ANP INSERTER TIP SUBASSEMBLY AMP* Tooling Kit 768900-5 Instruction Sheet 408-4054 31 AUG94 RevO INSERTER ASSEMBLY STOP MOUNTING SCREW WIRE INSERTION DEPTH STOP INSERTER ASSEMBLY SLIDING BLOCK MOUNTING SCREW MANDREL ASSEMBLY INSERTER POSITION ADJUSTMENT SCREW FRONT CONNECTOR CLAMP (Unlocked) CONNECTOR REAR CONNECTOR CLAMP (Locked) NEST SET Figure 1 1. INTRODUCTION This instruction sheet covers the installation and use of AMP Tooling Kit 768900-5, which is used in the CHAMPOMATOR?* 2.5 Bench Terminating Machine to apply discrete-wire cable to CHAMP .050 Series II Plug Connectors. Refer to AMP Catalog 82244 for application requirements and product part number information. All dimensions on this sheet are in metric units {followed by U.S. customary units in brackets]. Figures ar for identification only and are not drawn to scale. These instructions are supplied in the documen- tation package for Tooling Kit 768900-5. Make sure to retain all material in the documentation package for reference. For detailed information on the operation of the CHAMPOMATOR 2.5 Machine, refer to AMP Customer Manual 409-5839, which is supplied with the machine. 2. DESCRIPTION (Figure 1) The tooling kit consists of two inserter assemblies, a mandrel assembly, a set of connector nests, anda set of setup gages (used for adjusting the insertion guide opening). The inserter assemblies trim and insert the individual wires into the connector contacts. The mandrel assembly supports the connector during the termination process and helps guide the wires into the inserter assembly termination area. The connector nest set locates the connector in the mandrel assembly. 3. INSTALLATION Disconnect the power to the control module and lockout the pneumatic vaive BEFORE installing the tooling onto the base machine. AMP Incorporated, Harisburg, PA 17105 TECHNICAL ASSISTANCE CENTER 1-800-722-1111 AMP FAX/PRODUCT INFO 1-800-522-6752 10f6 This AMP controlled document is subject io change. For latest revision call the AMP FAX number. Copyright 1994 by AMP Incorporated. All Rights Reserved. Trademark LOC BAMF Tooling Kit 768900-5 408-4054 MANDREL ASSEMBLY LOCKING SCREW In A AIR CYLINDER (In Access Hole} Ane ALIGNMENT PINS FOR MOUNTING SCREW INSERTER ASSEMBLY {For Mandrel Assembly) CONNECTOR CLAMP FORCE ADJUSTMENT (Self-Locking Setscrews) ALIGNMENT PINS FOR \ INSERTER ASSEMBLY MANDREL ASSEMBLY MACHINE BASE BLOCK ASSEMBLY (Ref} Figure 2 For clarity, the illustrations used in this sheet may show the machine without guarding. Be sur to have ail guarding in place before operat- ing the machine. 3.1. Mandrel Assembly (Figure 2) All inserter assemblies must be removed before NOTE . . : installing or removing the mandrel assembly. 1, Place the mandrel assembly onto the machine base block assembly. 2. Using a 5/32-in. hex wrench, secure the mandrel assembly onto the base block assembly with the two socket head cap (mounting) screws supplied with the machine. 3.2. Inserter Assemblies (Figure 3) 1. Align the inserter assembly T-slot over the air cylinder ram. 2. Locate the base of the inserter assembly onto the two alignment pins on the machine's inserter assembly mounting area. Refer to Figure 2. 3. Using a 5/32-in. hex wrench, install the two inserter assembly mounting screws. 4. ADJUSTMENTS NOTE Disconnect the power to the control module and lockout the pneumatic valve BEFORE adjusting any tooling. 4.1, Mandrel Assembly Height The mandrel assembly height is adjustable to locate the connector contacts in correct relation to the inserter assemblies inserter tips. To adjust the height: 1. Place a new (unterminated) connector onto the connector nest and lock into place. 2. Using a 1/8-in. hex wrench, remove the machine's front access plate. 3. Using a 5/32-in. hex wrench, loosen the mandrel assembly focking screw, which is located in the center access hole. Refer to Figure 2. 4. With the machine's electrical and air power disabled, manually move the machine's carriage assembly out to the connector termination area, then partially extend the inserter tips on each inserter assembly. 5. Observe the relationship between the connector contacts and the inserter assemblies guides. Refer to Figure 4. EEE 2cf6 RevOAINIF Tooling Kit 768900-5 408-4054 lee INSERTER 3 ASSEMBLY INSERTER 3 ASSEMBLY So INSERTER oe ASSEMBLY INSERTER ASSEMBLY T-SLOT ON MOUNTING SCREW AIR CYLINDER a RAM o o SLIDING BLOCK MOUNTING SCREW S 8 RACK HEIGHT-ADJUSTMENT NSERTER ASSEMBLY WHEEL SLIDING BLOCK MOUNTING SCREW MOUNTING SCREW Figure 3 6. Turn the machine's height-adjustment wheel until the height is within the adjustment range, as shown in Figure 4. Turn the wheel CLOCKWISE to LOWER the mandrel (and connector) and COUNTERCLOCKWISE to RAISE the mandrel {and connector). To 7. Once the desired height has been reached, use a 5/32-in. hex wrench to tighten the mandrel assembly locking screw. ADJUSTMENT RANGE CONNECTOR (Approx. 0.025-0.127 mm CONTACTS [.001~.005in.}) GUIDE Figure 4 cad 9822 4.2. Connector Nest adjust the connector nest for different connector sizes: 1. Using a 3/32-in. hex wrench, loosen and remove the rear connector clamp and rear nest. 2. Place the rear nest on a connector of the new size to be terminated. 3. While holding the rear nest in the connector, locate the connector over the front nest. 4. Engage the rear nest with the rack in the mandrel assembly. 5. Using a 3/32-in. hex wrench, secure the rear nest with the socket head cap screw. 6. Secure the rear connector clamp assembly behind the rear nest assembly. One tooth of the rack must be visible between the rear nest and the rear connector clamp assembly for proper positioning. NOTE Rev 0 30f6ANP 4.3. Connector Clamp Force The connector camps should place sufficient and retention of the connector during termina- damage to the connector might occur. With a connector loaded onto the mandrel assembly, use a .050-in. hex wrench to adjust the connector clamp self-locking setscrews as desired. Refer to Figure 2. Tooling Kit 768900-5 408-4054 ADJUSTMENT CONNECTOR RANGE (Approx. 0.08 mm [.003 in.} force on the connector to ensure proper location tion. The clamps should NOT be set too tightly, or premature wear of the clamp component and : C INSERTER GUIDING SURFACE 4.4, Inserter Assemblies A. Inserter Position The inserter position is important in that the quiding surfaces for the wire must control the wire up to the time it enters the connector contact. To adjust the inserter position: 1. Load a connector into the mandrel assembly and secure it in place. 2. Press the machines INDEX button. The machine will move to the connectors first position. 3. Using a 5/32-in. hex wrench, loosen the two inserter assembly mounting screws. 4. Loosen the sliding block mounting screw. Refer to Figure 1. 5. While viewing the inserter guiding surfaces, use a 5/32-in. open end or box wrench and turn the inserter position adjustment screw to move the assembly. Refer to Figure 1. Turn the screw CLOCKWISE to move the assembly AWAY from the connector, and COUNTERCLOCKWISE to move the assembly TOWARD the connector. 6. Check that the inserter guiding surface is within the adjustment area, as shown in Figure 5. 7. Using a 5/32-in. hex wrench, tighten the sliding black mounting screw and the two inserter assembly mounting screws. B. Wire Insertion Depth The length of travel of the inserter air cylinder ram may be adjusted. Normally, the inserters will not require this adjustment unless the insulation diameter is changed. To adjust the depth, refer to Figure 1 and proceed as follows: 1. Look at the top of the inserter assembly and read the wire insertion depth stop currently in use. cad 9822 Figure 5 2. Using a 5/32-in. hex wrench, remove the stop mounting screws, and remove the stop from the inserter assembly. 3. Determine the stop dimension from the marking on the top of the stop directly over the inserter tip. Each stop is designed with four stop dimen- sions. For example, the 18.034 mm [710 in] stop also includes a 17.907 mm [.705 in] sec- tion, a 17.780 mm [.700 in] section, anda 17.653 mm [.695 in] section. 4. Measure the insulation diameter of the wire presently being used, then measure the insulation diamter of the new wire to be used. 5. Determine the difference between the two insulation diameters, then subtract one half of this difference. Use the resulting number to determine the dimension of the new stop (add the figure to the old stop dimension of the diameter is increasing, subtract if the diameter is decreasing). 6. Place the correct stop onto the inserter assembly and install the stop mounting screws. 7. Repeat the above procedure for the other inserter assembly. Make sure that the inserter vane switches make in the inserted position by using Diag- nostic Mode 3 on the control module. Refer to Customer Manual 409-5791 which is supplied with the module, NOTE C. Inserter Guide Opening The inserter guide opening helps contro! the placement of the wire into the connector contacts. This gap should be adjusted to accommodate changing wire outside diameter. To adjust the opening: 1. Remove the inserter assembly from the machine by removing the two inserter mounting Screws, Ceeeeeeeeeeeeeeeeeeeeeeeee eee eee eee nce ere ere e cca eecceee 4o0f6 RevOANF Tooling Kit 768900-5 408-4054 2. Remove the inserter tip subassembly from the turning the screw COUNTERCLOCKWISE will inserter assembly. DECREASE the clamp force. 3. Using a 7/64-in. hex wrench, loosen the guide 3. Terminate several wires to verify the block and housing mounting screws. adjustment. 4. Measure the outside diameter of the new wire to 4. Using a .035-in. hex wrench, tighten the wire be used. clamp locking screw. 5. Locate the setup gage that is the same size as, 5. OPERATION or that is one size larger than, the measured wire. Insert the setup gage into the inserter assembly 1. Load the connector to be terminated onto the until the gage bottoms against the guide block. connecior nest. f i . Refer to Figure 6 2. Fasten the front and rear connector clamps onto 6. Gently force the guide blocks against the setup the connector. gage and secure. 3. Load the cable into the cable clamp. Refer to the instructions supplied with the cable clamp. . 4, Select the part number, CHAMP(50B on the 8. Install the inserter assembly onto the machine control module. as previously described. 7. Re-install the inserter tip subassembly. nia Refer to the customer manual supplied with the : . module for ific information lectin D. Wire Clamp Force (Figure 6) aon mber orpregranmai a now pat a The clamp force exerted on the wire during the number. termination process controls the wires vertical 5. Press the machines INDEX button. The placement in the connector contacts. Excessive clamp force will tend to extrude the wire insulation during termination, resulting in poor termination machine will move to the connectors first position to be terminated. quality. To adjust the force: 6. Untwist the wire pair designated for the first pair . of connector contacts. 1. Using a .035-in. hex wrench, loosen the wire clamp locking screw. 7. Place each wire into its own insertion area and actuate the machines inserter switches. The 2. Using a .050-in, hex wrench, turn the wire machine will trim and insert the wires into the clamp adjustment screw. Turning the screw contacts, then will automatically index to the next CLOCKWISE will INCREASE the clamp force, and connector position. GUIDE BLOCK MOUNTING SCREW INSERTER a ASSEMBLY WIRE CLAMP ADJUSTMENT SCREW WIRE CLAMP LOCKING SCREW HOUSING MOUNTING SCREW Figure 6 cad 9822 RevO 5o0t6AMP 6. MAINTENANCE Tooling Kit 768900-5 _ ona 6.1. Periodic Cleaning Clean all debris and insulation buildup from the inserter assemblies. 6.2, Lubrication Remove the cover plate and place a few drops of light ail onto the wire clamp slide. Cycle several times and wipe off excess oil before terminating wires. 6.3. Visual Inspection 1. Inserter tip - check for cracks, chips, or burrs. Remove or replace as necessary. 2. Guide block housing - check for burrs or gouges. Remove burrs. 3. Shear blade - check for chips or burrs. Replace as necessary. 4. Inserter mounting plate - check for cracks, specifically around the lower shear mounting slot. Replace as necessary. 6of6 408-4054 7, REPLACEMENT PARTS Figure 7 lists the items that are recommended as either expendable tooling or spare tooling. Expendable tooling, which includes items that are subject to wear, should be inspected regularly and replaced, if necessary. Recommended spare tooling includes items that should be stocked to prevent machine downtime in the event that they become damaged. For detailed information on the location of these items, and other replacement parts, refer to the drawings supplied in the tooling kit's documentation package. EXPENDABLE TOOLING NUMBER DESCRIPTION ASSEMBLY 1-21008-7 SETSCREW 2 21018-3 HEX NUT 2 852753-1 SPRING, Modified 2 856467-1 LOWER SHEAR 2 RECOMMENDED SPARE TOOLING 768774-1 ADJUSTMENT SCREW 2 189359-1 INSERTER TIP 2 Figure 7 RevO