amp stack mark iv instruction sheet tool kit and

Rev. C of 10

Instruction Sheet 411-22037

09/MAY/2005 Rev. C

AMP STACK MARK IV TOOL KIT AND ACCESSORIES

Operation and Maintenance Procedures

Universal Clamp Bar Assembly

Mod C Frame Assembly (PICABOND* Clamp)

10 Pair Bar Clamp

Holder Bar

Separating Tool

Electrical Tester

Single Point Separating Tool

Piece Out Fixture

Check Comb

Hand Tool Assembly

Splicing Head Assembly (Standard)

Splicing Head Assembly (Universal)

T-Pedestal

Single Insertion Tool

Adjustable Holder Bar

Adapter Block Assembly

Figure 1

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1. Introduction

This Instruction Sheet covers all application tools and accessories

of the AMP STACK Mark IV tool kit at the time of this issue. Tools

and accessories are grouped together in kits. See Figure 3 and 4

for kits content.

Application tools and accessories released are: See Figure 1.

• Hand Tool Assembly PN 790115-1

• Splicing Head Assembly (Standard) PN 790114-3

• Splicing Head Assembly (Universal) PN 790114-4

• Check Comb PN 356073-1

• Electrical Tester PN 790106-1

• Separating Tool PN 790104-1

• Single Point Separating Tool PN 790141-1

• Single Insertion Tool PN 790172-1

• Bar Clamp (10 pairs) PN 1-525424-6

• Holder Bar, 10 pairs PN 790138-1

• Adjustable Holder Bar PN 790144-1

• T-Pedestal PN 790136-1

• Piece Out Fixture PN 1-525421-4

• PICABOND Clamp PN 247284-1

• Adapter Block Assembly PN 356152-1

• Universal Clamp Bar Assembly PN 1-525421-2

These tools and accessories are designed to join telephone cable

conductors using the connectors listed in Figure 2.

Connector Type Splicing Half- Tap

Dry Standard 737858 737860

Pre- Sealed 737869 737873

Figure 2

The tool terminates one 10 Pair Straight or Half-Tap AMP STACK

Mark IV connectors to wires with 0,40-0,90 mm [26-19 AWG]

conductor diameter. The connectors are designed to accept wires

with plastic or paper insulation with a maximum outside diameter of

1,95 mm [.077 inch]. Refer to AMP Application Specification

114-22007 and AMP Product Specification 108-22074 and 108-

22075 for further connector information.

Note: For wire insulation diameters larger than 1,85 mm it is

necessary to test the tool application, especially for high-density

polyethylene insulations.

Note: All dimensions in this document are in metric units [With U.S.

customary units in brackets]

The operation procedures include crimping and inspecting the

crimped connectors. The maintenance procedures include

cleaning, lubricating and servicing the Hand Tool.

Tooling Kit Standard 790112 1- 5

Carrying Case 790116-1 1

Splicing Head Assy 790114-3 1

Hand Tool Assy 790115-1 1

Check Comb 356073-1 1

Separating Tool 790104-1 1

Single Insertion Tool 790172-1 1

Electrical Tester 790106-1 1

Instruction Sheet 411-22037 790127-2 1

Figure 3

Accessories

This case can also accept the following accessories:

• Piece Out Fixture 1-525421-4

• Holder Bar, 10p 790138-1

Tooling Kit Universal 790142 1-1 Carrying Case 790116-1 1 Splicing Head Assy 790114-4 1 Hand Tool Assy 790115-1 1 Check Comb 356073-1 1 Separating Tool 790104-1 1 Single Insertion Tool 790172-1 1 Instruction Sheet 411-22037 790127-2 1 Electrical Tester 790106-1 1

Figure 4

Note: This tooling kit is recommended to be used in conjunction

with the Universal Clamp Bar Assembly 1-525421-2.

Accessories

The case can also accept the following accessories:

• Piece Out Fixture 1-525421-4

• T-Pedestal 790136-1

• Holder Bar, 10p 790138-1

Tooling Kit Universal 790142 1-2 Carrying Case 790116-1 1 Splicing Head Assy 790114-4 1 Hand Tool Assy 790115-1 1 Check Comb 356073-1 1 Single Insertion Tool 790172-1 1 Holder Bar 790142-2 1 Instruction Sheet 411-22037 790127-2 1 Electrical Tester 790106-1 1

Figure 5

Accessories

The case can also accept the following accessories:

• Separating Tool 790104-1

• T-Pedestal 790136-1

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Additional Accessories

Not to be placed in the Carrying Case:

• Bar Clamp (10 pair) 1-525424-6

• Adjustable Holding Bar 790144-1

• Single Point Separating Tool 790141-1

• PICABOND Clamp 247284-1

• Universal Clamp Bar 1-525421-2

• Adapter Block Assembly 356152-1

2. Description

• The Hand Tool is a hand held tool that terminates a connector

with a single handle operation. The Hand Tool and

corresponding Splicing Head Assembly crimp anyone of the

above listed AMP STACK Mark IV connectors without extra tools

or adjustments.

• By means of the Splicing Head Assembly the operator can

place the connector and sort the wires to be terminated in order

to crimp them properly by applying the Hand Tool onto it.

• Once attached to the Splicing Head Assembly (Universal) the

T-Pedestal provides reliable support to it. Up to two (2) Splicing

Heads may be attached to each T-Pedestal.

• The Check Comb is a template to visually inspect the correct

placement of the wires on the Splicing Head.

• The Electrical Tester permits an electrical testing of the

terminated connector and wires without damaging the wire

insulation. This accessory shapes the interface between

connector and testing equipment.

• The Separating Tool has been designed to separate a

pluggable module from the module to which it has been mounted

with only one operation and also to separate Cover and Base

from the module if needed. The Separating Tool is compatible

with Pluggable versions from other manufacturers.

• The Single Point Separating Tool has the same purpose as

the Separating Tool never the less, with this tool more than one

operation is necessary.

• The Single Wire Insertion Tool is used to rearrange wiring

mistakes.

• The Bar Clamp is used to position the Splicing Head Assembly

close to the wires to be terminated. A Universal Splicing Head

Assembly will need a T-Pedestal to be attached to its base prior

to be positioned in the Bar Clamp.

• The Holder Bar and the Adjustable Holder Bar provide similar

functions as the Bar Clamp. In this case, only Universal Splicing

Head is accepted. The Holder Bar accepts up to two (2) Splicing

Head. The Adjustable Holder Bar accepts up to four (4) Splicing

Head.

• The Piece Out Fixture is designed as a substitute Splicing Head

for use in situations where there is little or no slack cable

available for jointing. Please refer to Instruction Sheet 411-3195

for its proper use and maintenance.

• The PICABOND Clamp together with the Adapter Block

Assembly provides a solid clamp structure for a Splicing Head

Assembly. A Universal Splicing Head Assembly will need a T-

Pedestal. Refer to Instruction Sheet 408-6569 for PICABOND

Clamp general practice.

• The Universal Clamp Bar Assembly provides rigid support for

up to 4 Splicing Head Assembly. [In case of Universal Splicing

Head Assembly a T-Pedestal is required]. Please Refer to

Instruction Sheet 411- 3193 for Universal Clamp Bar Assembly

general practices.

3. Preparation

3.1. Cable and Connector

Open and prepare the cable according to usual practices.

Determine the connector to be terminated (Straight or Half-Tap).

Refer to Figure 2 for Part Numbers.

3.2. Tooling Setup

• Adjustable Holder Bar. Unfold and secure by means of

included screws. Attach Adjustable Holder Bar to ends of cable

sheathing by wrapping the included rubber bands around them.

Once the rubber bands are tightly wrapped, insert each bar

anchor post in the corresponding rubber band hole. See Figure

6. Attach up to four Splicing Head Assemblies (Universal) onto

Adjustable Holder Bar by means of the thumbscrews provided

with the Bar. See Figure 7.

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Figure 6

Figure 7

• Holder Bar. Attach one or two Splicing Head Assembly

(Universal) onto the bar by means of the thumbscrews provided

with the bar. See Figure 8. Attach Holder Bar to ends of cable

sheathing by wrapping the included rubber bands around them.

Once the rubber bands are tightly wrapped, insert each bar

anchor post in the corresponding rubber band hole. See

Figure 9.

Figure 8

Figure 9

• Bar Clamp. Attach to ends of cable sheathing according to local

practices. Insert Splicing Head into the clamp grip and fix it at the

appropriate height by the grip screws. In case of using a

Universal Splicing Head, attach T- Pedestal to it and then insert

the new assembly into the clamp grip. See Figure 10.

Figure 10

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Figure 11

Note: Attach the T-Pedestal to the Universal Splicing Head base by

means of the screws included in the T-Pedestal. See Figure 11.

• Adapter Block Assembly. The Adapter Block Assembly is to be

joined to the PICABOND Clamp. Refer to Instruction Sheet

408-6569 in order to attach PICABOND Clamp to cable stub

sheathing. Insert the Adapter Block Assembly Mounting Stud into

the Applicator Clamp of the PICABOND Clamp. Next, position

Adapter Block Assembly and secure by closing clamp handle.

See figure 12. Insert Splicing Head into the Adapter Block

Assembly and fix it at the appropriate height by the Adapter

thumbscrews. See Figure 13. In case of using a Universal

Splicing Head, attach T- Pedestal to it and then insert the new

assembly into the clamp grip. See Figure 11.

Figure 12

Figure 13

Mounting Stud

Applicator Clamp

Adapter Block Assembly

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Figure 14

• Universal Clamp Assembly. Insert Splicing into the clamp grip

and fix it at the appropriate height by the grip screws. See Figure

14 for further details see Instruction Sheet 411-3193. In case of

using a Universal Splicing Head, attach T- Pedestal to it and then

insert the new assembly into the clamp grip. See Figure 11.

4. Connector Setup

4.1. Terminating a Straight or a Half-Tap connector

1. Place the connector base (with pins marked in black colour) into

the Splicing Head Assembly with the chamfered edge in the top left

location. See Figure 15. Base colours: Gold for Straight connectors,

green for Half- Tap connectors. In both cases, a transparent base is

also available.

Note: The Splicing Head Assembly has some protrusions on it to

avoid a wrong positioning of the base.

2. Lace the wires according to the colour code. See Figure 15.

Position the wire across the connector base and into the wire

retention springs to hold it.

Figure 15

3. After all the wires have been positioned over the connector base,

place the Check Comb into the Splicing Head Assembly, on wires

and connector base. Place the Check Comb to the left on the

Splicing Head. See Figure 16. Visually inspect the wires to ensure

that all of the wires shown are the correct colour. Slide the Check

Comb to the right and visually inspect the wires to ensure that all of

the visible wires are correct. See Figure 17. Rewire any mistakes.

Figure 16

Figure 17

Chamfered edge of connector

Connector Base

Wire Retainer Springs

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4. Next, place a connector body on top of the wires, making sure

that the chamfered edge is to the top left as shown in Figure 18.

Note: The ivory side of the connector body must always be on

the top.

Figure 18

5. Lace the wires following the same procedure and inspect them

with the Check Comb. Place the ivory or transparent cover (no

cover pins marked in black) of the connector on top of the

connector and wire stack. Make sure that the chamfered edge is to

the top left location. Apply Hand Tool to terminate wires according

to paragraph 5 (Using the Hand Tool).

5. Using The Hand Tool

1. Adjust the ram spacer on the Hand Tool to the proper position.

When terminating Straight, Half-Tap, or in the case of finding

Straight plus Pluggable or Half-Tap plus Pluggable connector

combination already installed, the words "ONE OR TWO

PLUGGABLE" shall not be visible on the face of the ram; for

Pluggable or Pluggable plus Pluggable connector combination, the

words “ONE OR TWO PLUGGABLE” must be visible on the face of

the ram. To adjust the ram spacer, push the extended lip of the ram

spacer forward and rotate the ram spacer until the ball stops snap

into position. The ball stop must be in position to secure the spacer.

See Figure 19.

Figure 19

Caution: Do not rotate the Ram Spacer to front of the tool. Always

switch between lower and rear (handles) position.

2. Place the Hand Tool onto the Splicing Head Assembly by

squeezing the latches with your fingers. When terminating only one

connector, the latches must fully engage with the bottom set of

teeth on the Splicing Head Assembly. When terminating a

combination of two connectors, the latches must fully engage with

the upper set of teeth on the Splicing Head Assembly. See figure

20.

Figure 20

Ram Spacer

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Figure 21

Caution: The Hand Tool and/or the Splicing Head Assembly may

be damaged if the tool is incorrectly mounted on the head. It is

important that BOTH latches be in the SAME tooth on both sides of

the head.

Note: If the Hand Tool becomes difficult to place onto the Splicing

Head Assembly, check the ram spacer to make sure that it is

seated flat.

3. Squeeze the handles of the tool together with both hands.

Caution: Be careful not to allow the handles to spring open freely,

releasing the stored energy instantly.

4. Release the handles slowly. See Figure 21. The connector(s)

should now be terminated.

Note: If the connector is not fully terminated, check the ram spacer

to make sure that it is seated flat.

5. Remove the tool; then, carefully pull the wires out of the wire

retention spring. Pulling a few wires out at a time will reduce the risk

of damage to the spring. See Figure 22.

Figure 22

Figure 23

Note: A terminated Half-Tap connector will not cut the bottom 10

pairs of wires. Do not attempt to remove these wires. See figure 23.

6. Carefully remove the connector from the Splicing Head

Assembly and visually inspect the connector according to

Paragraph 6.

6. Inspecting And Rearranging The Terminated

Connector

Inspect the terminated connectors to be sure that the latches that

hold the covers into the connector body are fully engaged on both

sides. After termination, make sure that the wires are fully cut and

are not turned out of the connector.

Caution: When terminating larger wires, the wires may appear to

stick inside the connector and require extra force to pull out. In this

case, the insulation may not be fully cut. Inspect the wire samples

to be sure that the copper is being fully cut.

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Inspect the connector to be sure that only one wire is present in

each connector slot. Make sure there are no wires missing from the

connector.

If some wiring mistakes are found, the connector must be opened:

• Base and/or cover can be peeled away by hand.

• In the case of finding stacked connectors already installed, they

can be separated with the Separating Tool. Its pins shall be

placed into the long holes between the light blue side of the

upper Pluggable connector and the ivory side of the lower

connector. Squeeze the handles of the tool to separate the

connectors.

Caution: Never insert Separating Tool pins into wrong connector

holes. See Figure 24.

The wire to be rearranged shall be laced across the connector and

held it in place using the wire retention springs. See Figure 25.

Position the Single Wire Insertion Tool and push it squarely so that

the metal tip will push the wire into the insulation displacement slot

in the connector. Reposition the tool above blade and push the tool

so that the connector cut-off blade cuts off the wire.

Figure 24

Figure 25

After all of the wiring mistakes have been corrected, the connector

must be closed:

• Base and/or cover can be reassembled by hand.

• If a combination of two connectors has been opened to

rearrange a wire in the intermediate layer, they can be stacked

again with the Splicing Head Assembly and the Hand Tool

according to paragraph 5.

If a wire has not been cut during the usual crimping process:

1. Check that the connector is assembled correctly.

2. Check that the latches of the Hand Tool have been engaged with

the right set of teeth of the Splicing Head Assembly. (See

paragraph 5)

3. Check that the ram spacer of the Hand Tool is in the right

position (See paragraph 5)

4. Check that nothing is obstructing the handles and that they close

fully

5. If after the above checks the tool still does not operate, return it to

AMP.

After terminating the connector, it can be electrically tested without

damaging the wire insulation. The Single Pair Electrical Tester has

2 (two) pin probes that fit in the test ports of the connector. See

figure 26. Each pair can be checked by placing the probes in the

corresponding ports.

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Tyco Electronics UK Ltd Global Application Tooling Division Barton Tors Bideford, Devon. ENGLAND Tel.: 44-(0)12 3742 8668 Fax: 44-(0)12 3742 8689 http://tooling.tycoelectronics.com/europe/

Tyco Electronics Raychem NV Telecom Outside Plant Diestsesteenweg 692 3010 Kessel-Lo, Belgium Tel.: 32-16 351 011 Fax: 32-16 351 697 www.tycoelectronics.com

Tyco Electronics Raychem, S.A. Polígono industrial Mediterráneo C/. La Fila, parcela 1 46550 Albuixech-Valencia, España Tel.: 34-96-141 70 72 Fax: 34-96-141 74 15


09/MAY/2005 Rev. C



Tyco Electronics and AMP are trademarks. © Copyright 2005 by Tyco Electronics. All of this information, including illustrations, is believed to be reliable. Users, however, should independently evaluate the suitability of each product for their application. Tyco Electronics makes no warranties as to the accuracy or completeness of the information and disclaims any liability regarding its use. Tyco Electronics’ only obligations are those in the Standard Terms and Conditions of Sale for this product and in no case will Tyco Electronics be liable for any incidental, indirect or consequential damages arising from the sale, resale, use or misuse of the product. Tyco Electronics Ordering Guide are subject to change without notice. In addition, Tyco Electronics reserves the right to make changes in materials or processing, without notification to the Buyer, which do not affect compliance with any applicable specification.

Figure 26

Figure 27

Caution: To mate or unmate properly, the tester should be slightly

angled respect to the connector. See Figure 27.

7. Inspection And Maintenance

The procedures described in the following paragraphs have been

established to ensure quality and reliability of the application tooling.

The tooling kits are inspected before shipment and should be

inspected immediately upon arrival at your facility to ensure that the

components have not been damaged in transit. A record of

scheduled inspections should remain with each kit or be supplied to

the personnel responsible for the tool. Although it is recommended

for at least one inspection per month, the frequency should be

based on:

• Care, amount of use, and handling of tooling kit.

• The degree of operator training and skill.

• The ambient working conditions (abnormal amounts of dust, dirt,

and temperature changes will necessitate more frequent

inspections).

• Established company standards.

7.1. Inspection

A. Hand Tool

Inspect the Hand Tool to make sure that it opens and closes freely.

Clean any dirt or dust that may be present in the tool. Inspect the

safety ring on the handle of the tool and ensure that the ring is

secure and can support more than the weight of the tool.

B. Splicing Head Assembly

The wire retention springs should be clean of any grease for best

performance. Make sure that the screws securing the guides to the

head are tight. Ensure that the connector retainer springs are

working properly and are able to support the connector, even when

the head is turned upside down.

7.2. Maintenance

A. Lubrication

It is strongly recommended to lubricate all pivot points of the tool

with a thin coat of any SAE 20 motor oil. Do not oil excessively. See

Figure 28. Under normal conditions, lubrication is required every

1.000 tool cycles, or whenever the interface is dry. Otherwise, the

tool will not open properly.

Figure 28

B. General Cleaning Procedure

Clean and lubricate the tool at the beginning of each shift, or

according to local practice. Use a telephone company approved

solvent cleaner or equivalent.

Note: Also available is AMP® Cleaning Kit 229333-1 which

contains a bristle brush for general cleaning, a tube cleaner for

cleaning exterior polished surfaces, an extractor for removing scrap

wire and plastic particles, and a tube brush for cleaning inside the

tool. For detailed information about the cleaning kit, refer to AMP

Instruction Sheet 408-7534.

Electrical Tester

Connector

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