AMP STACK MARK IV Instruction Sheet TOOL KIT AND ...
Transcript of AMP STACK MARK IV Instruction Sheet TOOL KIT AND ...
Rev. C Page 1 of 10
Instruction Sheet 411-22037
09/MAY/2005 Rev. C
AMP STACK MARK IV TOOL KIT AND ACCESSORIES
Operation and Maintenance Procedures
Universal Clamp Bar Assembly
Mod C Frame Assembly (PICABOND* Clamp)
10 Pair Bar Clamp
Holder Bar
Separating Tool
Electrical Tester
Single Point Separating Tool
Piece Out Fixture
Check Comb
Hand Tool Assembly
Splicing Head Assembly (Standard)
Splicing Head Assembly (Universal)
T-Pedestal
Single Insertion Tool
Adjustable Holder Bar
Adapter Block Assembly
Figure 1
Rev. C Page 2 of 10
Instruction Sheet 411-22037
09/MAY/2005 Rev. C
AMP STACK MARK IV TOOL KIT AND ACCESSORIES
Operation and Maintenance Procedures
1. Introduction
This Instruction Sheet covers all application tools and accessories
of the AMP STACK Mark IV tool kit at the time of this issue. Tools
and accessories are grouped together in kits. See Figure 3 and 4
for kits content.
Application tools and accessories released are: See Figure 1.
• Hand Tool Assembly PN 790115-1
• Splicing Head Assembly (Standard) PN 790114-3
• Splicing Head Assembly (Universal) PN 790114-4
• Check Comb PN 356073-1
• Electrical Tester PN 790106-1
• Separating Tool PN 790104-1
• Single Point Separating Tool PN 790141-1
• Single Insertion Tool PN 790172-1
• Bar Clamp (10 pairs) PN 1-525424-6
• Holder Bar, 10 pairs PN 790138-1
• Adjustable Holder Bar PN 790144-1
• T-Pedestal PN 790136-1
• Piece Out Fixture PN 1-525421-4
• PICABOND Clamp PN 247284-1
• Adapter Block Assembly PN 356152-1
• Universal Clamp Bar Assembly PN 1-525421-2
These tools and accessories are designed to join telephone cable
conductors using the connectors listed in Figure 2.
Connector Type Splicing Half- Tap
Dry Standard 737858 737860
Pre- Sealed 737869 737873
Figure 2
The tool terminates one 10 Pair Straight or Half-Tap AMP STACK
Mark IV connectors to wires with 0,40-0,90 mm [26-19 AWG]
conductor diameter. The connectors are designed to accept wires
with plastic or paper insulation with a maximum outside diameter of
1,95 mm [.077 inch]. Refer to AMP Application Specification
114-22007 and AMP Product Specification 108-22074 and 108-
22075 for further connector information.
Note: For wire insulation diameters larger than 1,85 mm it is
necessary to test the tool application, especially for high-density
polyethylene insulations.
Note: All dimensions in this document are in metric units [With U.S.
customary units in brackets]
The operation procedures include crimping and inspecting the
crimped connectors. The maintenance procedures include
cleaning, lubricating and servicing the Hand Tool.
Tooling Kit Standard 790112 1- 5
Carrying Case 790116-1 1
Splicing Head Assy 790114-3 1
Hand Tool Assy 790115-1 1
Check Comb 356073-1 1
Separating Tool 790104-1 1
Single Insertion Tool 790172-1 1
Electrical Tester 790106-1 1
Instruction Sheet 411-22037 790127-2 1
Figure 3
Accessories
This case can also accept the following accessories:
• Piece Out Fixture 1-525421-4
• Holder Bar, 10p 790138-1
Tooling Kit Universal 790142 1-1 Carrying Case 790116-1 1 Splicing Head Assy 790114-4 1 Hand Tool Assy 790115-1 1 Check Comb 356073-1 1 Separating Tool 790104-1 1 Single Insertion Tool 790172-1 1 Instruction Sheet 411-22037 790127-2 1 Electrical Tester 790106-1 1
Figure 4
Note: This tooling kit is recommended to be used in conjunction
with the Universal Clamp Bar Assembly 1-525421-2.
Accessories
The case can also accept the following accessories:
• Piece Out Fixture 1-525421-4
• T-Pedestal 790136-1
• Holder Bar, 10p 790138-1
Tooling Kit Universal 790142 1-2 Carrying Case 790116-1 1 Splicing Head Assy 790114-4 1 Hand Tool Assy 790115-1 1 Check Comb 356073-1 1 Single Insertion Tool 790172-1 1 Holder Bar 790142-2 1 Instruction Sheet 411-22037 790127-2 1 Electrical Tester 790106-1 1
Figure 5
Accessories
The case can also accept the following accessories:
• Separating Tool 790104-1
• T-Pedestal 790136-1
Rev. C Page 3 of 10
Instruction Sheet 411-22037
09/MAY/2005 Rev. C
AMP STACK MARK IV TOOL KIT AND ACCESSORIES
Operation and Maintenance Procedures
Additional Accessories
Not to be placed in the Carrying Case:
• Bar Clamp (10 pair) 1-525424-6
• Adjustable Holding Bar 790144-1
• Single Point Separating Tool 790141-1
• PICABOND Clamp 247284-1
• Universal Clamp Bar 1-525421-2
• Adapter Block Assembly 356152-1
2. Description
• The Hand Tool is a hand held tool that terminates a connector
with a single handle operation. The Hand Tool and
corresponding Splicing Head Assembly crimp anyone of the
above listed AMP STACK Mark IV connectors without extra tools
or adjustments.
• By means of the Splicing Head Assembly the operator can
place the connector and sort the wires to be terminated in order
to crimp them properly by applying the Hand Tool onto it.
• Once attached to the Splicing Head Assembly (Universal) the
T-Pedestal provides reliable support to it. Up to two (2) Splicing
Heads may be attached to each T-Pedestal.
• The Check Comb is a template to visually inspect the correct
placement of the wires on the Splicing Head.
• The Electrical Tester permits an electrical testing of the
terminated connector and wires without damaging the wire
insulation. This accessory shapes the interface between
connector and testing equipment.
• The Separating Tool has been designed to separate a
pluggable module from the module to which it has been mounted
with only one operation and also to separate Cover and Base
from the module if needed. The Separating Tool is compatible
with Pluggable versions from other manufacturers.
• The Single Point Separating Tool has the same purpose as
the Separating Tool never the less, with this tool more than one
operation is necessary.
• The Single Wire Insertion Tool is used to rearrange wiring
mistakes.
• The Bar Clamp is used to position the Splicing Head Assembly
close to the wires to be terminated. A Universal Splicing Head
Assembly will need a T-Pedestal to be attached to its base prior
to be positioned in the Bar Clamp.
• The Holder Bar and the Adjustable Holder Bar provide similar
functions as the Bar Clamp. In this case, only Universal Splicing
Head is accepted. The Holder Bar accepts up to two (2) Splicing
Head. The Adjustable Holder Bar accepts up to four (4) Splicing
Head.
• The Piece Out Fixture is designed as a substitute Splicing Head
for use in situations where there is little or no slack cable
available for jointing. Please refer to Instruction Sheet 411-3195
for its proper use and maintenance.
• The PICABOND Clamp together with the Adapter Block
Assembly provides a solid clamp structure for a Splicing Head
Assembly. A Universal Splicing Head Assembly will need a T-
Pedestal. Refer to Instruction Sheet 408-6569 for PICABOND
Clamp general practice.
• The Universal Clamp Bar Assembly provides rigid support for
up to 4 Splicing Head Assembly. [In case of Universal Splicing
Head Assembly a T-Pedestal is required]. Please Refer to
Instruction Sheet 411- 3193 for Universal Clamp Bar Assembly
general practices.
3. Preparation
3.1. Cable and Connector
Open and prepare the cable according to usual practices.
Determine the connector to be terminated (Straight or Half-Tap).
Refer to Figure 2 for Part Numbers.
3.2. Tooling Setup
• Adjustable Holder Bar. Unfold and secure by means of
included screws. Attach Adjustable Holder Bar to ends of cable
sheathing by wrapping the included rubber bands around them.
Once the rubber bands are tightly wrapped, insert each bar
anchor post in the corresponding rubber band hole. See Figure
6. Attach up to four Splicing Head Assemblies (Universal) onto
Adjustable Holder Bar by means of the thumbscrews provided
with the Bar. See Figure 7.
Rev. C Page 4 of 10
Instruction Sheet 411-22037
09/MAY/2005 Rev. C
AMP STACK MARK IV TOOL KIT AND ACCESSORIES
Operation and Maintenance Procedures
Figure 6
Figure 7
• Holder Bar. Attach one or two Splicing Head Assembly
(Universal) onto the bar by means of the thumbscrews provided
with the bar. See Figure 8. Attach Holder Bar to ends of cable
sheathing by wrapping the included rubber bands around them.
Once the rubber bands are tightly wrapped, insert each bar
anchor post in the corresponding rubber band hole. See
Figure 9.
Figure 8
Figure 9
• Bar Clamp. Attach to ends of cable sheathing according to local
practices. Insert Splicing Head into the clamp grip and fix it at the
appropriate height by the grip screws. In case of using a
Universal Splicing Head, attach T- Pedestal to it and then insert
the new assembly into the clamp grip. See Figure 10.
Figure 10
Rev. C Page 5 of 10
Instruction Sheet 411-22037
09/MAY/2005 Rev. C
AMP STACK MARK IV TOOL KIT AND ACCESSORIES
Operation and Maintenance Procedures
Figure 11
Note: Attach the T-Pedestal to the Universal Splicing Head base by
means of the screws included in the T-Pedestal. See Figure 11.
• Adapter Block Assembly. The Adapter Block Assembly is to be
joined to the PICABOND Clamp. Refer to Instruction Sheet
408-6569 in order to attach PICABOND Clamp to cable stub
sheathing. Insert the Adapter Block Assembly Mounting Stud into
the Applicator Clamp of the PICABOND Clamp. Next, position
Adapter Block Assembly and secure by closing clamp handle.
See figure 12. Insert Splicing Head into the Adapter Block
Assembly and fix it at the appropriate height by the Adapter
thumbscrews. See Figure 13. In case of using a Universal
Splicing Head, attach T- Pedestal to it and then insert the new
assembly into the clamp grip. See Figure 11.
Figure 12
Figure 13
Mounting Stud
Applicator Clamp
Adapter Block Assembly
Rev. C Page 6 of 10
Instruction Sheet 411-22037
09/MAY/2005 Rev. C
AMP STACK MARK IV TOOL KIT AND ACCESSORIES
Operation and Maintenance Procedures
Figure 14
• Universal Clamp Assembly. Insert Splicing into the clamp grip
and fix it at the appropriate height by the grip screws. See Figure
14 for further details see Instruction Sheet 411-3193. In case of
using a Universal Splicing Head, attach T- Pedestal to it and then
insert the new assembly into the clamp grip. See Figure 11.
4. Connector Setup
4.1. Terminating a Straight or a Half-Tap connector
1. Place the connector base (with pins marked in black colour) into
the Splicing Head Assembly with the chamfered edge in the top left
location. See Figure 15. Base colours: Gold for Straight connectors,
green for Half- Tap connectors. In both cases, a transparent base is
also available.
Note: The Splicing Head Assembly has some protrusions on it to
avoid a wrong positioning of the base.
2. Lace the wires according to the colour code. See Figure 15.
Position the wire across the connector base and into the wire
retention springs to hold it.
Figure 15
3. After all the wires have been positioned over the connector base,
place the Check Comb into the Splicing Head Assembly, on wires
and connector base. Place the Check Comb to the left on the
Splicing Head. See Figure 16. Visually inspect the wires to ensure
that all of the wires shown are the correct colour. Slide the Check
Comb to the right and visually inspect the wires to ensure that all of
the visible wires are correct. See Figure 17. Rewire any mistakes.
Figure 16
Figure 17
Chamfered edge of connector
Connector Base
Wire Retainer Springs
Rev. C Page 7 of 10
Instruction Sheet 411-22037
09/MAY/2005 Rev. C
AMP STACK MARK IV TOOL KIT AND ACCESSORIES
Operation and Maintenance Procedures
4. Next, place a connector body on top of the wires, making sure
that the chamfered edge is to the top left as shown in Figure 18.
Note: The ivory side of the connector body must always be on
the top.
Figure 18
5. Lace the wires following the same procedure and inspect them
with the Check Comb. Place the ivory or transparent cover (no
cover pins marked in black) of the connector on top of the
connector and wire stack. Make sure that the chamfered edge is to
the top left location. Apply Hand Tool to terminate wires according
to paragraph 5 (Using the Hand Tool).
5. Using The Hand Tool
1. Adjust the ram spacer on the Hand Tool to the proper position.
When terminating Straight, Half-Tap, or in the case of finding
Straight plus Pluggable or Half-Tap plus Pluggable connector
combination already installed, the words "ONE OR TWO
PLUGGABLE" shall not be visible on the face of the ram; for
Pluggable or Pluggable plus Pluggable connector combination, the
words “ONE OR TWO PLUGGABLE” must be visible on the face of
the ram. To adjust the ram spacer, push the extended lip of the ram
spacer forward and rotate the ram spacer until the ball stops snap
into position. The ball stop must be in position to secure the spacer.
See Figure 19.
Figure 19
Caution: Do not rotate the Ram Spacer to front of the tool. Always
switch between lower and rear (handles) position.
2. Place the Hand Tool onto the Splicing Head Assembly by
squeezing the latches with your fingers. When terminating only one
connector, the latches must fully engage with the bottom set of
teeth on the Splicing Head Assembly. When terminating a
combination of two connectors, the latches must fully engage with
the upper set of teeth on the Splicing Head Assembly. See figure
20.
Figure 20
Ram Spacer
Rev. C Page 8 of 10
Instruction Sheet 411-22037
09/MAY/2005 Rev. C
AMP STACK MARK IV TOOL KIT AND ACCESSORIES
Operation and Maintenance Procedures
Figure 21
Caution: The Hand Tool and/or the Splicing Head Assembly may
be damaged if the tool is incorrectly mounted on the head. It is
important that BOTH latches be in the SAME tooth on both sides of
the head.
Note: If the Hand Tool becomes difficult to place onto the Splicing
Head Assembly, check the ram spacer to make sure that it is
seated flat.
3. Squeeze the handles of the tool together with both hands.
Caution: Be careful not to allow the handles to spring open freely,
releasing the stored energy instantly.
4. Release the handles slowly. See Figure 21. The connector(s)
should now be terminated.
Note: If the connector is not fully terminated, check the ram spacer
to make sure that it is seated flat.
5. Remove the tool; then, carefully pull the wires out of the wire
retention spring. Pulling a few wires out at a time will reduce the risk
of damage to the spring. See Figure 22.
Figure 22
Figure 23
Note: A terminated Half-Tap connector will not cut the bottom 10
pairs of wires. Do not attempt to remove these wires. See figure 23.
6. Carefully remove the connector from the Splicing Head
Assembly and visually inspect the connector according to
Paragraph 6.
6. Inspecting And Rearranging The Terminated
Connector
Inspect the terminated connectors to be sure that the latches that
hold the covers into the connector body are fully engaged on both
sides. After termination, make sure that the wires are fully cut and
are not turned out of the connector.
Caution: When terminating larger wires, the wires may appear to
stick inside the connector and require extra force to pull out. In this
case, the insulation may not be fully cut. Inspect the wire samples
to be sure that the copper is being fully cut.
Rev. C Page 9 of 10
Instruction Sheet 411-22037
09/MAY/2005 Rev. C
AMP STACK MARK IV TOOL KIT AND ACCESSORIES
Operation and Maintenance Procedures
Inspect the connector to be sure that only one wire is present in
each connector slot. Make sure there are no wires missing from the
connector.
If some wiring mistakes are found, the connector must be opened:
• Base and/or cover can be peeled away by hand.
• In the case of finding stacked connectors already installed, they
can be separated with the Separating Tool. Its pins shall be
placed into the long holes between the light blue side of the
upper Pluggable connector and the ivory side of the lower
connector. Squeeze the handles of the tool to separate the
connectors.
Caution: Never insert Separating Tool pins into wrong connector
holes. See Figure 24.
The wire to be rearranged shall be laced across the connector and
held it in place using the wire retention springs. See Figure 25.
Position the Single Wire Insertion Tool and push it squarely so that
the metal tip will push the wire into the insulation displacement slot
in the connector. Reposition the tool above blade and push the tool
so that the connector cut-off blade cuts off the wire.
Figure 24
Figure 25
After all of the wiring mistakes have been corrected, the connector
must be closed:
• Base and/or cover can be reassembled by hand.
• If a combination of two connectors has been opened to
rearrange a wire in the intermediate layer, they can be stacked
again with the Splicing Head Assembly and the Hand Tool
according to paragraph 5.
If a wire has not been cut during the usual crimping process:
1. Check that the connector is assembled correctly.
2. Check that the latches of the Hand Tool have been engaged with
the right set of teeth of the Splicing Head Assembly. (See
paragraph 5)
3. Check that the ram spacer of the Hand Tool is in the right
position (See paragraph 5)
4. Check that nothing is obstructing the handles and that they close
fully
5. If after the above checks the tool still does not operate, return it to
AMP.
After terminating the connector, it can be electrically tested without
damaging the wire insulation. The Single Pair Electrical Tester has
2 (two) pin probes that fit in the test ports of the connector. See
figure 26. Each pair can be checked by placing the probes in the
corresponding ports.
Page 10 of 10
Tyco Electronics UK Ltd Global Application Tooling Division Barton Tors Bideford, Devon. ENGLAND Tel.: 44-(0)12 3742 8668 Fax: 44-(0)12 3742 8689 http://tooling.tycoelectronics.com/europe/
Tyco Electronics Raychem NV Telecom Outside Plant Diestsesteenweg 692 3010 Kessel-Lo, Belgium Tel.: 32-16 351 011 Fax: 32-16 351 697 www.tycoelectronics.com
Tyco Electronics Raychem, S.A. Polígono industrial Mediterráneo C/. La Fila, parcela 1 46550 Albuixech-Valencia, España Tel.: 34-96-141 70 72 Fax: 34-96-141 74 15
Instruction Sheet 411-22037
09/MAY/2005 Rev. C
AMP STACK MARK IV TOOL KIT AND ACCESSORIES
Operation and Maintenance Procedures
Tyco Electronics and AMP are trademarks. © Copyright 2005 by Tyco Electronics. All of this information, including illustrations, is believed to be reliable. Users, however, should independently evaluate the suitability of each product for their application. Tyco Electronics makes no warranties as to the accuracy or completeness of the information and disclaims any liability regarding its use. Tyco Electronics’ only obligations are those in the Standard Terms and Conditions of Sale for this product and in no case will Tyco Electronics be liable for any incidental, indirect or consequential damages arising from the sale, resale, use or misuse of the product. Tyco Electronics Ordering Guide are subject to change without notice. In addition, Tyco Electronics reserves the right to make changes in materials or processing, without notification to the Buyer, which do not affect compliance with any applicable specification.
Figure 26
Figure 27
Caution: To mate or unmate properly, the tester should be slightly
angled respect to the connector. See Figure 27.
7. Inspection And Maintenance
The procedures described in the following paragraphs have been
established to ensure quality and reliability of the application tooling.
The tooling kits are inspected before shipment and should be
inspected immediately upon arrival at your facility to ensure that the
components have not been damaged in transit. A record of
scheduled inspections should remain with each kit or be supplied to
the personnel responsible for the tool. Although it is recommended
for at least one inspection per month, the frequency should be
based on:
• Care, amount of use, and handling of tooling kit.
• The degree of operator training and skill.
• The ambient working conditions (abnormal amounts of dust, dirt,
and temperature changes will necessitate more frequent
inspections).
• Established company standards.
7.1. Inspection
A. Hand Tool
Inspect the Hand Tool to make sure that it opens and closes freely.
Clean any dirt or dust that may be present in the tool. Inspect the
safety ring on the handle of the tool and ensure that the ring is
secure and can support more than the weight of the tool.
B. Splicing Head Assembly
The wire retention springs should be clean of any grease for best
performance. Make sure that the screws securing the guides to the
head are tight. Ensure that the connector retainer springs are
working properly and are able to support the connector, even when
the head is turned upside down.
7.2. Maintenance
A. Lubrication
It is strongly recommended to lubricate all pivot points of the tool
with a thin coat of any SAE 20 motor oil. Do not oil excessively. See
Figure 28. Under normal conditions, lubrication is required every
1.000 tool cycles, or whenever the interface is dry. Otherwise, the
tool will not open properly.
Figure 28
B. General Cleaning Procedure
Clean and lubricate the tool at the beginning of each shift, or
according to local practice. Use a telephone company approved
solvent cleaner or equivalent.
Note: Also available is AMP® Cleaning Kit 229333-1 which
contains a bristle brush for general cleaning, a tube cleaner for
cleaning exterior polished surfaces, an extractor for removing scrap
wire and plastic particles, and a tube brush for cleaning inside the
tool. For detailed information about the cleaning kit, refer to AMP
Instruction Sheet 408-7534.
Electrical Tester
Connector