How to Connectorize Cables 135
Practice 450-1011-201
(11) Insert the connector into the block holder between the shear plates, and turn
the torque screw until slippage occurs (indicating the correct torque).
(12) Pull the group of wires forward. Select the first pair of wires that corresponds
with the color bar guide, starting from the center of the tool. Split the pair (tip &
ring), one wire to the left and the other to the right, to correspond with the
colour bar guide. For example, if the first pair being wired in a male connector
is blue (tip) and white (ring), the blue wire goes to the left and the white wire
goes to the right (for a female connector the opposite applies).
(13) Feed both wires through the appropriate left or right outer comb (rear) and
inner comb (front). While keeping the wire taut, bend each wire under the inner
comb and around the inside of the guides toward the center of the tool. Ensure
that both wires are laced through both combs properly.
(14) Repeat Steps 12 and 13 until half the pairs are laced into the tool. Then
continue with the remaining pairs in the same manner, but bend the wires in the
opposite direction toward the tool handle.
(15) Ensure that all wires are parallel in the combs and that the connector is
bottomed (fully inserted) in the block holder. Raise the block holder to the
vertical position.
(16) Raise both the right and left wire holders (one by one) to the vertical position,
making sure that the wires remain in the combs.
(17) Hook the locking latch onto the right wire holder, then press on the left side of
the locking latch until it is secure.
(18) Check alignment of wires from the sides of both wire holders. Each conductor
must be aligned with a single contact.
(19) Raise the handles until the handle stop of both handles butt against each other.
This shears all wire ends and fully crimps all wires into the connector.
(20) Lower the handles and remove the sheared wire ends from the wire holders.
(21) Loosen the torque screw by turning counterclockwise. Then open the locking
latch and rotate both wire holders downward. Open the cable clamp and slide
the terminated connector straight out of the block holder.
(22) Ensure that each wire is fully and evenly inserted into the contact slot.
(23) Check that all wires have been sheared to the proper length, and that no
exposed conductor strands are visible. Check that the insulation is not cut in any
area except where the wire is inserted into the slot.
(24) Ensure that the contacts are not deformed or crushed, and that the wires have
not been cut above the strain relief slot in the contacts.
Note: If any of the wires are not properly terminated, reinsert them using the
AMP T-Handle Insertion Tool. (See Fig. 16-2.)
Connectorization of DS1 Cables (CERTI-CRIMP)
This procedure describes how to connectorize DS1 cables used with the Digital
Trunk Link SRU. The CERTI-CRIMP tool is used to crimp individual leads with
female socket pins (AMP 66504-9) for 20/24 guage wires. (Refer to Fig. 16-3, View
