which the applicator is installed. The quick–release
latching feature on Machines –1, –2, –5, and –6 permits fast, easy installation and removal of the
applicator. Note that Machines –3 and –4, restricted to Asia/Pacific market, do not include the
quick–release latching feature. See Figure 5.
4. An optional crimp height adjustment group uses an eccentric located in the ram linkage, along
with detented stops in the mechanism to adjust the crimp height. Indexing the mechanism in either
direction will change the crimp height in increments of approximately 0.013 mm [.0005 in.] per step.
Figure 5
Base Plate f r Machines
-1, -2, -5, and -6
Quick-Release
T-Handle
Shown with Optional
Precision Crimp Height
Adjustment Mechanism
Base Plate f r Machines
-3 and -4
Alternate Rear St p
M unting P siti n
2.2. Electrical Description
The ELT machine electrical components consist of the operator control panel, the motor, and the CPU/motor
controller package. The machine operates on 100/240 Vac, 50/60 Hz, single–phase current with ground. The
machine will automatically detect the supply voltage and adjust the controller accordingly.
The operator control panel (Figure 6) is mounted on the left side of the machine frame. The control panel
consists of two indicator lights, one jog button, and one speed control knob, with icons depicting each function.
See Paragraph 4.1 for control panel operation.

409-10016
ELT Machine 1338600-[ ]
Rev H 7 of 34
Tyco Elect onics Co po ation
A main power switch/circuit breaker (Figure 7) is located on the back of the machine. This switch connects ac
power to the control system. The CPU/motor controller is located behind the back cover of the machine. It is a
modular unit that contains all of the electronics necessary to operate the machine. See Figure 7.
The CPU/motor controller package contain high voltage which can remain even after power ha been removed.
Contact the Tooling A i tance Center at 1-800-722-1111 for precautionary mea ure to follow if internal acce to
the CPU/motor controller i required.
Figure 6
Gua d Open
Icon
G een
Indicato
Yellow
Indicato Jog Button Speed Cont ol Knob
Fault
Icon
Gua d Disabled
Icon
Machine Ready
Icon
Speed Cont ol
Icon
Jog Button
Icon
Batch Counte
Kit
DANGER

409-10016
ELT Machine 1338600-[
Rev H8 of 34 Tyco Electronics Cor oration
Figure 7
DC Motor
Back Cover
CPU/Motor Controller
(Behind Back Cover)
Motor Access
Cover
Reel Su ort Hole
Power Switch/Circuit
Breaker
Terminal
Stri Guide

409-10016
ELT Machine 1338600-[ ]
Rev H 9 of 34
Tyco Electronics Corporation
2.3. Machine Guar (Figure 8)
A guard is installed to provide protection for the operator while maintaining proper visibility of the work area.
The guard swings open to allow easy access for applicator installation and setup. A safety interlock on the
guard prevents the machine from cycling if the guard door is open during production operation.
Machine -4 does not include the safety interloc feature. To avoid personal injury, remember that the power is not
automatically shut off when the guard doors are opened.
Figure 8
Machine
Guard
Shown with Safety Interloc
(Not on Machine -4)
Hole for Customer
Supplied Lift Ring
Quic -Release T-Handle
for Machines -1, -2, -5,
and -6
Shown with Optional
Precision Crimp Height
Adjustment Mechanism
3. RECEIVING INSPECTION AND INSTALLATION
3.1. Receiving Inspection
ELT machines are thoroughly inspected during and after assembly. A final series of inspections is made to
insure the proper machine functioning before packaging and shipping.
To protect against damage that may have occurred during shipment, remove the machine from the crate
(Paragraph 3.2) and carefully inspect the machine for damage. If damage is evident, file a claim against the
carrier and notify Tyco Electronics immediately.
3.2. Installation
Remove all mounting bolts securing the machine to the shipping pallet. Install lift ring (see Figure 8) on top of
the machine.
Lift ring (M12  20 eye bolt) is customer supplied.
DANGER
NOTE
i

409-10016
ELT Mac ine 1338600-[
Rev H10 of 34 Tyco Electronics Corporation
Install the lift ring carefully . A 19.05-mm [.75-in.] thread length engagement is required for the lift ring to su ort the
machine.
Attach a suitable hoist to the lift ring, lift the machine, and place it in the selected operating location.
Insert the reel support post into the appropriate hole on top of the machine (Figure 7) until the roll pin engages
a groove in the machine frame.
Attach the terminal strip guide included with the machine with the two thumbscrews supplied. Mount the guide
on the left guard for side–feed applicators. Mount the guide on the right guard for end–feed applicators.
Connect the power cord to a suitable electrical supply.
The machine will automatically detect the su ly voltage and adjust the controller accordingly.
Machines ex orted to Euro e will be installed by Tyco Electronics service engineers. These engineers will verify that
the electrical and neumatic connections are correct. Both neumatic and electrical connections must be installed in a
way that rovides a lockable isolation switch for hard-wired or direct i ed machines. This is necessary to interru t
ower to the machine for setu or maintenance.
3.3. Considerations Affecting Placement of Benc Mac ines
The location of the machine in relation to the operator’s position is extremely important in terms of both safety
and maximum efficiency. Studies have repeatedly shown that operator fatigue will be reduced, and greater
efficiency achieved, if:
1. the bench is of appropriate height, preferably with sound–deadening rubber mounts;
2. the machine is properly located on the bench with ample work areas on both sides to facilitate work
flow;
3. the operator uses a swivel chair with padded seat and back rest which are independently adjustable;
and
4. the foot switch, on machines so equipped, is placed on a rubber mat to maintain its movability, while
preventing it from sliding unintentionally.
Figure 9 illustrates proper machine location and operator position and the following:
A. Benc
The bench to be used should be of sturdy construction, preferably with rubber mounts to minimize noise. A
height of 762 to 812.8 mm [30 to 32 in.] is the most suitable for operator comfort and convenience. This
height allows the operator to rest both feet on the floor, thereby providing for the shifting of weight and leg
position.
B. Mac ine Location on Benc
The machine should be located near the front of the bench with the “target area” (tooling area where the
product is applied) not more than 152.4 to 203.2 mm [6 to 8 in.] from the front edge. This location will
eliminate unnecessary operator motion and help to avoid back strain and fatigue.
Orientation of the machine should be such that the “target area” is facing the front of the bench and is
parallel to the front edge (access to the back of the machine MUST also be provided).
Machines have rovisions for being bolted to the bench.
C. Operator's C air
The operator’s chair should swivel, and should have independent seat height and back rest adjustments.
The seat and back rest should be padded, and the back rest should be large enough to provide support
both above and below the waist line.
CAUTION
!
NOTE
i
NOTE
i
NOTE
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