Amphe-EX
assembly instructions
L-2124
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.
8. Make certain that all contacts are the correct size before
attempting to assemble in insert cavities. This point is par-
ticularly important when both power and control types of
contacts are used in the same connector.
9. Be sure that ground contacts are correctly located.
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 indi-
vidual 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.
10. Seat all contacts properly so that they will not be damaged
or become disengaged during connector 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.
3. Follow Table 1 Figure 1 covering maximum cable stripping
lengths for effective cable gland sealing. All conductors
should be fit into contact wire wells correctly. A practice lay-
out should be done so that an assembler can oversee what
the finished termination will look like.
13. After all terminated contacts are inserted in their respective
cavities and inspected, the cable adapter or insert clamp nut
should be tightened with a wrench. This assembly operation
should be done by placing the components in a vise with
smooth-faced jaws and using a strap wrench.
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 elimi-
nate 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.
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.
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 connec-
tor. Follow the removal of sufficient amount of outer jacket
(see Table 1) 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 cov-
ered with mastic impregnated heat shrink, creating an inti-
mate bond to the armor. At the opposite end of the short
piece of wire a contact should be crimped and inserted into
the insert.
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 arrange-
ments should be used to prevent mismatching and possible
damage to the electrical system.
18. Always inspect all aspects of connector assembly opera-
tions before putting connector into actual operation.
6. Use only correctly sized and provided Exd glands to assure
resistance to moisture and other contaminates.
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.
7. Use only the proper crimping tools that have been set or
calibrated with precision gages.
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