412-5231 ANP (WAS CM-231J) 16NOV99 REV.A1 DL! CONNECTORS INSTRACTION MANUAL AMP Japan Ltd. Hisamoto 3-5-8, Takatsu-ku, Kawasaki-shi, Kanagawaken, Japan lof7 AMP FAX/PRODUCT INFO 1-800-522-6752 This AMP conirolled document is subject to change. For latest revision call the AMP FAX number. Copyright 1897 by AMP Incorporated. All Rights Reserved. Drawn Per EC FIK-1980-99 *Trademark2 of 7 A12-5231 Rev Al (WAS CM-231J) DLI CONNECTORS INSTRUCTION MANUAL 1. Description of DLI Connectors DLI connectors have been developed for connecting wires to printed circuit boards of automotive electronic devices being increasingly miniaturized and densified. They are available in two types - horizontal connection type and vertical connection type - according to the leading direction of wires. The PCB terminal arrangement is two rows spaced 4 mm for the horizontal connection type and 4.6 mm for the vertical connection type. The terminal spacing in each row is 3 mm. 1.1 Applicable connector numbers Number of Name Connector Number Plating Terminals Horizontal Type | Vertical Type a Receptacle contact 170291-1 Tin a Receptacle contact 170291-3 Gold 36(20+16) Cap assembly 172023-2 172255-2 Tin 36(20+16) Cap assembly 1-172023-2 ar Gold 28(16+12) Cap assembly 172241-2 172256-2 Tin 28(16+12) Cap assembly 1-172241-2 7 Gold 20 Cap assembly 172143-2 172257-2 Tin 20 Cap assembly 1-172143-2 a Grold 16 Cap assembly 172242-2 172258-2 Tin 16 Cap assembly 1-172242-2 we Gold 12 Cap assembly 172243-2 172259-2 Tin 12 Cap assembly 1-172243-2 a Gold 8 Cap assembly 172244-2 172260-2 Tin 8 Cap assembly 172244-3 a Gold 20 Plug housing 172047-2 re 16 Plug housing 172021-2 we 12 Plug housing 172245-2 7 8 Plug housing 172246-2 ar412-5231 Rev Al (WAS CM-231J) 1.2 Names of parts Oo . ' Contact C nductor crimp portion p Covering erimp portion Lance Receptacle Contact Horizontal type cap assembly & /\ Receptacle contact , -(Terminal) lug housing PCB mounting flange (M3 screw or M4 tapped ea serew hole) oe /Wertical type Cap assembly ac Receptacle contact (Terminal) 2, Crimping Operation Crimping should be made by the tools and in the methods specified by AMP. For the detaiis, refer to the applicable standards listed at the end of the manual. 3 of 74of 7 3.1 412-5231 Rev Al (WAS CM-231J) Management of Crimped In-Process Works (1) Store the works in a dry, clean place. Must not expose the works when they are being stored extending to the next day. To bundie works, one bundle must not exceed 100 works. Don't stack many works directly one upon the other, Otherwise, the projections may stick to each other and the terminals may be deformed by weight, causing poor contact and other defects. If works are twisted together, don't try to separate them forcibly but disentangle them carefully. Harness Assembly Operation Inserting wires into housings (1) (4) Confirm the circuits being connected prior to inserting crimped terminals into plug housings. Insert each terminal so that the lance faces the opposite terminal of the other row. Be sure that the inserted terminal is locked positively. (The terminal snaps when it is locked. Enfarce to check the inserted terminal if locked, by lightly pulling the terminal toward you.) Tn insertion, ensure that the poorly crimped terminals are not included.5 of 7 2 412-5231 Rev Al (WAS CM-231J) (5) Pollow the next Para. 3.2 if the terminal once inserted is being removed for re-insertion, Lance Removing method of terminals Use the special tool and comply with the instruction manual of the tool for removing a terminal inserted into the housing by mistake, If the special terminal extracting tool is not available, use a metal bar with a thickness of approx. 0.6 mm and a with of approx. 1 mm (with the tip chamfered for easy insertion into the housing and protection of the terminal from scratching). Hold the wire of the terminal being removed and push it inwards. Introduce the metal bar between the lance of the terminal and the housing as illustrated, and pull the wire. If it is hard to remove the terminal, don't pull the wire forcibly but follow the steps again from the beginning. Open the folded lance by the tip of a watch repair screwdriver or the like before re-inserting the removed terminal. Don't re-use the terminal if deformed.412-5231 Rev Al (WAS CM-231J) Metal Bar (Thickness C.6mm, width Approx. imm) 3.3 Taping (Bundling) Don't bundle or bend 90 the wires connected to the housing at a point close te the housing. Otherwise, excess strains are applied tc the terminals in the housing, causing poor fitting. Bundle or bend the wires at a point somewhat apart from the housing as illustrated below. P 50mm or over ~ Wires must be free Plug housing 6 of 7412-5231 Rev Atl (WAS CM-231J) 4, Clamping Harnesses It is desirable to clamp the harness to the same vibrating surface as that of the connector as illustrated below for ereventing heavy vibration or shocks from working on the connector, when the connector is located in a place of heavy vibration, p_- Approx. 100mm as 3 Taping ] Cap Plug housing Harness must be iree from excess strain assembly or extreme slack. 5. Reference Standard and Instruction Manuals (1) 108-5124 : "Product Specification of DLI Connectors" (2) 114-5045 : "Crimping Conditions of DLI Connector, Receptacle Contacts" (3) IS-1373 : "DLI Connector and Receptacle Contact Manual Tools Operation Manual" (4) IS-1753 : "Contact Extractor for DLI Connectors Operation Manual" 7 of?