Instruction Sheet Inspection of AMPINNERGY* System Power Contacts 408-3198 02 FEB 99 ~RevD @ NOT FOR INTERRUPTING CURRENT @ @ NE PAS EMPLOYER POUR LA RUPTURE DU COURANT @ Inspect crimped contacts for ACCEPT or REJECT conditions shown below. Refer to the chart for the wire strip length and the wire barrel and bellmouth crimp heights. Refer to the instructions packaged with the AMP tooling for tooling adjustments or parts replacement ents ineh equivalents in brackets}. the REVISION SUMMARY section. Measurements are in millimeters [followed by Reasons for reissue of this document are provided in information. CONTACT STRANDED WIRE APPLICATOR TOOLING INFORMATION PART STRIP AWG CRIMP HEIGHT CRIMP BELLMOUTH | APPLICATOR NUMBERS | LENGTH SIZE DIM. wipTH | CRIMP HEIGHT PART SETTING | 4.0.05 [.002] 40.25 [.010] NUMBER 48 C 2.21 2.72 556135-1 [.087] [.107] 567403-1@ 556883-2 5.54 6.35 46 B 2.31 3.56 2.82 567403-200 [.218 to 250] [.091] [.140] [111] 788109-188 a 1 349 3.00 680447-3ee0 [.098] [118] 555485-1 555928-1 12 C 2.92 3.48 56725630 5559161 [115] [195] 6.35 -7.14 4.57 567256-4ee 556136-1 segaop | [250-281] [.180] 10 A 3.28 3.79 80449-3000 [.129] [149] 788 110-188 @ Used in the T Terminaior. Refer io Applicator Instructions 408-8040 for applicator information. ee Used in the AMP* AMPO-LECTRIC* Model K Machine 5654355. Refer to Customer Manual 409-51 28 for machine information. NOTE: The Model K AMP-O-LECTRIC Terminating Machine PN 5654355 has been superseded by the Model G Terminating Machine PN 354500-1 (409-5842) for new applications. For existing applications, the Model K is still recommended because of the large number of installed machines. eee Used in ihe AMPO-LECTRIC Model G Terminating Machine 3545001 (409-5842). # Use Applicaior 680447-3 only. Applicaior 680447-3 only crimps Contact 788109-1 . i Use Applicator 6804433 only. Applicator 680449-3 only crimps Contact 788110-1. ACCEPT No Nicked or Missing Wire Strands End of Wire to be Flush to 1.52 [.060] Max. frem End of Wire Barrel No Front Bellmouth fo XN Insulation Does Not Enter Wire Barrel Correct Bellmouth Correct Crimp Height Crimp NOTE Dual beam contact shown. Height Same inspections apply for the blade and hermaphroditie contacts. AMP Incorporated, Harrisburg, PA 17105 TOOLING ASSISTANCE CENTER 1-800-722-1111 AMP FAX*/PRODUCT INFO 1-800-522-6752 This AMP controlled document is subject to change. For latest revision call the AMP FAX number. Copyright 1999 by AMP Incorporated. All Rights Reserved. Trademark 1of2 LOC BANP AMPINNERGY System Power Contacts 408-3198 | REJECT | Wire Extends Too Far Beyond Wire Barrel Front Wire Insulation \ Bellmouth Entered Wire r= A Barrel li Section A-A Lp A NOTE Wrong crimp height indicates worn dies or wrong crimp height selector setting. Nels Adjust applicator Front bellmouth indicates incorrect adjusiment of feed irack. aa hold-town bumper. ee } STRANDED WIRE HAND TOOL INFORMATION CONTACT NUneers STRIP AWG Aaa CRIMP CHM HelGur DIEASSY | HAND TOOL LENGTH SIZE 40.05 [002] WIDTH +0.25 [010] PART NO. PART NO. 2.21 2.67 18 10871 105] 58493-1 69710-1 556135-2 6.99 7.87 16 2.21 3.56 2d? 58493-1 556883-1 | [.275 to 310] [.087| [.140] [109] 2.44 2.95 14 [.096] [116] 58492-1 697101 9 8A 3.35 189721-2 12 , , 58490-1 189722-2 556136-2 7.87 - 8.66 [112] 4.57 [132] 556880-1 [.310 .341] 3.90 [.180] 371 10 [126] [146] 58491-1 69710-1 End of Wire to be Flush to WM Nee Missing 1.52 [.060] Max. from End Ire strands Wire Barrel SSE Insulation Does Not No Front selon Enter Wire Barrel NOTE Hermaphroditic contact shown. Correct Correct Bellmouth Same inspections apply for dual == Crimp Crimp Height beam and blade contacts. Height REVISION SUMMARY Per EC 0990-0106-99: * Changed cocument from obsolete status to Since the previous release of this sheet, the following active status changes were made: 2 0f2 Rev D