412-5476 (WAS CM-476y) AMP 28 JUN 99 REVB HYBRID I/O CONNECTOR Customer Manual AMP Japan Ltd. Hisamoto 3-5-8, Takatsu-ku, Kawasaki-shi, Kanagawa-ken, Japan AMP FAX/PRODUCT INFO 1-800-522-6752 This AMP controlled document is subject to change. For latest revision call the AMP FAX number. Copyright 1998 by AMP Incorperated. All Rights Reserved. Drawn Per EG FJ00-0956-99 * Trademark412-5476 REV B (WAS CM-476J) CONTENTS Page 1. PRODUCT NAMES AND PART NUMBERS Pr 2 1.1 Contact a 2 1.2 Housing a 2 1.35 Product Part Numbers a 4 4.3.1 Contact a 3 1.3.2 Housing ee 3 2. COMLACT AND KOUSING INSPECTION ae ee ee ee ee 3 2.1 AMP Products Shipping Inspection wee ee 4 2.2 Customer Receiving lnspection re u 3. CRIMPING OPERATION a h 3.1 torage and Handling woe ee ee eee ee 5 3.2 Crimping Procedure Control ee 5 3.2.1 Inspection of Wire-Crimped Contact a a ee ee 6 3.2.2 Crimping Data woe ee ee ee 7 3.3 Crimped Lead Inspection Prior to harness Assembly . 8 3.3.1 Inspection se ee ee 8 3.5.2 Storage ee ee ee ee 9 4. HARNESS ASSEMBLY OPERATION woe ee ee ee g 4&4 Gontact Loading into Housing and Double Locking - + 9 4.2 extracting Contacts from the Housing cone ew ee 14 4.2.1 Unlocking the Hinge Double Lock Plates - ss 14 h.2.2 Extracting Contacts a 12 4.3 Harness Product Control Coe ee ee ee ee 12 4.3.1 Inspection a 12 4.3.2 Storage wo ee ee ee ee ee 12 4.3.3 Shipment and Transportation coe ee ee ee 12 5. MOUNPING ON VEHICLES a 13 5.1 Acceptance Inspection ee Le ee 13 5.2 Mounting Operation Control eee ee ee ee ee 15 5.3 Unmating Connectors ee 13 1of13412-5476 REV B (WAS CM-476J) T NUMBER D wat PRODUCT NAMES and PA <i Contact 7.1 Cc _ oO Ow ord o BY - 5 it TL A a A YMmMH & a . ago Goo 7 9 dig a. 4 > & u GHW wt A . g dip v a mom G5 3) wor ay w OP cH rt AO =o Boh ce "ey # be cg 5h = en y ch , OD a _ ct en o 3 fa P eee i] pac GO-H ba at . 5 CS Cc: om | + (] a s- ih \ (in Fox Body} Shoulder \ Contact Ares .O40 CONTACT (Signal) Housing Engaging Lance Housing 1.2 Wire Support r La ov ca o mA Sg 4 Oy I 44 a Goer wd G8 a 6 Pe ed wa Polarizing (46-P. Rib Plug Housing (Signal) 12-Pos. Double Lock ha @ = Oo A, SH cm ao n Oo aon 0 meow 4 oo ja, aH) Dey rd 4 wos oO. ay 1 <0 sw oOo a 26-Pos. Plug Housing f16-P. Signal, 40-P. Power) Cap Housing 20f131.3 Product Part Numbers 412-5476 REV B. (WAS CM-476J) 1.3.1 Contact | Name Part No. Wire Size Insulation Dia. | -O40 Receptacle | 173681-0 AVS 0.3 - 0.5 1.8 - 2.0 .040 Receptacle 173716- AVS 0.3 - 0.5 1.8 - 2.0 .070 kKeceptacle | 173630-f AVS 0.2 - 0.3 1.4 - 1.9 .070 keceptacle 173631-( AVS 0.5 - 1.2 2.0 - 2.6 1.3.2 Housing Name P/N Remarks 12P Plug Housing (Signal) 174913-O0 12P Plug Housing (Power) 175442-D 16P Plug Housing (Signal) 174514-0 ; . oo 22P Plug Housing (Signal 16) 174515-O Mismating preventive rib (Power 6) location differs. 26P Plug Housing (Signal 16) 174516-D (Power 10) 26P Plug Housing (Siganal 16) 175567-D (Power 10) 26P Cap Housing Horizontal Type 4-175569-0 Wireto- Board 26P Cap Housing Horizontal Type O-175571-0 Wire-toBoard 34P Cap Housing Horizontal Type O-175444-0 Wireto Board 38P Cap Housing Horizontal Type O-175521-(C) Wire toBoard 42P Cap Housing Horizontal Type F-176446- Wireto Board 48P Cap Housing Horizontal Type O-174917-0 WiretoBoard 54P Cap Housing Horizontal Type O-175448-0 WiretoBoard 54P W/O 16P Cap HOusing Horizontal Type | -1318471-0 WiretoBoard 64P Cap Housing Horizontal Type O-174518-U WiretoBoard | 76P Cap Housing Horizontal Type H-174915-0 WiretoBoard 2. 30f13 CONTACTS AND HOUSING INSPHCT1ON We conduct inspections referring AMP Products Shipping Inspection to specific standards, under strict statistical management, and according to our quality control regulations, to maintain an overall lot control.. each package is marked with manufacturing date code to tracing production history using inspection, manu- and machinery adjustment records. principle, facilitate facturing, in rianufacturing date code(denoted as date code) is as follows: 89 LQ UC om ce] MY cr iD BW m om Fh o Kt (1989) ~ This represents the last two \ Monday) 2 nvs the th week) digits of western calender. Represents the day of the week week number of the year412-5476 REV B (WAS CM-476J) 2.2 Customer Heceiving inspection In addition, the customers should conduct at least the follow- ing receiving inspections pased on the specific customer draw- ings. (Terminal) iten inspection Description & Methods Measuring Methocs 1) Shave i i ti Appearance t Tae Visual SREP CeO Inepection 2) Plated condition Visual inspection 3) Reeled condition Visual inspection . . 41) Wire barrel width and height Vernier Calivers Dimension s ae Ta : , _ 2) Insulation barrel width & height |Vernier Calipers Inspection = 7 3; Locking lever height Vernier Calivers When reels are delivered, each reel is classified by date code and insvected visually for AQL 4% based on Level if (MIL-STD~105) standards, including additional inspection of 5 contacts on reel ends. The lot may be accepted if all reels successrully pass the inspection. (Housing) Item Inspection Description & Methods Measuring Methods Visual 1) Burrs, discoloring & deformation|Visual inspection Inspection 2) Cracks, fissure, or ahipping Visual inspectioz | ~Functional 1) Mating/Unmating: Inspection Corresponding tabs fit into each other to allow them to By hand lock. The unlocking leg can be smoothly pulled out while being depressed. wach package is classified by date code and inspected for appearance for aQL 40% based on Level IL (MIL-~STD-105) standards, and then inspected for the functions of 5 pieces: in each package. rhe lot may be accepted if ali of then successfully pass the inspection. 3. CRIMPING OPERATION Any crimping of contacts must be performed by using appropriate AMP tools according to the applicable Instruction Sheet and Specification. he part numbers and date code(such as the above example ,&9402) should be recorded for future reference. 4of13412-5476 REV B 3.4 Storage and Handling ~~ (WAS CM-476J) 4) Avoid carrying unpacked products. Carry and store products in the containers. 2) Carrying reels by only one of flanges can damage the reel and makes it unusable, or unloadable onto crimping machines. Ke sure to carry a reel vy holding both flanges as shown below. Never carry reels horizontally holding only one flange Recommended method 3) Do not place reels in places with high humidity. Reels should be stored in a relatively dry, clean room where they will not be exposed to direct sunlight, and maintained at normal tempe- rature and humidity. (5 to 35C and 45 to 85% relative humidity) 4k) Tf reels are temporarily taken off the crimping machine when suspending operation, tie the reel end to the flange with string to prevent the reel from loosening. Tic reel ends to prevent them from loosening, _.2 Crimping Procedure Control An instruction manual for the crimping procedure control should be prepared referring to the following documents: O40 series .0O70 series Service ool instruction Sheet Ts-288 TS-287 Application Svecification 474-5094 174-5091 Automatic Machine Customer Manual CM-O2ed Applicator instruction AT-8025 take the following precautions. (1) When stripping the wire, care must be taken not to nick, (or f cut or scrape the conductors. " tieked 5of13 a Aeceptabdle412-5476 REV B (WAS CM-476J) insulation stripping length fhe length of the wire varrel of the contact used + 0.5 to 1.0mm is applicable. (3) Crimp cross-sectional diagram Note: The crimp height tolerance varies with the terminal. | + 0.05 mn _VRIMP HEIGHT TOLERANCE WIRE BARREL CONDUCTORS for HICROMETE! (4) Micrometer( for measuring the crimp height ) Part No. 4007 (J-980A2+2) 3.2.1 Inspection of ylire-Crimped Contact ( Refer to Crimping Specification on .040 and .O70 series contacts for detaiis } (CONDUCTOR MUST NOT SE VISIBLE IN THE SEAM) BEND-UP (2 or less) Ne NN TWISTING (3 or less), ROLLING (Stor less) WIRE BARREL BEUD-BOwN INSULATION BARREL on 1 } + or 1655 6of713412-5476 REV B (WAS CM-476J) (3.5 - 4nn ) WIE INSULATION STRIPPING LENGTH (RE?) ( Oo - Imm ) WIRE END PROTRUSION LENGTH (0.15 = 0.65nm) (0 - 0.4mm } BELLMOUTH (Rear) aan BELLMOUTH (Front) . ~ ; . A I | INSULATION BARREL CRIMP HEIGHT - WIRE BARREL CRIMP HEIGHT || CUT-OFF TAB (0.25mm maximum) 3.2.2 Crimping Data Applicator numbers and dimensions are listed below. Be sure to refer to the following table before starting the operation. .o40 series Keceptacle - _ Ware Barrel Crimo Insulation Barrel Crimp Cr Contact Wire Applicata : Crimp e/N Type | eidth Height { ; Height . strence *) (Strip form)}|\Nominal)| vart No. ; 40.05 mm Disk Width (ma) . Disk ngthess : : - (om (Fig. ) ( mm ) (Fig.1@) (Ref. 173681 _ 0.3 955830 1.57 0.92 B 1.78 3.740.1 4 6 Mininun -2 F, 173716 7 - 0.5 1.092 A 5 9 minimum f | . | Note: 17 Crimp tensile strength includes the strength with the support of the insulation. .070 series xeceptacle Wire Barrel Crimp Insulation Barrel Crimp . : Crico a+ Contact Wire Applicator a Tensile P/N ype width Height ; Height Strengtns) /iStrip form) | (Nominal)} wart No. [ mm }} 999 | nick Width | (nm) Disk . | (rig.1 Com) | (pie. 1 @Q) [KRet-? r - ) 7? Minimum : oo o o:2 47-755758 | 1.78 0.96 D 2 2 (Note 1) 1 =f = = - 3.8 . ~ o Minimum 173630 0.3 -2 i 1.03 c s 3.54+0.1 > (Note 7) | 0.5 1.25 C 3 G Minimum = ST - 173631 0.85 | 755769 | 2.29 1.37 gs | 2.6 | 3.80.1 4 143 Maninual 1.25 -2 | F 4.52 A | F 5 (16 minimum] or automobiles, aVS 0.2 - 1.25 Fy Tofthiote: Applicable wire: Low voltage caocles412-5476 REV B (WAS CM-476J) 3.5 Crimved Lead Inspection Prior to Harness Assembly 3.4.1 Inspection We recommend that crimped products be inspected under the sane conditions observing the following tables. Each product i an inspection unit. That is, either vroducts successively manufactured during one adjustment cycle of a crimping machine, or vroducts manufactured within one working day are assumed to be one lot. ta fu Type of : Timing - nspection Item Inspection insp iten First-sight| When applicator is set up for a Appearance and dimensions inspec- Inspection specific wire for the first time.| tion (All items described below) Lot when daily operation starts. Same as above Inspection Any time during successive manu- Appearance (All items described facturing processing. below) and dimensions inspection (Section 3) . Measuring tem Inspection Standards and Methods iter P Methods 4. tire conductors not gripped in wire crim Visual Inspection or cut conductor(s). 2, Deviative crimp(Belimouth) (Wire-end protru- appearance sion) Visual Inspection Inspection 3. Defective crimp bottom (Burr) Visual Inspection kh. Insulation not gripped in insulation parrel |Visual Inspection 5. Inadequate forming of contact area of contact] Visual Inspection 6. Locking lever falling Visual Inspection 1. Cut-off tab dimension: 0.25mm maxinum Vernier Calipers Dimensions 2. Terminal deformation\( Bending ,rolling,and Inspection twisting) Magnifying giass 43, Urimp height Micrometer i, Front and rear Bellmouth for core crimp; Front: 0-O.4mm, Kear: 0.15-0.65mm Vernier Calipers 5. Locking lever neight: 3.5mm minimun Yernier Calivers > Vernier calipers or other equivalent measuring instruments Bof135.3.2 412-5476 REV B (WAS CM-4/76J) Storage a) Keep the products in 4 dry, clean place. They must be covered if stored for more than one day. b) If units are bundled, one bundle must not have more than 100 units in it. c) Stacking lerge amounts of crimped wire leads will cause en- tanglement of strip contacts resulting deformation by the weight. These will cause defective contacts. d) When unreeling the contacts, they apt to become caught one another and entangled. Care must be taken not to become deformed, when separating. 4. HARNESS ASSEMBLY OPERATION -1 Sof 13 Contact Leading into Housing anc Double Locking (1) Before loading receptacles into the housing, verify that there are no incomplete crimps. As shown in the illustra- tion in the next page, vlace the plug housing with the locking lever facing upward and then rightly insert the receptacles, its crimps are facing upward, into the housing. if the receptacle is not easily seated in the housing, Go not force it, but make sure that it is going in the right direction. Terminals forced in backwards will accidentally scrape the housing lance off. (2) Verify that the terminal has been firmly locked to the housing lance. Locking it te the housing lance correctly will make a clicking sound. After inserting the receptacle in place, check locking conditions by lightly pulling the wire toward you. whenever the receptacle has to be removed for remounting, use the svecified extraction tool. (3) Double Lock Ratchet: @ The double lock plates are used to reinforce contact retention force in housing. (They firmly hold the contact in housing, by locking the contact on insulation barrel of the contact.) \ is - 'poUBLE Lock > vondition of contact correctly locked412-5476 REV B (WAS CM-4/76J) e If contacts are not mounted correctly inside the housing, the double lock device may fail to lock the contacts securely, or secure the contact at inadquate position. When detent locking is incomplete and is effec- ;tive at only one side of housing, correct the contact mounting at the right position, using extraction tool, DOUBLE LOCK | ree ON BARREL Detent lock fee ~ (Ratenet teeth are ne oe caeide) r - =e one side) oN (| ; ann CN 000g! = - ~ 6 rye ho C ae Defective condition N Condition of'incomplete detent locking >< Verify that the double lock is firmly engaged. Press the double lock plates after checking completion of Steps (1) and (2) above. the double lock turns 90 to lock into the detent lock groove having a clicking sound. upon completion of the said work, check locking conditions by lightly pulling the wire toward you. oe / PULL THE WIRE TO THE ARROW DIRECTION DOUBLE LOCK (Upper ) PLUG HOUSING | LOCKING LEVER 7 DOUaLE LOCK CRIMP - TNSULATION BARREL LURN <O - Condition of double Locking completed oh L RECEPTACLE DOUBLE LOCK (Lower) wo sO Qo, 100f13412-5476 REV B (WAS CM-476J) Lh 2 Extracting Contacts from the Housing The extraction tool(jig) is used to pull Hybrid I/O series Contacts out of the double lock housings. 4.2.4 Unlocking the Hinge Lock Ratchet Releasing the hinge lock ratchet must be orderly made one by one from one side of the housing taking the following procedures. ah oo a PROCEDURES @ AND @ x | : TCO {poo cH Procedures: Unlocking the side lock G) Insert the tool\jig) into the insertion slot. @ Release the hinge lock by turning the tool in the direction of the arrow so that the housing wall bends to allow you to lift the tool upward, @) (A tap view ) ; | SLOT FOR INSERTING LR oe el os 30 Xe v a / |. f- A Lao . ee EXTRACTION JIG : , : : /_ Material: SKH-5' b. Bend the housing until 4 Hardness: HRC 58-60 the lock is released. . a 6) c. When the housing is bent, 13 . . lift the hinge upward. Caution: Bending the housing wall excessively may damage it. 110f13120f13 412-5476 REV B (WAS CM-476J) Extracting Uontacts Remove contacts by inserting the extraction tool from the connector mating side to lift up the connector housing lance. Procedures: @ 'Press~ the contact in the direction of the arrow of @in the right picture. @) Insert the extraction tool. Lift up the lance. Remove the contact. Note: Never insert the extraction tool end into the mating area of receptacle contacts (in order to prevent the contact leaf from deforming). 4.3 Harness Product Control 4.3.1 4.3.2 43.3 Tnspection. while total product inspection is required based on an inspection unit of one completed harness product, the following requirements must also be satisfied. a. Corresponding tab or its equivalent should be used as a probe to check the entire circuit within the connector. b>. inserting an inspection probe into the terminal is strictly prohibited, since it may cause deformation of the mating area. The inspection probe must be used inserting from the wire side, if needed. Storage a) Storage must be done in a dry & clean area. The products should not be stored without covering for more than one day. Shipment and Transportation a) Use appropriate packaging cartons to avoid any dust or moisture, and handle the cartons with care. b) Cartons must have necessary information on them.412-5476 REV B (WAS CM-476J) 5S. MOUNTLNG ON VEHICLES 5.1 Acceptance Inspection A minimum of the following points must be checked. a) Bundling location of each wire protruding out of the housing (more than 20mm for unbent wire, and more than 10mm for bent wire). b) Acceptability of contact mounting onto the housing. c) Contact cracks, defects, discoloring, and deformation, etc. ad) Housing cracks, defects and discoloration, etc. e) Confirmation and removal of defective parts. 1 he Mounting Operation Vvontrol a) Mating action should be made straightly along the mating axis. then, confirm that the locking mechanism works correctly. When engaged correctly, 4 small clicking sound is heard. Lightly pull the connector toward you after mating to make sure it is locked. b) vo not repeat mating/unmating connectors if not necessary. co) When the contact has to be pulled ont of the housing during processing, use the specified extraction tool and follow the instructions in paragraph 4.2.2. d) When checking the circuit, use the corresponding tabs or their eauivalent. e) Handle the harness with as much care as vossible. Take the following precautions in handling it. 4) Do not handle the harnesses roughly such as throwing them around. 344) Do not draw the harness bundle dragging on the floor. iii) Do not carry harnesses by the connectors. carry them by holding the wires. jv) Do not handle them in such a way that pulls on the wire and puts unnecessary force on the connectors. f) If connectors have to be removed, follow the instruc~- tions in paragraph 5.5 below. 5.5 Unmating Vonnectors Hold the housing locking lever and press downward. While pressing downward, pull the connector straight out. Caution: * Do not pull the wire harness. Pull the connector straight. 130713