768900-1 - TE Connectivity AMP Connectors

Instruction Sheet

408-9822

LOC B

of 7

2008 Tyco Electronics Corporation, Harrisburg, PA

All International Rights Reserved

TE logo and Tyco Electronics are trademarks.

*Trademark. Other products, logos, and company names used are the property of their respective owners.

TOOLING ASSISTANCE CENTER 1-800-722-1111

PRODUCT INFORMATION 1-800-522-6752 This controlled document is subject to change.

For latest revision and Regional Customer Service,

visit our website at

www.tycoelectronics.com

07 MAR 08 Rev C

Tooling Kit 768900-1

Figure 1

Inserter Tip

Subassembly

Inserter

Assembly

Tie Bar (Ref)

Inserter

Assembly

Vane

Switch

Stop

Mounting

Screw

Wire Insertion

Depth Stop

Inserter Position

Adjustment Screw

Sliding Block

Mounting Screw

Rear Connector Clamp

Mandrel Assembly

Front Connector Clamp Shroud

Shroud

Connector Nest Sets

(Plug Nest Set

Installed)

1. INTRODUCTION

This instruction sheet covers the installation and use

of Tooling Kit 768900–1, which is used in the

CHAMPOMATOR* 2.5 Bench Terminating Machine to

apply discrete–wire cable to AMPLIMITE* .050 Series

III Connectors. This sheet also provides part number

information for the tooling required to apply the

various connector sizes.

All dimensions on this sheet are in millimeters

[with inch equivalents provided in brackets].

Figures and illustrations are for identification only

and are not drawn to scale.

These instructions are supplied in the

documentation package for Tooling Kit 768900-1.

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 Customer

Manual 409-5839, which is supplied with

the machine.

Reasons for reissue of this instruction sheet are

provided in Section 9, REVISION SUMMARY.

2. DESCRIPTION

(Figure 1)

The tooling kit consists of two inserter assemblies, a

mandrel assembly, two sets of connector nests, one

set of connector shrouds, and a set of setup gages

(used for adjusting the insertion guide opening). A tie

bar, purchased separately, is used to position and

secure the connector during machine operation.

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 sets locate the connector in the

mandrel assembly. One set, designed for plug

connectors, polarizes the connector in the mandrel

assembly. The other set, designed for receptacle

connectors, does not polarize the connector in the

mandrel assembly.

Receptacle connectors MUST be correctly

located by the operator.

NOTE

408-9822

Tooling Kit 768900-1

Rev

of 7 Tyco Electronics Corporation

Figure 2

Air Cylinder Ram

Alignment Pins for

Inserter Assembly

Alignment Pins for

Inserter Assembly

Mandrel Assembly

Locking Screw

(In Access Hole)

Mounting Screw

Connector

Clamp Force

Adjustment

Mandrel

Assembly

Machine Base

Block Assembly

(Ref)

3. INSTALLATION

Disconnect the power to the control module and

lockout the pneumatic valve BEFORE installing

the tooling onto the base machine.

For clarity, the illustrations used in this sheet may

show the machine without guarding. Be sure to

have all guarding in place before operating the

machine.

3.1. Mandrel Assembly

(Figure 2)

All inserter assemblies must be removed before

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 screws supplied with

the machine.

3.2. Inserter Assemblies

(Figures 2 and 3)

1. Align the inserter assembly T–slot over the air

cylinder ram assembly.

2. Locate the base of the inserter assembly onto

the two alignment pins on the machine’s inserter

assembly mounting area.

3. Using a 5/32–in. hex wrench, install the two

inserter mounting screws.

4. ADJUSTMENTS

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, install the tie bar, 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 locking 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.

DANGER

NOTE

408-9822

Tooling Kit 768900-1

of 7Rev

Tyco Electronics Corporation

Figure 3

Inserter

Assembly

Inserter

Assembly

Inserter Assembly

Mounting Screw

Height-Adjustment

Wheel

Inserter Assembly

Mounting Screw

T-Slot in Inserter

on Air Cylinder Ram

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

RAISE the mandrel (and connector) and

COUNTERCLOCKWISE to LOWER the mandrel

(and connector).

7. Once the desired height has been reached, use

a 5/32–in. hex wrench to tighten the mandrel

assembly locking screw.

Figure 4

Connector

Contacts Adjustment Range

(Approx. 0.025

to 0.127 mm

[.001 to .005 In.])

Guide

4.2. Connector Nest

A. Connector Size - Same Type

To adjust for different connector sizes of the

same type:

1. Using a 3/32–in. hex wrench, loosen and

remove the rear connector clamp and rear

nest section.

2. Place the rear nest section on a connector of

the new size to be terminated.

3. While holding the rear nest section in the

connector, locate the connector over the front

nest section.

4. Engage the rear nest section with the rack in the

mandrel assembly.

5. Using a 3/32–in. hex wrench, secure the rear

nest section with the socket head cap screw.

6. Secure rear clamp assembly behind the rear

nest assembly.

One tooth of the rack must be visible between

the nest section and the rear clamp assembly for

proper positioning.

B. Connector Polarity (Plug Connectors Only)

To adjust the plug connector nest set to

accommodate different polarity:

1. Using a 3/32–in. hex wrench, loosen and

remove the mounting screws for both connector

nest sections, then remove both connector

nest sections.

2. Rotate the nest sections and place back onto

the rack section of the mandrel assembly.

3. Using a 3/32–in hex wrench, secure the nest

sections with the socket head cap screws.

NOTE

408-9822

Tooling Kit 768900-1

Rev

of 7 Tyco Electronics Corporation

C. Connector Nest Types - Same Size

To change the type of connector (plug or receptacle)

to be terminated:

1. Using a 3/32–in. hex wrench, loosen and

remove the mounting screws for both connector

nest sections, then remove both connector

nest sections.

2. Replace the connector nest sections with the

nest sections of the desired type.

When installing the plug nest sections, make sure

that the sections are placed to provide correct

connector polarity.

3. Using a 3/32–in. hex wrench, secure the nest

sections with the socket head cap screws.

When installing the receptacle nest, place the

shroud on top of the receptacle nest and secure

with screw used to secure nest.

Make sure that one tooth of the rack is visible

between the nest and the front clamp for proper

positioning.

4.3. Connector Clamp Force

The connector clamps should place sufficient

force on the connector to ensure proper location

and retention of the connector during termination.

The clamps should NOT be set too tightly, or

premature wear of the clamp component and

damage to the connector and connector nest

may occur.

With a connector loaded onto the mandrel assembly,

and with the tie bar in place, proceed as follows:

1. Using a 3/16–in. open–end or box wrench,

loosen the locking hex nut.

2. Using a .035–in. hex wrench, adjust the

connector clamp set screws as desired.

3. Using a 3/16–in. open–end or box wrench,

tighten the locking hex nut, making sure that the

flats on the nut align with the flats on the

connector clamp.

4.4. Inserter Assemblies

A. Inserter Position

The inserter position is important in that the guiding

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. Index the machine to connector contact No. 1.

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

block mounting screw and the two inserter

mounting screws.

Figure 5

Connector

(Typ)

Inserter Guiding Surface

Adjustment Range

(Approx. 0.0762 mm

[.003 In.])

B. Wire Insertion Depth

The length of travel of the inserter 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.

2. Using a 5/32–in. hex wrench, remove the stop

mounting screw, 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.

4. Measure the insulation diameter of the wire

presently being used, then measure the insulation

diameter of the new wire to be used.

NOTE

CAUTION

408-9822

Tooling Kit 768900-1

of 7Rev

Tyco Electronics Corporation

Figure 6

Guide Block

Mounting

Screw

Wire Clamp

Locking Screw Housing

Mounting

Screw

Inserter

Assembly

Setup

Gages

Wire Clamp

Adjustment Screw

Each stop is designed with four stop dimensions.

For example, the 18.034 mm [.710 in.] stop also

includes a 17.907 mm [.705 in.] section, a

17.780 mm [.700 in] section, and a 17.653 mm

[.695 in.] section.

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 Diagnostic Mode

3 on the control module. Refer to the Customer

Manual supplied with the module.

C. Inserter Guide Opening

The inserter guide opening helps control 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.

2. Remove the inserter tip subassembly from the

inserter assembly.

3. Using a 7/64–in. hex wrench, loosen the guide

block and housing mounting screws.

4. Measure the outside diameter of the new wire to

be used.

5. Locate the setup gage that is the same size as,

or that is one size larger than, the measured wire.

Insert the setup gage into the inserter assembly

until the gage bottoms against the guide block.

Refer to Figure 6.

6. Gently force the guide blocks against the setup

gage and secure.

7. Re–install the inserter subassembly.

8. Install the inserter assembly onto the machine

as previously described.

D. Wire Clamp Force

(Figure 6)

The clamp force exerted on the wire during the

termination process controls the wire’s vertical

placement in the connector contacts. Excessive

clamp force will tend to extrude the wire insulation

during termination, resulting in poor termination

quality. To adjust the force:

1. Using a .035–in. hex wrench, loosen the wire

clamp locking screw.

2. Using a .050–in. hex wrench, turn the wire

clamp adjustment screw. Turning the screw

CLOCKWISE will INCREASE the clamp force, and

turning the screw COUNTERCLOCKWISE will

DECREASE the clamp force.

3. Terminate several wires to verify the adjustment.

4. Using a .035–in. hex wrench, tighten the wire

clamp locking screw.

NOTE

408-9822

Tooling Kit 768900-1

Rev

of 7 Tyco Electronics Corporation

5. OPERATION

1. Load the connector to be terminated onto the

connector nest.

2. Place the tie bar (purchased separately; refer to

Figure 7) onto the connector.

3. Fasten the front and rear connector clamps onto

the tie bar.

4. Load the cable into the cable clamp, if

applicable. Refer to the instructions supplied with

the clamp.

NUMBER OF

CONNECTOR POSITIONS TIE BAR

PART NUMBER

20 762637-1

26 1-762637-1

28 1-762637-2

40 762637-3

50 762637-4

60 762637-5

68 762637-6

80 762637-7

100 762637-9

120 1-762637-0

Figure 7

5. Press the machine’s INDEX button. The

machine will move to the first connector position to

be terminated.

6. Untwist the wire pair designated for the first pair

of connector contacts.

7. Place each wire into its own insertion area and

actuate the machine’s inserter switches. The

machine will trim and insert the wires into the

contacts, then will automatically index to the next

connector position.

6. MAINTENANCE

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

oil 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.

7. REPLACEMENT PARTS

Figure 8 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

PART NUMBER DESCRIPTION

1-21006-8 Set Screw

21018-3 Hex Nut

768753-1 Inserter Tip

852753-1 Spring (Modified)

856467-1 Lower Shear

RECOMMENDED SPARE TOOLING

PART NUMBER DESCRIPTION

354047-1 Front Connector Clamp Assembly

354047-2 Rear Connector Clamp Assembly

354048-1 Plug Nest Set

354049-1 Receptacle Nest Set

768774-1 Adjustment Screw

318618-1 Shroud

318618-2 Shroud

Figure 8

408-9822

Tooling Kit 768900-1

of 7Rev

Tyco Electronics Corporation

8. TROUBLESHOOTING

PROBLEM PROBABLE CAUSE SUGGESTED ACTION

Connector contacts being

damaged. Incorrect mandrel height. Adjust height as described in this

sheet.

Inserter assembly out of

adjustment. Adjust inserter assembly as described

in this sheet.

Machine’s offset not set correctly. Adjust offset. Refer to Customer

Manual 409–5839, which is supplied

with the machine.

Damaged inserter tip. Inspect/replace inserter.

Connector clamp too tight. Adjust connector clamp force as

described in this sheet.

Wire shear length varying. Inserter guide opening not properly

set. Adjust opening as described in this

sheet.

Wire clamp force not correct. Adjust force as described in this sheet.

Inserter assembly out of

adjustment. Adjust inserter assembly as described

in this sheet,

Damaged inserter tip or lower

shear. Inspect/replace inserter or shear as

necessary.

Insulation extruded. Wire clamp force too great. Adjust force as described in this sheet.

Inserter guide opening not properly

set. Adjust opening as described in this

sheet.

Damage to wires above

contact’s wire insertion area. Inserter assembly position too

close to connector. Adjust inserter assembly position as

described in this sheet.

Cable breakout too low. Raise position of cable (and wire

breakout) on cable clamp.

Wire not centered in contact’s

wire insertion area. Inserter guide opening not properly

set. Adjust opening as described in this

sheet.

Machine’s offset not set correctly. Adjust offset. Refer to Customer

Manual 409–5839, which is supplied

with the machine.

Damaged inserter tip. Inspect/replace inserter.

Damaged connector clamps. Inspect/replace connector clamps.

Wire strands cut. Wire insertion too deep. Adjust inserter eccentric as described

in this sheet.

Wire falling out of contacts. Wire insertion too short. Adjust inserter eccentric as described

in this sheet.

Adjust inserter vane using control

module’s Diagnostic Mode 3. Refer to

Customer Manual 409–5791, which is

supplied with the module.

Adjust machine offset. Refer to

Customer Manual 409–5839, which is

supplied with the machine.

9. REVISION SUMMARY

Since the previous release of this sheet, the following

changes were made:

Updated logo and format.