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Familiarization & Assembly Information
1.
Read manufacturer’s assembly instructions before actually starting
to assemble connectors. Besides the matter of instruction on correct
procedures, there are two important reasons for this preliminary
step: To identify the various component parts, and to check for any
missing parts.
2.
Cut cable jacket and sheathing squarely and sheathing squarely and
to correct length, using only wire strippers that have been approved
for the operation. In preparing the individual wires in cables and
harnesses for assembly, make allowances in length for reaching the
outer most circle of contacts cavities in the conductors. The
insulation should be cut progressively longer as they extend out
from the center of the cable or harness to assure sufficient length.
3.
Follow chart on Page 5 covering maximum cable stripping lengths
for effective cable gland sealing. All conductors should be fit into
contact wire wells correctly. A practice layout should be done so
that an assembler can oversee what the finished will look like when
finished.
4.
Before starting actual termination of wires, it is essential that cables
and harnesses be laid out in a specific order in accordance with the
wiring diagram. Proper layout will eliminate the need for twisting
and crossover of conductors. If the wiring layout is not correct, the
termination operation will be difficult or even impossible and the
chances for making errors will be increased. Cable and harness
assemblies having a spiral layout must also be matched carefully to
the correct contacts in both the male and female inserts.
5.
Some cables that will be used will have a “basket weave” type of
armor under the outer jacket (sheath) and over the inner jacket. Since
many regulatory entities require that the armor be grounded at least
at the source end, it is beneficial to ground the armor via a spare
contact within the connector. Follow the removal of sufficient
amount of outer jacket (see chart on Page 5) ample amount of armor
can be clipped away, but not all. An adequate amount should remain
in order that a small cross-section conductor, short in length, be
woven into the remaining armor weave and either soldered or
covered with mastic impregnated heat shrink, creating an intimate
bond to the armor. At the opposite end of the short piece of wire a
contact should be crimped and inserted into the insert.
6.
Use only correctly sized and ingress protected certified glands
provided to assure resistance to moisture and other contaminates.
7.
Use only the proper crimping tools that have been set or calibrated
with precision gages.
8.
Make certain that all contacts are the correct size before attempting
to assemble in insert cavities. This point is particularly important
when both power and control types of contacts are used in the same
connector.
9.
Be sure that any ground contacts (when applicable) are correctly
located.
10.
Seat all contacts properly so that they will not be damaged or
become disengaged during connectors mating operation.
11.
Use only the proper insertion tools and be sure that they are
aligned axially when pushing contact into their fully seated
position.
12.
When inserts have more cavities than the conductors, plug unused
cavities with furnished contacts.
13.
After all terminated contacts are inserted in their respective
cavities and inspected (detailed on page 5), the cable adapter
should be installed and tightened with a strap wrench (detailed on
page 8).
14.
When handling cables, use adequate support to prevent damage
to the internal wires. Exd glands are intended for sealing purposes
and should not be used as a cable grip.
15.
If for any reason, terminated conductors have to be removed from
an insert because of an assembly error or change in circuitry, be
sure to remove the cable gland or cable adapter first before
extracting the contact and re-inserting it.
16.
If one of the connector poles is a ground wire, make sure that it is
grounded properly before the connector actually is engaged.
17.
When connectors have the same configuration are to be mounted
closer together, different or alternate key arrangements should be
used to prevent mismatching and possible damage to the
electrical system.
18.
Always inspect all aspects of connector assembly operations
before putting connector into actual operation.
19.
Crimping and terminating of conductors to contacts must be done
carefully. Make certain that all wire strands are fully bottomed in
contact wells by checking through inspection hole provided
(detailed on page 5).
20.
Never try to straighten bent contacts. Straightening cannot be
done properly and the plating on contacts very likely will be
marred. This will result in a high resistance connection and will
expose the base material to possible corrosion.
21.
Each assembly operator should be his own inspector. Worn,
damaged, or defective tolls should be reported immediately to
foreman and supervisors. Assembly operators should be
indoctrinated with this attitude and made to understand the
importance of always guarding quality. Assembly workmanship
is significant factor in terminating the quality of multiple contact
connectors. Quality cannot be “inspected” into connectors; it must
be “built-in” during each and every assembly operation.
Summary of Contents for AMPHE-EX L-2124
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