REDUCED FOR PACKAGING Alt international Rights Reserved. AMP Incorporated products covered Copyright 1975, 1976, 1977 by AMP Incorporated, Harrisburg, Pa. by U.S. and Foreign patents and/or patents pending. APPLICATION AND MAINTENANCE Instruction Sheet FOR AMP * CRIMPING HEAD ASSEMBLY 90329-1 IS 7755 AMP INCORPORATED HARRISBURG, PA.17105 Section ff provides maintenance and inspection procedures for AMP crimping head assembties. Section / of this instruction sheet provides application pracedures for AMP crimping head assemblies. SHOULDER DOT TYPE 1tt(+} ASSEMBLY SOCKET CONTACT PIN MOUNTING x (Ref) LUG s ce WIRE Re STRIP ee INSULATION LENGTH BARREL - MOUNTING LOCATOR LINK SLOT TYPE VI PIN CONTACT TOGGLE (Ref} ro LINK CONTACT SHOULDER WIRE TOGGLE LEVER RETAINING RINGS SETSCREW CONTACT Wine Seow PNEUMATIC 6) IRE STOP aNvIL then JAWS e WIRE INSUL CRIMP SECT CONTACT WIRE SIZE OA WIRE SIZE ryee | COLOR | oe LOOSE PIECE STRIP STRIP (AWG) MARKING DOT PIN SOCKET PIN SOGKEY| LENGTH 28 to 28 035 to 055 28-24 vi None 16 66595 66596 66585 66586 1/8 26 to 24 mt Red 16 66107 66109 66108 66108 (125) 18 66237 66238 66188 66190 20 66306 66307 66204 66295 24 to 20 040 to 080 24-20 VI None 16 86593 66594 66583 66584 1/8 mey Yel 16 86103 66105 66102 66104 (.125) 18 66230 66240 66192 66194 20 66308 66309 66295 66207 18 080 to .100 18 VI None 16 56589 66590 66579 66580 1/8 TH) Blu 16 66099 66101 66008 66100 (125) 18 66241 a6242 66196 66198 30 66310 66311 66298 66299 Fig. I-1. SECTION | APPLICATION Read this instruction sheet (IS) for specific infor- mation concerning the head assembly, contacts, wire specifications, and crimping procedures. Refer to IS 1410 packaged with tool 69005, or IS 1300 -1, INTRODUCTION AMP Crimping Head Assembly 90329-1 is designed for crimping the AMP Type III(+) and Type VI loose piece (LP) pin and socket contacts listed in Figure I-1. The head assembly can be used in the bench mounted AMP Pneumatic Tool 69005 or the AMPLI-PRESS* Tool 69011. * TRADEMARK OF AMP INCORPORATED packaged with tool 69071, for information con- cerning the bench mounted setup. All dimensions presented on this instruction sheet are in inches, unless otherwise stated. PAGE 10F 4IS 7755 I-2. DESCRIPTION The head assembly features two crimper jaws, two anvil jaws, three crimp sections with applicable color coded wire size markings, a contact locator/wire stop, a contact support, two mounting links, a toggle link, and a toggle lever with shank (see Figure |-1}. Type I11(+) contacts have a color dot located on the contact spring. Type VI contacts have the applicable wire size stamped on the underside of the insulation barrel, 1-3. INSTALLATION OF HEAD ASSEMBLY CAUTION if using pneumatic tool, da NOT attach air supply to the too! until crimping head is completely installed. Proceed as follows: 1. Remove the two assembly pins from the mounting lugs (see Figure I-1). 2. Pull the toggle arm forward and hold. Loosen, but do NOT remove, the setscrew in the toggle arm. When using pneumatic tool, make sure the toggle link is ABOVE the toggle fever, as shown in Figure 1-1. When using AMPLI-PRESS tool, make sure the toggle link is BELOW the toggie fever. if fink is NOT in the correct position, remove the two retaining rings shown in Figure {-1 and reverse the positions of the link and fever. 3. With the crimping jaws open, insert the head assembly shank into the toggle arm until it bottoms. The mounting links must fit between the mounting lugs of the tool, 4. Tighten the setscrew in the toggle arm. 5. Align the mounting holes of the head assembly and tool. Insert the assembly pins through the mounting holes until the locking beads pass the outer edge of the mounting !ugs. See Figure |-2. BPEMBLY MOUNTING LUG CRIMPING HEAD LOCKING BEAD PAGE 20F 4 AMP CRiIMPING HEAD ASSEMBLY 90329-1 I-4. CRIMPING PROCEDURE Refer to the chart in Figure |-1, and select wire within the specified size and insulation diameter. Strip the wire to the length indicated do NOT cut or nick the wire strands. Select an applicable loose piece contact for the wire size, and identify the appropriate crimp section. The color dot or wire size marking on the contact must match the color coded wire size marking beside the appropriate tool crimp section. Refer to Figure |-3 and proceed as follows: 1. if using pneumatic tool, attach the air supply. 2. Position contact in crimper jaws, with locator/wire stop aligned with locator slot between contact wire barrel and shoulder. Push contact into crimper jaws and hold in this position, 3. Insert a properly stripped wire into the wire barrel of the contact until the wire butts against the locator/wire stop. 4. Holding wire and contact in place, depress operating pedal until crimping cycle is com- pleted. 5. Release operating pedal and crimped contact from crimper jaws. remove TYPE VI PIN CONTACT (Ref) = LOCATOR/ WIRE STOP we CONTACT SUPPORT LOCATOR SLOT (In Contact)_ N \ BACK OF ( CRIMP SECTION HEAD WIRE SIZE ~~ ASSEMBLY MARKINGS Fig. 1-3. I-5. REMOVAL OF HEAD ASSEMBLY 1. Hf using pneumatic tool, disconnect the air supply. 2. Remove the two assembly pins from the tool, 3. Pull the head assembly forward to expose the setscrew in the toggle arm. Loosen the setscrew and remove the head assembly.AMP CRIMPING HEAD ASSEMBLY 90329-1 IS 7755 Section / ef this instruction sheet provides application procedures for AMP crimping head assembties. Section Hf provides maintenance and inspection procedures far AMP crimping head assemblies. A Cc 24-20 18 CG) 28-24 (6) bs KO O% B O oO @) ; | @& SC 4 TOOL SPECIFICATIONS REPLACEMENT PARTS DIMENSION WEIGHT ITEM DESCRIPTION PART NUMSER OTY REG A 21/2 10 oz, 1 RING, Retaining 21045 3 6 B 41/4 2 PIN, Retaining 38783 1 Cc 1 3 PIN, Retaining 33781 2 Engineering Approval Date 4 SPACER 305471-2 2 9 5 RING, Retaining 21045-6 4 \) o7/ 6 PIN, Retaining ?- 9558-5 2 o mw A ) 7 LINK, Toggle 127024-1 2 a7 8 LEVER, Toggle 127025-1 1 Fig. 1-1. SECTION Ii MAINTENANCE/INSPECTION 1-1, CRIMPING HEAD ASSEMBLY CERTIFICATION These instructions have been approved by AMP Design, Production, and Quality Control Engineers to provide documented maintenance and inspection procedures in accordance with AMP Corporate Policy Number 3-3. Through AMP test laboratories and the inspection of production assembly, the procedures described herein have been established to assure quality and reliability of AMP crimping head assemblies, Customer replaceable parts are listed in Figure 11-1. A complete inventory should be stocked and controlled to prevent lost time when replacement of parts is deemed necessary. lIl-2. INSPECTION PROCEDURES A. Daily Maintenance It is recommended that each operator be made aware of and responsible for the following four steps of daily maintenance: 1. Remove dust, moisture, and other con- taminants with a clean brush, or a soft, lint-free cloth. Do NOT use objects that could damage the head assembly. 2. Make sure the proper retaining pins are in place and secured with the proper retaining rings. 3. Make certain all pins, pivot points, and bearing surfaces are protected with a THIN coat of good SAE No. 20 moter oil. Do NOT oil excessively. 4. When the head assembly is not in use, keep the jaws closed to prevent objects from be- coming jodged between them, and store in a clean, dry area. B. Periodic Inspection Regular inspections should be performed by quality control personnel. A record of scheduled inspections should remain with the head assembly and/or supplied to respensible supervisory personnel. Though recommendations call for at least one inspection a month, the inspection frequency should be based on the amount of use, ambient working PAGE 30F 41S 7755 conditions, operator training and skill, and estab- lished company standards. These inspections should be performed in the following sequence: B-1. Visual Inspection 1. Remove ail lubrication and accumulated film by immersing the head assembly in a suitable commercial degreaser that will not effect paint or plastic material. 2. Make certain ail retaining pins are in place and secured with retaining rings. If replacements are necessary, refer to parts listed in Figure II-1. 3. Inspect the head assembly, with special emphasis on checking for worn, cracked, or broken jaws. If damage to any part of the head assembly is evident, return it to AMP for evaluation and repair (see Paragraph li-3, REPAIR}. B-2. Crimp Height Inspection This inspection incorporates the use of a micrometer with a modified anvil as shown in Figure II-2. We recommend the modified micrometer (Crimp Height Comparator RS-1019-5L) which can be purchased from: York Machinery & Supply Co. VALCO 20 Nerth Penn St, or 1410 Stonewood Dr. York, PA 17401 Bethlehem, PA 18017 Proceed as follows: 1. Refer to the chart in Figure II-2, and then select a contact {loose piece) and wire (maximum size) for each crimp section. 2. Refer to Paragraph |-4, CRIMPING PRO- CEDURE, and crimp the contacts accordingly. 3. Using a crimp height comparator, measure each wire barrel crimp height as shown in Figure |I-2. If the crimp height conforms to that shown in the chart the head assembly is considered dimensionally correct. [f not, return PAGE 40F 4 AMP CRIMPING HEAD ASSEMBLY 90329-1 POSITION POINT ON CENTER OF WIRE BARREL OPPOSITE SEAM MCDIFIED ANVIL CONTACT WIRE NUMBER SIZE (LP) IMAX) 66596 26 66109 24 66238 662307 66594 20 66105 66240 66309 66590 18 18 66101 66242 66311 CRIMP SECT CRIMP HGT WIRE SIZE DiM MARKING A 86595 28-24 030 + 002 $6107 66237 65306 66593 66103 66239 66308 66589 66099 66241 66310 24-20 039 + .005 0525 + .0045 Fig. 1-2. the head assembly to AMP for evaluation and repair {see Paragraph 11-3}. For additiona! infor- mation concerning the use of the crimp height comparator, refer to AMP Instruction Sheet IS 7424, 1-3. REPAIR Parts other than those specified in Figure Il-1 must be replaced by AMP to insure certification of the head assembly. When repair is necessary, return the head assembly with a written description of the problem to: AMP Incorporated Customer Repair 1523 North 4th Street Harrisburg, Pennsylvania 17105 or a wholly owned subsidiary of AMP Incorporated.