AMP/TYCO ELECTRONICS 58063-2

Instruction Sheet Terminating Head 58063–2 For AMPLIMITE* High Density (HDE)–20 408–9414 Connectors 12 JUL 04 Rev A Wire Guide Anti–Backup Pawl Wire Inserter Feed Slide Adjuster (Inserter Rod) Feed Channel Figure 1 Adjuster (inserter rod)—is a piston for, and regulates 1. INTRODUCTION the travel of, the wire inserter. Terminating Head 58063–2 is designed to terminate unstripped discrete wire sizes 30 through 20 AWG Feed slide—automatically advances the connector onto AMPLIMITE HDE–20 all plastic connectors after each termination. (reference part number 745203–2) and metal shell Anti–backup pawl—prevents the connector from connectors (reference part number 745492–2). These moving out of position after it has been advanced by connectors contain insulation displacement contacts. the feed slide. The head must be used with one of the following After the head is installed onto the power unit, it power units (for operating procedure, refer to the serves as a guide and support for the connector instructions packaged with the power unit). during termination. The arrow on the top of the head Instruction Sheet (408) or indicates the direction that the connector will move in Power Unit Customer Manual (409) the head. The wires are terminated onto the connector using the insulation displacement Pistol Grip Manual Handle 408–6790 technique. Assembly 58074–1 Pistol Grip Pneumatic Handle 3. TERMINATION PROCEDURE 408–6789 Assembly 58075–1 Make sure that the connector matches the wire size Pneumatic Power Bench 408–9393 to be terminated, then refer to Figure 2, and proceed Assembly 58338–1 as follows: Electric Power Unit 931800–1 409–5746 1. Align the side of the connector with the side of the head (so that it will move in the direction of the Dimensions in this instruction sheet are in metric NOTE arrow), and slowly slide the connector into the feed units [with U.S. customary units in brackets]. channel. Stop when the desired contact position Figures are not drawn to scale. aligns with the wire slot. Reasons for reissue of this instruction sheet are If the connector cannot be inserted into the head NOTE provided in Section 7, REVISION SUMMARY. or if the connector is too loose in the head, refer to Paragraph 4.2 for wire guide adjustment. 2. DESCRIPTION (Figure 1) 2. Insert the wire into the wire slot until the wire Features of the head and their function are as follows: bottoms on the head. Wire inserter—forces the wire into the slotted beams 3. Center the wire in the wire slot, then actuate the of the contact. power unit until the wire inserter bottoms (the wire Wire guide—holds the connector properly in relation inserter will retract, and the connector will advance to the wire. to the next contact position). 2004 Tyco Electronics Corporation, Harrisburg, PA This controlled document is subject to change. TOOLING ASSISTANCE CENTER 1–800–722–1111 1 of 4 For latest revision, call the FAX/PRODUCT INFO number. FAX/PRODUCT INFO 1–800–522–6752 All International Rights Reserved AMP and Tyco are trademarks. *Trademark For Regional Customer Service, visit our website at LOC B Other products, logos, and company names used are the property of their respective owners. www.tycoelectronics.com Terminating Head 58063–2 408–9414 Terminating Connector B. Manual and Electric Power Units To prevent personal injury when using electric Wire Wire DANGER power units, ALWAYS disconnect the electrical Slot Connector power supply before making any adjustments. Power Unit (Ref) 1. Remove the head from the power unit according to the instructions packaged with the power unit. Make sure to observe any cautions and dangers. 2. Turn the adjuster (inserter rod) one–sixth of a revolution clockwise if the wire is too deep in the contact, and counterclockwise if the wire is not deep enough in the contact. Refer to Figure 3. This will decrease or increase the wire insertion depth by approximately 0.20 mm [.008 in.]. Slide Connector Into Feed Channel 3. Install the head onto the power unit according to the instructions packaged with the power unit. Make sure to observe any cautions and dangers. Figure 2 Wire Insertion Depth Adjustment 4. Repeat Steps 2 and 3 until all applicable contacts are terminated. 5. Slide the connector out of the head in the Turn CLOCKWISE direction of the arrow. To Decrease 6. Inspect each terminated contact according to Wire Insertion Depth Figure 4. If any contact does not meet the requirements, DO NOT use the connector. Refer to Section 4 for adjustments. For application requirements for the connectors, NOTE refer to application specification 114–40002. Turn COUNTERCLOCKWISE Adjuster To Increase For assembly procedure, refer to 408–6621 for (Inserter Rod) Wire Insertion Depth all plastic connectors and 408–6645 for metal shell connectors. Figure 3 4. ADJUSTMENTS 4.2. Wire Guide 4.1. Wire Insertion Depth If the connector cannot be inserted into the head, the connector is too loose in the head, or the connector If the wire is inserted too deep or not deep enough in housing is damaged after termination, refer to Figure the contact after termination, adjust the wire insertion 1, and adjust the wire guide as follows: depth as follows: 1. For pneumatic power units, disconnect the air A. Pneumatic Power Units supply. For electric power units, disconnect the electrical power supply. To avoid personal injury when using pneumatic DANGER power units, ALWAYS disconnect the air supply 2. Loosen the two screws on the wire guide. before making any adjustments. 3. Slide the wire guide until the connector fits Increase the air pressure by 10 psi [69 kPa]. Repeat properly in the head. the termination and inspection procedure. Continue in 4. Finger–tighten the screws. this manner until the proper wire insertion depth is obtained or the air pressure is set to 70 psi [483 kPa]. 5. INSPECTION AND MAINTENANCE If proper wire insertion depth is not obtained at 70 psi [483 kPa], return the air pressure to 40 psi [276 kPa] 5.1. Inspection and follow Paragraph B. Regular inspections should be performed by quality For pneumatic power units, it might be necessary control personnel with a record of quality control NOTE to adjust either the air pressure or the adjuster inspections remaining with the personnel responsible (inserter rod). for the head. One inspection per month is the 2 of 4 Rev A 408–9414 Terminating Head 58063–2 Termination Inspection Correct Acceptable Arms of Insulation Support Arms of Insulation Support Barrel Partially Closed Barrel Completely Closed Section A–A 0.51 mm Centerline of [.020 in.] Conductor AMPLIMITE HDE–20 Min Receptacle Connector A A 0.84+0.10 mm [.033+.004 in.] Incorrect Damaged Housing— Wire Was Not Inserted Wire Was Inserted With Wire Was Not Inserted Wire Was Not Fully Connector Was Too Deep Enough During Too Much Force During Straight Before Inserted Before Tight or Too Loose in Termination Termination Termination Termination Head During Termination Figure 4 recommended frequency; however, operator training 2. Check for chipped, cracked, worn, or broken and skill, amount of use, working conditions, and areas on the head. If damage is evident, repair or established company standards are all factors to be replace the head. considered in establishing inspection frequency. 6. REPLACEMENT AND REPAIR 5.2. Daily Maintenance Customer–replaceable parts are listed in Figure 5. A complete inventory should be stocked and 1. Remove dust, moisture, and other contaminants controlled to prevent lost time when replacement of with a clean, soft brush or lint–free cloth. DO NOT parts is necessary. Parts other than those listed use objects that could damage the head. should be replaced by Tyco Electronics to ensure quality and reliability. Order replacement parts 2. Make sure that all components are in place and through your representative, or call 1–800–526–5142, properly secured. or send a facsimile of your purchase order to 717–986–7605, or write to: 3. Make sure that the mechanisms inside the head function smoothly. CUSTOMER SERVICE (038–035) TYCO ELECTRONICS CORPORATION 5.3. Periodic Maintenance PO BOX 3608 HARRISBURG PA 17105–3608 1. Remove any accumulated film with a suitable cleaning agent that will not affect plastic. For customer repair service, call 1–800–526–5136. Rev A 3 of 4 Terminating Head 58063–2 408–9414 A A 25.4 mm [1.0 in.] 2 8 7 9 6 3 Section A–A 10 44.45 mm [1.75 in.] 1 12 11 13 15 4 5 14 84.07 mm [3.31 in.] REPLACEMENT PARTS ITEM PART NUMBER DESCRIPTION QTY PER HEAD 1 312331–1 HEAD 1 2 28593–1 SCREW, Self–Tapping 2 3 314011–1 HOUSING, Insert 1 4 314012–1 PAWL 1 5 1–23147–2 SPRING, Compression 2 6 312339–1 INSERTER, Wire 1 7 312340–1 GUIDE, Wire 1 8 4–23715–7 SCREW, Machine, 4–40.750 in. L 2 9 3–21028–2 PIN, Slotted Spring 1 10 312149–1 ADJUSTER (Inserter Rod) 1 11 22488–5 SPRING, Compression 1 12 312148–2 ROD, Inserter 1 13 314013–1 SLIDE, Feed 1 14 304580–0 PIN, Spirol 1 15 314014–1 PAWL, Locator 1 Figure 5 7. REVISION SUMMARYReplaced Figures 2 and 3 with reference connector part numbers Revisions to this instruction sheet per EC Removed instruction for feed adjustment 0990–0902–04 include: Removed Item 3 from Figure 5 Updated document to corporate requirements Added electric power unit to Section 1 4 of 4 Rev A