TM
Amphe-EX Series
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.
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.
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.
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).
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.
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.
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.
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.
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.
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.
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.
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