Instruction Sheet
Tooling Kit 768900-1
408-9822
07 MAR 08
Rev C
Inserter Tip
Subassembly
Inserter
Assembly
Stop
Mounting
Screw
Wire Insertion
Depth Stop
Vane
Switch
Tie Bar (Ref)
Inserter
Assembly
Connector Nest Sets
(Plug Nest Set
Installed)
Shroud
Inserter Position
Adjustment Screw
Sliding Block
Mounting Screw
Shroud
Front Connector Clamp
Rear Connector Clamp
Mandrel Assembly
Figure 1
1. INTRODUCTION
This instruction sheet covers the installation and use
of Tooling Kit 768900–1, which is used in the
CHAMPOMATOR* 2.5 Bench Terminating Machine to
apply discrete–wire cable to AMPLIMITE* .050 Series
III Connectors. This sheet also provides part number
information for the tooling required to apply the
various connector sizes.
NOTE
All dimensions on this sheet are in millimeters
[with inch equivalents provided in brackets].
2. DESCRIPTION
(Figure 1)
The tooling kit consists of two inserter assemblies, a
mandrel assembly, two sets of connector nests, one
set of connector shrouds, and a set of setup gages
(used for adjusting the insertion guide opening). A tie
bar, purchased separately, is used to position and
secure the connector during machine operation.
The inserter assemblies trim and insert the individual
wires into the connector contacts. The mandrel
assembly supports the connector during the
termination process and helps guide the wires into the
inserter assembly termination area.
The connector nest sets locate the connector in the
mandrel assembly. One set, designed for plug
connectors, polarizes the connector in the mandrel
assembly. The other set, designed for receptacle
connectors, does not polarize the connector in the
mandrel assembly.
NOTE
Receptacle connectors MUST be correctly
located by the operator.
i
NOTE
Figures and illustrations are for identification only
and are not drawn to scale.
These instructions are supplied in the
documentation package for Tooling Kit 768900-1.
i
Make sure to retain all material in the
documentation package for reference. For
detailed information on the operation of the
CHAMPOMATOR 2.5 Machine, refer to Customer
Manual 409-5839, which is supplied with
the machine.
Reasons for reissue of this instruction sheet are
provided in Section 9, REVISION SUMMARY.
i
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at
E
2008 Tyco Electronics Corporation, Harrisburg, PA
TOOLING ASSISTANCE CENTER 1-800-722-1111
PRODUCT INFORMATION 1-800-522-6752
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
1
of 7
LOC B
www.tycoelectronics.com
*Trademark. Other products, logos, and company names used are the property of their respective owners.
Tooling Kit 768900-1
408-9822
Mandrel Assembly
Locking Screw
(In Access Hole)
Alignment Pins for
Inserter Assembly
Alignment Pins for
Inserter Assembly
Air Cylinder Ram
Mounting Screw
Connector
Clamp Force
Adjustment
Machine Base
Block Assembly
(Ref)
Mandrel
Assembly
Figure 2
3. INSTALLATION
DANGER
Disconnect the power to the control module and
lockout the pneumatic valve BEFORE installing
the tooling onto the base machine.
3. Using a 5/32–in. hex wrench, install the two
inserter mounting screws.
4. ADJUSTMENTS
NOTE
Disconnect the power to the control module and
lockout the pneumatic valve BEFORE adjusting
DANGER
For clarity, the illustrations used in this sheet may
show the machine without guarding. Be sure to
have all guarding in place before operating the
machine.
i
any tooling.
4.1. Mandrel Assembly Height
The mandrel assembly height is adjustable to locate
the connector contacts in correct relation to the
inserter assemblies’ inserter tips. To adjust the height:
1. Place a new (unterminated) connector onto the
connector nest, install the tie bar, and lock into
place.
2. Using a 1/8–in. hex wrench, remove the
machine’s front access plate.
3. Using a 5/32–in. hex wrench, loosen the
mandrel assembly locking screw, which is located
in the center access hole. Refer to Figure 2.
4. With the machine’s electrical and air power
disabled, manually move the machine’s carriage
assembly out to the connector termination area,
then partially extend the inserter tips on each
inserter assembly.
5. Observe the relationship between the connector
contacts and the inserter assemblies’ guides.
3.1. Mandrel Assembly
(Figure 2)
NOTE
All inserter assemblies must be removed before
installing or removing the mandrel assembly.
1. Place the mandrel assembly onto the machine
base block assembly.
2. Using a 5/32–in. hex wrench, secure the
mandrel assembly onto the base block assembly
with the two socket head cap screws supplied with
the machine.
3.2. Inserter Assemblies
(Figures 2 and 3)
1. Align the inserter assembly T–slot over the air
cylinder ram assembly.
2. Locate the base of the inserter assembly onto
the two alignment pins on the machine’s inserter
assembly mounting area.
2
of 7
Tyco Electronics Corporation
Rev
C
Tooling Kit 768900-1
408-9822
Inserter
Assembly
Inserter
Assembly
T-Slot in Inserter
on Air Cylinder Ram
Inserter Assembly
Mounting Screw
Height-Adjustment
Wheel
Inserter Assembly
Mounting Screw
Figure 3
6. Turn the machine’s height–adjustment wheel
until the height is within the adjustment range, as
shown in Figure 4. Turn the wheel CLOCKWISE to
RAISE the mandrel (and connector) and
COUNTERCLOCKWISE to LOWER the mandrel
(and connector).
7. Once the desired height has been reached, use
a 5/32–in. hex wrench to tighten the mandrel
assembly locking screw.
Connector
Contacts
Adjustment Range
(Approx. 0.025
to 0.127 mm
[.001 to .005 In.])
1. Using a 3/32–in. hex wrench, loosen and
remove the rear connector clamp and rear
nest section.
2. Place the rear nest section on a connector of
the new size to be terminated.
3. While holding the rear nest section in the
connector, locate the connector over the front
nest section.
4. Engage the rear nest section with the rack in the
mandrel assembly.
5. Using a 3/32–in. hex wrench, secure the rear
nest section with the socket head cap screw.
6. Secure rear clamp assembly behind the rear
nest assembly.
NOTE
One tooth of the rack must be visible between
the nest section and the rear clamp assembly for
i
proper positioning.
B. Connector Polarity (Plug Connectors Only)
Guide
To adjust the plug connector nest set to
accommodate different polarity:
Figure 4
4.2. Connector Nest
1. Using a 3/32–in. hex wrench, loosen and
remove the mounting screws for both connector
nest sections, then remove both connector
nest sections.
2. Rotate the nest sections and place back onto
the rack section of the mandrel assembly.
3. Using a 3/32–in hex wrench, secure the nest
sections with the socket head cap screws.
A. Connector Size - Same Type
To adjust for different connector sizes of the
same type:
Rev C
Tyco Electronics Corporation
3 of 7
Tooling Kit 768900-1
C. Connector Nest Types - Same Size
To change the type of connector (plug or receptacle)
to be terminated:
1. Using a 3/32–in. hex wrench, loosen and
remove the mounting screws for both connector
nest sections, then remove both connector
nest sections.
2. Replace the connector nest sections with the
nest sections of the desired type.
NOTE
When installing the plug nest sections, make sure
that the sections are placed to provide correct
408-9822
2. Index the machine to connector contact No. 1.
3. Using a 5/32–in. hex wrench, loosen the two
inserter assembly mounting screws.
4. Loosen the sliding block mounting screw. Refer
to Figure 1.
5. While viewing the inserter guiding surfaces, use
a 5/32–in. open–end or box wrench and turn the
inserter position adjustment screw to move the
assembly. Refer to Figure 1. Turn the screw
CLOCKWISE to move the assembly AWAY from
the connector, and COUNTERCLOCKWISE to
move the assembly TOWARD the connector.
6. Check that the inserter guiding surface is within
the adjustment area, as shown in Figure 5.
7. Using a 5/32–in. hex wrench, tighten the sliding
block mounting screw and the two inserter
mounting screws.
Connector
Adjustment Range
(Approx. 0.0762 mm
[.003 In.])
(Typ)
i
connector polarity.
3. Using a 3/32–in. hex wrench, secure the nest
sections with the socket head cap screws.
NOTE
When installing the receptacle nest, place the
shroud on top of the receptacle nest and secure
i
NOTE
with screw used to secure nest.
Make sure that one tooth of the rack is visible
between the nest and the front clamp for proper
i
CAUTION
positioning.
4.3. Connector Clamp Force
The connector clamps should place sufficient
force on the connector to ensure proper location
!
and retention of the connector during termination.
The clamps should NOT be set too tightly, or
premature wear of the clamp component and
damage to the connector and connector nest
may occur.
Inserter Guiding Surface
With a connector loaded onto the mandrel assembly,
and with the tie bar in place, proceed as follows:
1. Using a 3/16–in. open–end or box wrench,
loosen the locking hex nut.
2. Using a .035–in. hex wrench, adjust the
connector clamp set screws as desired.
3. Using a 3/16–in. open–end or box wrench,
tighten the locking hex nut, making sure that the
flats on the nut align with the flats on the
connector clamp.
Figure 5
B. Wire Insertion Depth
The length of travel of the inserter ram may be
adjusted. Normally, the inserters will not require this
adjustment unless the insulation diameter is changed.
To adjust the depth, refer to Figure 1 and proceed as
follows:
1. Look at the top of the inserter assembly and
read the wire insertion depth stop currently in use.
2. Using a 5/32–in. hex wrench, remove the stop
mounting screw, and remove the stop from the
inserter assembly.
3. Determine the stop dimension from the marking
on the top of the stop directly over the inserter tip.
4. Measure the insulation diameter of the wire
presently being used, then measure the insulation
diameter of the new wire to be used.
4.4. Inserter Assemblies
A. Inserter Position
The inserter position is important in that the guiding
surfaces for the wire must control the wire up to the
time it enters the connector contact. To adjust the
inserter position:
1. Load a connector into the mandrel assembly
and secure it in place.
4
of 7
Tyco Electronics Corporation
Rev
C
Tooling Kit 768900-1
408-9822
Guide Block
Mounting
Screw
Inserter
Assembly
Wire Clamp
Adjustment Screw
Setup
Gages
Wire Clamp
Locking Screw
Housing
Mounting
Screw
Figure 6
NOTE
Each stop is designed with four stop dimensions.
For example, the 18.034 mm [.710 in.] stop also
3. Using a 7/64–in. hex wrench, loosen the guide
block and housing mounting screws.
4. Measure the outside diameter of the new wire to
be used.
5. Locate the setup gage that is the same size as,
or that is one size larger than, the measured wire.
Insert the setup gage into the inserter assembly
until the gage bottoms against the guide block.
Refer to Figure 6.
6. Gently force the guide blocks against the setup
gage and secure.
7. Re–install the inserter subassembly.
8. Install the inserter assembly onto the machine
as previously described.
i
includes a 17.907 mm [.705 in.] section, a
17.780 mm [.700 in] section, and a 17.653 mm
[.695 in.] section.
5. Determine the difference between the two
insulation diameters, then subtract one half of this
difference. Use the resulting number to determine
the dimension of the new stop (add the figure to
the old stop dimension of the diameter is
increasing, subtract if the diameter is decreasing).
6. Place the correct stop onto the inserter
assembly and install the stop mounting screws.
7. Repeat the above procedure for the other
inserter assembly.
NOTE
Make sure that the inserter vane switches make"
in the inserted position by using Diagnostic Mode
D. Wire Clamp Force
(Figure 6)
3 on the control module. Refer to the Customer
Manual supplied with the module.
i
C. Inserter Guide Opening
The inserter guide opening helps control the
placement of the wire into the connector contacts.
This gap should be adjusted to accommodate
changing wire outside diameter. To adjust
the opening:
1. Remove the inserter assembly from the
machine by removing the two inserter
mounting screws.
2. Remove the inserter tip subassembly from the
inserter assembly.
The clamp force exerted on the wire during the
termination process controls the wire’s vertical
placement in the connector contacts. Excessive
clamp force will tend to extrude the wire insulation
during termination, resulting in poor termination
quality. To adjust the force:
1. Using a .035–in. hex wrench, loosen the wire
clamp locking screw.
2. Using a .050–in. hex wrench, turn the wire
clamp adjustment screw. Turning the screw
CLOCKWISE will INCREASE the clamp force, and
turning the screw COUNTERCLOCKWISE will
DECREASE the clamp force.
3. Terminate several wires to verify the adjustment.
4. Using a .035–in. hex wrench, tighten the wire
clamp locking screw.
Rev
C
Tyco Electronics Corporation
5
of 7
微控制器 MCU
京公网安备 11010802033920号
Copyright © 2005-2026 EEWORLD.com.cn, Inc. All rights reserved
电子工程世界
