AMP INCORPORATED J Hamisburg, Pa.i7105 Ey CUSTOMER HOTLINE 1 B00 722-1111 AMP* AMPLIMITE*~ HIGH DENSITY (HDE-20) INSULATION DISPLACEMENT METAL SHELL CONNECTORS CABLE TYPES CISCRETE WIRES \ nr Cs at Sn LOCKING 1 LANCE CAVITY (Typ) WIRE SIZE NUMBER CODE (On Contact) a x \ PLUG (Pin Contacts) Od MATING FACES 5 (Numbered , Cavities) JACKETED CAVITY SS RECEPTACLE (Socket Contacts) WIRE SIZE CONNECTOR DESCRIPTION [COND (AWG) | INSUL DIA | NO. CODE TYPE ' POSITION | 15-POSITION | 25-POSITION | 37-POSITION a O thru 26 360 Max ; Receptacle | 745491-14-4 | 74549318 4 | 745495-1 8-4 | 748407-1 & 4 De ; Plug | 745492-14-4 | 745404-18-4 | 745496-1 4-4 | 7454081 & 4 l Receptacle | 745491-24-5 | 74549328 -5 | 7454052 8-5 | 745407-2 8-5 h bo 26 thru zz; .060 Max 2 Plug 7454922 4-5 | 74549428 -5 | 745496245 | 7454082 & 5S Receptacie 745491-38 6 | 745499-34-6 | 745495-3 & 6 749407-3 & 5 | (960 M 3 22 thru 20 | ~~ Plug | 745492-3 8-6 | 745404386 | 74549638 -6 | 7454083 & 6 Fig. 1 1. INTRODUCTION This instruction sheet dS) covers selection and assembly of the AMPLIMITE HDE-20 Insulation Dis- placement Metal Shell Connectors tisted in Figure 1. Read these instructions thoroughly before siarting assembly. ' NOTE All dimensions on this sheet are in inches uniess otherwise stated. 2. DESCRIPTION Plug and receptacie connectors are available in 9, 15, 25, and 37 circuit positions. They are designed to terminate discrete wire, jacketed cable, and pre- slit ribbon cable with an insulation thickness that * Trademark of AMP Incorporated: Copyright 1981, 1988 by AMP incorporated. AH International Fights Reasrved, must not exceed .075 in. at any point. The conduc- tors can be solid or stranded (7 strands) ranging fram 30 to 20 AWG. Each connector consists of a housing with preloaded, insulation displacement contacis. The housings feature easily accessible contacts, cavity barrirs, and contact cavities which are numerically identified on the mating face, and have an internal design that accepts insulation cisplace- ment and crimp-type contacts. (Crimp contacts are recommended for two-wire circuits, drain wire termi- nation, service, etc.) Primary contacts are the insuiation displacement type-which are pre-assembled in the connectors _ listed in-Figure 1. They feature two locking lances; PAGE 1 OF 2iS 6645 INSULATION PIN UNSTRIPPED DISPLACEMENT ? WIRE a? CONTACT \ ae io f a LOCKING ek DISPLACEMENT LANCES NUMBER {ea cope -**"* BEAMS (For Wire Size) INSULATION BARREL Soeer STRIPPED C WIRE at u WIRE 7 OS BARREL oe INSULATION = CRIMP BARREL CONTACT CONTACT WIRE NUMBER | TYPE SIZE. CODE. PARTNO. | STYLE 74 3j 30 thru 26 | 1 3930 in 745931 21 Skt Insulation fs, 745888 | Fin Disolacement) Nr 22 | 2 745890 Sn : 745887 Pin 22 thru 20. | 3 a | 748266. 1 Pin 26 thru 22 4 Crime om 785269 =~ Skt ype | 745267 Pin 29 thry 1 2 thru 18 3 : 45270 Skt Fig. 2 twa insulation displacement beams, a single wrapa- round (strain relief) insulation barrei, and a number code inside tne insulation barrel that indicates the wire siz to De used in the contact. See Figure 2. Secondary contacts are crimp type contacts designed for aiscrete wire applications wnere more ihan one wire is required per contact. or where the care drain wire/braid needs to be terminatea. Sec: ondary contacts feature two iocking lances. an AMP F-crimp wire Darrel, and a wraparound insulation barrer. See Figure 2. Accessores for these connectors consist of various cable clamp assemblies and connector nardware and are supped in kits. AMPLIMITE HDE METAL SHELL CONNECTORS The instructions for the selection and assembly of the various accessories are packaged with each kit. For additional information, consult your iocal AMP represeniative. 3. TERMINATING TOOLS (Figure 3) Insulation displacement terminating tools hold the connector in place, insert wire into the insulation displacement beams, and form the insuiation barret around the insulation of the wire. The crimp termi- nating toois hoid the contacts in position for wire insertion and termination. and form the wire and insulation barrel around the wire. There are manual and power assist toais for various ivpes of wire and production requirements. Consult your local AMP representative for assistance in seiecting tooling ta meet your specific needs. 4. TERMINATING PROCEDURE Determine the size of the wire you are terminating and proceed as follows: 1. Select connector/contacts coded for your wire size. See Figure 1. 2. Select taoling with the aid of ihe chart in Figure 3. 3. Position the wire in the contact according to the instructions packagd with the tool. 4. Make the terminationis} and inspect to be sure all wires are property inserted per AMP Application Specification 114-40002 for insuta- tion displacement contacts. and 114-40003 for crimp contacts. 3. If specified by your application require- ments. attach cable clamp assemoly and hard- ware according to the instructions packaged with the item. 5. EXTRACTION/INSERTION OF CONTACTS AMP Extraction/insertion Tool 91232-1 is available to extract and insert contacts into the connectors. Refer to AMP Instruction Sheet IS 6631 for procedures. CONTACT | WIRE j PART NO. | MAXIMUM: TYPE ' SIZE | APPLICATION | DESCRIPTION TERMINATIONS! USED WITH (AWG) + TOOLING | PEAR CYCLE : 5806-1 (Head) : . 58074-1 (Hanalei Manual Pistol Grip Tool . _ : 58062-1 (Head) i. Di i { 5B075-1 (Handle) Pneumatic Pistol Grip Tool | : insulation | 20 thru 20 Displacement | 231297-1 CHAMPOMATOR * Machine (90 Termination: \ 2 Control Module 231298-1 { CHAMPOMATOR Machine (180 Termnation | No. 231673-1 91255-1 & 91255-2 Mass Termination Tool (Manual) ! 19 Manuai Unit No. 91085-2 91262-1 Mass Termination Tool (Pneumatic) : Pneumatic Unit No. 91112-3 26 thru 22 90398-1 Hand Crimping Tooi Crime 1 22 thre 18 90399-1 Hand Crimping Too! ' | 26 thru 22 5671792 Miniature Applicator AMP-O-Lectric * Machine 22 thru 18 567180-2 Miniature Applicator No. 565436-5 Fig: 3 PAGE 2 OF 2