TE Connectivity IDC Hand tool RAST 2.5 Operation Manual Download

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Operation Manual

IDC Hand tool RAST 2.5 and 5

Customer Manual Nr.:

412-94126-1 Rev. A

Customer Manual PN:

744015-5

Language:

en (Translation of the original German version)

Summary of Contents for IDC Hand tool RAST 2.5

Page 1: ...Operation Manual IDC Hand tool RAST 2 5 and 5 Customer Manual Nr 412 94126 1 Rev A Customer Manual PN 744015 5 Language en Translation of the original German version ...

Page 2: ... a certain application can be derived from our information The information given does not release the user from the obligation of own judgment and verification It must be remembered that our products are subject to a natural process of wear and aging This document as well as the data specifications and other information set forth in it are the exclu sive property of TE Connectivity Ltd It may not ...

Page 3: ...ed use 6 3 2 Improper use 6 3 3 Reasonably foreseeable misuse 6 3 4 Qualification of personnel 7 3 5 Safety instructions in this document 7 3 6 Adhere to the following instructions 8 3 6 1 General instructions 8 3 6 2 During operation 8 3 6 3 During disposal 8 3 7 Obligations of the operator 8 4 Scope of delivery 9 5 Product description 10 5 1 Handled connectors 10 6 Content of case 11 6 1 Compone...

Page 4: ...he property of their respective owners 7 Using the table mounting 18 8 Preparation of the connector 20 9 Making a connection 23 9 1 AMP DUOPLUG 2 5 Mark II 23 9 2 AMP DUOPLUG 2 5 Power 29 9 3 AMP multifitting Mark II 34 9 4 AMP MONO SHAPE Mark II 40 9 5 AMP MONO SHAPE Mark I 46 10 Maintenance and Repair 52 10 1 Daily Maintenance 52 10 2 Periodically Maintenance 52 11 Disposal 53 12 Troubleshooting...

Page 5: ...hird parties without its consent This manual is exclusively meant for the carrier of the IDC Hand tool RAST 2 5 and 5 in further course called IDC Hand tool and its personnel for internal use only The additional device specific manual includes descriptions engineering drawings instructions and references that you may not copy reproduce or distribute without written consent neither completely nor i...

Page 6: ...the opera tion manual and strictly observe the instructions therein TE Connectivity Ltd decline to accept any liability for damages that are incurred due to the fact that the instructions in the operation manual have been disregarded The user is responsible for supplementing the operation manual with any instructions resulting from current national regulations for accident prevention and protectio...

Page 7: ...t number 3 1 Intended use The IDC RAST Hand tool 2 5 and 5 has been designed to apply connectors according to the AMP specifi cation section 5 Product description with wires following the grid connection plug technology using Insula tion Displacement Technique It is only permitted to use the IDC hand tool 2 5 and 5 exclusively for repair proposes or preparation of samples Do not use it for serial ...

Page 8: ...g to the work to be done Qualified personnel must observe the rules relevant to the subject area 3 5 Safety instructions in this document Type of risk Consequences Precautions Safety sign warning triangle Draws attention to the hazard Signal word Identifies the degree of hazard Type of danger Identifies the type or source of the hazard Consequences Describes the consequences of non compliance Prec...

Page 9: ...ot consume any alcohol drugs or pharmaceuticals that may affect their ability to respond Before putting the IDC Hand tool into operation it is always important to check whether all devices are at hand and functioning correctly The warranty only applies to the delivered configuration The warranty will not apply if the product is incorrectly assembled not used as intended and or handled improperly I...

Page 10: ...and Tyco Electronics are trademarks 9 55 Operation Manual 744015 5 Trademark Other products logos and company names used are the property of their respective owners 4 Scope of delivery The scope of delivery includes following parts 1 transport case containing misc tools section 6 1 Components overview 1 operating manual ...

Page 11: ...ion 5 Product description with wires using Insulation Displacement Technique RAST 2 5 and 5 It is only permitted to use the IDC hand tool 2 5 and 5 only for repair proposes or preparation of samples Do not use it for serial production 5 1 Handled connectors Following connectors of the type RAST 2 5 and RAST 5 are used Connector TE specification PN tool case ref Fig 1 AMP DUOPLUG 2 5 Mark II 114 18...

Page 12: ...ty of their respective owners 6 Content of case 6 1 Components overview Fig 1 Components overview 1 Set of socket head wrenches 5 Side cutter latching rib 2 IDC RAST Hand tool with tool head and adapter 6 End cutter Keying rib 3 Table clamp piece 7 Bracket 4 Transport case 8 Cutter knife This operating manual is stored in the inner shed of the transport case Pull the foam piece by using the clip a...

Page 13: ...ounting consists of the table clamp piece 2 and the bracket 3 as well as the tool head consists of the holding fixture with connector clamping 1 Fig 2 Hand Tool Design similarly 1 Holding fixture incl Connector clamping 2 Table clamp piece 3 Bracket 4 Guidance incl Stuffer unit 5 Adapter CAUTION Damage to property Stuffer damage hazard Strictly observe to exchange the complete tool head The fixtur...

Page 14: ...Trademark Other products logos and company names used are the property of their respective owners 6 3 Construction of the tool heads 6 3 1 AMP DUOPLUG 2 5 Mark II Fig 3 Tool Head Design AMP DUOPLUG 2 5 Mark II 1 Chamber s exterior fixation static 4 Stuffer 2 Press bar for connector s fixation 5 Tool head guidance incl stuffer unit 3 Chamber fixation 6 Forked sleeve for Chamber fixation ...

Page 15: ...eration Manual 744015 5 Trademark Other products logos and company names used are the property of their respective owners 6 3 2 AMP DUOPLUG 2 5 Power Fig 4 Head Design AMP DUOPLUG 2 5 Power 1 Tool head guidance incl stuffer unit 4 Tool head holding fixture incl connector clamping 2 Stuffer 5 Press bar for connector s fixation 3 Chamber s exterior fixation static ...

Page 16: ...d are the property of their respective owners 6 3 3 AMP multifitting Mark II Fig 5 Tool Head Design AMP multifitting Mark II 1 Locking screw 6 Chamber fixation 2 Tool head holding fixture incl connector clamping 7 Forked sleeve for Chamber fixation 3 Chamber s exterior fixation static foldaway 8 Stuffer 4 Chamber s exterior fixation adjustable 9 Tool head guidance incl stuffer unit 5 Gauge piece r...

Page 17: ...sed are the property of their respective owners 6 3 4 AMP MONO SHAPE Mark II Fig 6 Tool Head Design AMP MONO SHAPE Mark II 1 Locking screw 6 Chamber fixation 2 Tool head holding fixture incl connector clamping 7 Forked sleeve for Chamber fixation 3 Chamber s exterior fixation static foldaway 8 Stuffer 4 Chamber s exterior fixation adjustable 9 Tool head guidance incl stuffer unit 5 Gauge piece res...

Page 18: ...r respective owners 6 3 5 AMP MONO SHAPE Mark I Fig 7 Tool Head Design AMP MONO SHAPE Mark I 1 Locking screw 6 Gauge piece resp snap fitting of the connector s width 2 Tool head holding fixture incl connector clamping 7 Chamber fixation 3 Compensation bar for type PC 9 5 AMP MONO SHAPE Mark I 8 Stuffer 4 Chamber s exterior fixation static foldaway 9 Tool head guidance incl stuffer unit 5 Chamber s...

Page 19: ...g For assistance the hand tool can be fixed on a work table so you can use both the hands to work Attach the table mounting 1 see page 11 to an appropriate place Insert the bracket into the mounting bore arrow of the bracket 2 and fix it by the locking screw placed on the face of the table mounting Fig 8 Fastening the fixture Place the hand tool with its mounting hole onto the free end of the brac...

Page 20: ... 19 55 Operation Manual 744015 5 Trademark Other products logos and company names used are the property of their respective owners Fix the bracket in the requested position by using the two clamp screw of the adapter arrow Fig 10 Fixation of the bracket The complete hand tool is exemplary displayed in Fig 11 Fig 11 Complete hand tool with table mounting ...

Page 21: ...sed are the property of their respective owners 8 Preparation of the connector The preparation of the connector will be shown exemplarily by using the AMP multifitting Mark II and applies analogously to all similar products listed in 5 1 Handled Connectors The connectors will be delivered exclusively linked on strip Fig 12 Condition of the connectors at delivery Fig 13 Bundled connectors 1 Cover 3...

Page 22: ...sed and disconnect the connector Strictly observe not to damage the connectors when separating it Separate the connector s cover in consideration of its specification by moving it back and forth or alternatively by using the cutter knife Fig 14 Removing of cover CAUTION Risk of injury cuts from sharp edges Strictly wear protective gloves when doing the cutting work described subsequent Remove the ...

Page 23: ...onics are trademarks 22 55 Operation Manual 744015 5 Trademark Other products logos and company names used are the property of their respective owners Remove the keying ribs according to the respective specification by using the end cutter PN 539601 3 Fig 16 Cutting off keying ribs Ready to use connector Fig 17 Ready to use connector ...

Page 24: ...es used are the property of their respective owners 9 Making a connection 9 1 AMP DUOPLUG 2 5 Mark II Insert the prepared connector into the check rail between the stuffer unit and holding fixture incl connector clamping Fig 18 Inserting connector Press down the clamping bar 1 for an easier handling Push the connector 3 into the check rail against the fixation 2 The gripper has to be opened Fig 19...

Page 25: ...or s IDC contacts straight to the stuffer Fig 20 Positioning of the connector Make sure that the transport unit is explicit engaged An attempt of clamping using an incorrect engaged transport unit will damage the stuffer Move the forked sleeve 1 to the left arrow so that the green marker 2 appears This moves the chamber fixation in its functional position At once the gripper is getting released Fi...

Page 26: ... the insulted wire to the IDC contact so the wire rests flush with the bottom face arrow of the connector Check the correct position of the wire The gripper still remains open Make sure that the chamber fixation is arranged in its functional position This has to be in any case before executing the contacting The positioning of the wire above the IDC contact has a major impact on the quality of con...

Page 27: ...mark Other products logos and company names used are the property of their respective owners The stuffer heads for the IDC contact The chamber s exterior fixation protects the chamber s side walls against unintended deformation The stuffer inserts the wire into the IDC contact where the wire is insulated and fixed Fig 23 Pressing of stuffer Loosening the gripper Fig 24 Loosening the gripper ...

Page 28: ... against pinching Fig 25 Blocking the gripper Make sure that the red marker appears Only in this position the gripper is blocked against pinching Repeat the positioning of the stuffer below the insulation displacement termination to be handled by means of the guidance the locking of the chamber fixation by means of the forked sleeve the feeding of the insulated wire the pinching and loosening of t...

Page 29: ...re trademarks 28 55 Operation Manual 744015 5 Trademark Other products logos and company names used are the property of their respective owners Put the cover onto the connector considering the respective specifications and press it in The cover has to be in the correct position Use an appropriate tool if applicable Fig 27 Pressing in the cap ...

Page 30: ...ogos and company names used are the property of their respective owners 9 2 AMP DUOPLUG 2 5 Power Insert the prepared connector into the check rail between the stuffer unit and the transport unit Fig 28 Inserting connector Press down the clamping bar 1 for an easier handling Pull the connector 3 into the check rail against the contact support 2 The gripper must be opened Fig 29 Positioning connect...

Page 31: ...rs Move the transport unit to positioning the connector s IDC contacts straight to the stuffer Fig 30 Positioning of stuffer Make sure that the transport unit is explicit engaged An attempt of clamping using an incorrect engaged transport unit will damage the stuffer Feed the end of the insulted wire to the IDC contact so the wire rests flush with the bottom face arrow of the connector Check the c...

Page 32: ... products logos and company names used are the property of their respective owners Pinch the gripper Fig 32 Pinching the gripper The stuffer and the chamber fixation head for the IDC contact The stuffer inserts the wire into the IDC contact where the wire is insulated and fixed NOTE This AMP DUOPLUG 2 5 Power Tool Head comes with NO chamber fixation protecting the side walls Fig 33 Pressing of stu...

Page 33: ... owners Loosening the gripper Fig 34 Loosening the gripper Repeat the positioning of the stuffer below the insulation displacement termination to be handled by means of the guidance the feeding of the insulated wire as well as the pinching and loosening of the gripper for all chambers to be provided with a wire After finishing the process press down the press bar and pull off the connector Do not ...

Page 34: ...re trademarks 33 55 Operation Manual 744015 5 Trademark Other products logos and company names used are the property of their respective owners Put the cover onto the connector considering the respective specifications and press it in The cover has to be in the correct position Use an appropriate tool if applicable Fig 36 Pressing in the cap ...

Page 35: ...sed are the property of their respective owners 9 3 AMP multifitting Mark II Fold up the foldaway fixation to insert the connector into the guidance Insert the prepared connector into the check rail between the stuffer unit and the transport unit Fig 37 Inserting connector Fold down the foldaway fixation Move the adjustable chamber s fixation 1 against the connector 3 The gripper has to be open Fi...

Page 36: ...laced chamber fixations will cause a negative impact on the quality of contacting Move the transport unit to positioning the connector s IDC contacts straight to the stuffer Fig 39 Positioning of stuffer Make sure that the transport unit is explicit engaged An attempt of clamping using an incorrect engaged transport unit will damage the stuffer Move the forked sleeve 1 to the left arrow so that th...

Page 37: ...ripper is blocked against pinching Feed the end of the insulted wire to the IDC contact so the wire rests flush with the bottom face arrow of the connector Check the correct position of the wire The gripper still remains open Make sure that the chamber fixation is arranged in its functional position This has to be in any case before executing the contacting The positioning of the wire above the ID...

Page 38: ...mark Other products logos and company names used are the property of their respective owners The stuffer heads for the IDC contact The chamber s exterior fixation protects the chamber s side walls against unintended deformation The stuffer inserts the wire into the IDC contact where the wire is insulated and fixed Fig 42 Pressing of stuffer Loosening the gripper Fig 43 Loosening the gripper ...

Page 39: ... against pinching Fig 44 Blocking the gripper Make sure that the red marker appears Only in this position the gripper is blocked against pinching Repeat the positioning of the stuffer below the insulation displacement termination to be handled by means of the guidance the locking of the chamber fixation by means of the forked sleeve the feeding of the insulated wire the pinching and loosening of t...

Page 40: ...re trademarks 39 55 Operation Manual 744015 5 Trademark Other products logos and company names used are the property of their respective owners Put the cover onto the connector considering the respective specifications and press it in The cover has to be in the correct position Use an appropriate tool if applicable Fig 46 Pressing in the cap ...

Page 41: ...sed are the property of their respective owners 9 4 AMP MONO SHAPE Mark II Fold up the foldaway fixation to insert the connector into the guidance Insert the prepared connector into the check rail between the stuffer unit and the transport unit Fig 47 Inserting connector Fold down the foldaway fixation 1 Move the adjustable chamber s fixation 3 against the connector 2 The gripper has to be open Fi...

Page 42: ...laced chamber fixations will cause a negative impact on the quality of contacting Move the transport unit to positioning the connector s IDC contacts straight to the stuffer Fig 49 Positioning of stuffer Make sure that the transport unit is explicit engaged An attempt of clamping using an incorrect engaged transport unit will damage the stuffer Move the forked sleeve 1 to the left arrow so that th...

Page 43: ...ripper is blocked against pinching Feed the end of the insulted wire to the IDC contact so the wire rests flush with the bottom face arrow of the connector Check the correct position of the wire The gripper still remains open Make sure that the chamber fixation is arranged in its functional position This has to be in any case before executing the contacting The positioning of the wire above the ID...

Page 44: ...mark Other products logos and company names used are the property of their respective owners The stuffer heads for the IDC contact The chamber s exterior fixation protects the chamber s side walls against unintended deformation The stuffer inserts the wire into the IDC contact where the wire is insulated and fixed Fig 52 Pressing of stuffer Loosening the gripper Fig 53 Loosening the gripper ...

Page 45: ... against pinching Fig 54 Blocking the gripper Make sure that the red marker appears Only in this position the gripper is blocked against pinching Repeat the positioning of the stuffer below the insulation displacement termination to be handled by means of the guidance the locking of the chamber fixation by means of the forked sleeve the feeding of the insulated wire the pinching and loosening of t...

Page 46: ...re trademarks 45 55 Operation Manual 744015 5 Trademark Other products logos and company names used are the property of their respective owners Put the cover onto the connector considering the respective specifications and press it in The cover has to be in the correct position Use an appropriate tool if applicable Fig 56 Pressing in the cap ...

Page 47: ...C according to specification 114 20018 Handling type PC a compensation bar arrow has to be adopted into the tool head to compensate the TAB Type s different stack height When handling Type TAB the compensation bar must be removed by pulling out sideways Fig 57 Compensation bar Fold up the foldaway fixation to insert the connector into the guidance Insert the prepared connector into the check rail ...

Page 48: ...amber fixations will cause a negative impact on the quality of contacting Move the transport unit to positioning the connector s IDC contacts straight to the stuffer Fig 59 Positioning of the connector Make sure that the transport unit is explicit engaged An attempt of clamping using an incorrect engaged transport unit will dam age the stuffer Move the forked sleeve 1 to the left arrow so that the...

Page 49: ...ripper is blocked against pinching Feed the end of the insulted wire to the IDC contact so the wire rests flush with the bottom face arrow of the connector Check the correct position of the wire The gripper still remains open Make sure that the chamber fixation is arranged in its functional position This has to be in any case before executing the contacting The positioning of the wire above the ID...

Page 50: ...mark Other products logos and company names used are the property of their respective owners The stuffer heads for the IDC contact The chamber s exterior fixation protects the chamber s side walls against unintended deformation The stuffer inserts the wire into the IDC contact where the wire is insulated and fixed Fig 62 Pressing of stuffer Loosening the gripper Fig 63 Loosening the gripper ...

Page 51: ... against pinching Fig 64 Blocking the gripper Make sure that the red marker appears Only in this position the gripper is blocked against pinching Repeat the positioning of the stuffer below the insulation displacement termination to be handled by means of the guidance the locking of the chamber fixation by means of the forked sleeve the feeding of the insulated wire the pinching and loosening of t...

Page 52: ...re trademarks 51 55 Operation Manual 744015 5 Trademark Other products logos and company names used are the property of their respective owners Put the cover onto the connector considering the respective specifications and press it in The cover has to be in the correct position Use an appropriate tool if applicable Fig 66 Pressing in the cap ...

Page 53: ...rted and fixed by lock washers All pins pivot points and bearing surfaces must be provided with a high quality SAE20 motor oil Avoid excessive lubrication If the hand tool is no longer required pinching the gripper and store the hand tool dry and clean in the transport case 6 1 Components overview 10 2 Periodically Maintenance Depending on the degree of utilisation an inspection of the RAST hand t...

Page 54: ...marks 53 55 Operation Manual 744015 5 Trademark Other products logos and company names used are the property of their respective owners 11 Disposal Careless disposal of the applicator lead to pollution of the environment In case of disposal please send the hand tool and ist components back to the address specified in section 13 1 Contact information ...

Page 55: ... engagement of the holding fixture incl connector clamping is not positioned correctly the stuffer will drive against the connector Due to that the connector will get damaged arrow Fig 67 Damaging of connector If the gripper gets jammed you must not keep on pushing the gripper in no way but use the extrac tion mechanism arrow Fig 68 Extraction Mechanism In case of damage in every way that have an ...

Page 56: ...demarks 55 55 Operation Manual 744015 5 Trademark Other products logos and company names used are the property of their respective owners 13 Appendix 13 1 Contact information TE Connectivity c o Schenck Technologie und Industriepark GmbH Landwehrstr 55 Gebäude 83 64293 Darmstadt Field Service EMEA te com GATD Kundendienst Hotline 49 6151 607 1518 ...

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