TITLE PAGE GS-20-002 REVISION Specification Requirement

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NUMBER
TITLE PAGE
GS-20-002
REVISION
Specification Requirements Cable Preparation, Wire Termination Assembly Connectors Using 72392-type Contacts
AUTHORIZED STATUS
DATE
J.R. Volstorf
UNRESTRICTED
TABLE CONTENTS
PURPOSE.4 SCOPE.4
GENERAL.4 Method Specifying Workmanship.4 Usage Visual PRODUCT DESCRIPTIONS 72476 type 4-row MetralUnshielded Connector 72477 type 4-row MetralUnshielded Connector 88940 type 4-row MetralUnshielded Connector CABLE PREPARATION 72476, 72477 88940 type 4-row MetralUnshielded Connectors DESIGNING WIRING DIAGRAMS
RECOMMENDED WIRE SIZES INSULATIONS Wire Insulation Materials Maximum Insulation Diameters Wire Sizes Uninsulated Wires Conductor Materials.9 POSITION CONNECTOR SUB-ASSEMBLY CABLE 72476 72477 type 4-row MetralUnshielded Connectors 88940 type MetralUnshielded Connectors ACCEPTABLE WIRE TERMINATION Termination Requirements, Visual 9.1.1 Wire Location.11 9.1.2 Wire Depth.12 9.1.3 Strain Relief 9.1.4 Terminal Damage.13 9.1.5 Wire Damage Tool Setup Destructive Inspection Techniques 9.2.1 Wire Removal.13 9.2.2 Terminal Damage.13 9.2.3 Acceptable Metallic Contact
Copyright 2005
Form E-3334 06/06/05 V05-0553
GS-01-001
PDM: Rev:H
STATUS:Released
Printed: 2005
NUMBER
TITLE PAGE
GS-20-002
REVISION
Specification Requirements Cable Preparation, Wire Termination Assembly Connectors Using 72392-type Contacts
AUTHORIZED STATUS
DATE
J.R. Volstorf
UNRESTRICTED
10.0 CONNECTOR SUB-ASSEMBLIES GENERAL.13 10.1 Contact Retention.13 10.2 Connector Insulator Damage 10.2.1 Termination Tool Misalignment 10.3 Wire Terminators 10.3.1 Automatic Terminators 10.3.2 Hand Tools 11.0 ASSEMBLY COMPONENTS AFTER WIRE INSERTION.17 11.1 72476 72477 type MetralUnshielded Connectors.17 11.1.1 Assembly Covers Connector Sub-Assemblies 11.1.2 Assembly Latch Finger Covers.19 11.1.3 Assembly Cable Tie.19 11.1.4 Assembly Optional Coding Keys Covers 11.2 88940 type MetralUnshielded Connectors.20 12.0 REPAIR PROCEDURES 12.1 Repair Tooling 12.2 Wire Replacement 12.3 Damaged Contacts Completed Connector 12.4 Removing Contacts from Insulator.21 12.5 Inserting Contacts into Insulator.21 12.6 Wires Inserted Wrong Position Defective Insertion 12.6.1 Preferred Method Repair 12.6.2 Alternate Methods Repair 12.6.2.1 Wires Inserted Wrong Position.23 12.6.2.2 Defective Insertions.23 12.6.2.2.1 Reinsertion Wire Contact 12.6.2.2.2 Soldering Wire Contact.25 12.7 Replacing Latches.26 12.8 Replacing Removing Covers 13.0 CONNECTORS WITH MATING PRODUCTS.26 13.1 72476 72477 type MetralUnshielded Connectors.26 13.2 88940 type MetralUnshielded Connectors.26 14.0 15.0 16.0 NOTES NOTES REFERENCE DOCUMENTS
Copyright 2005
Form E-3334 06/06/05 V05-0553
GS-01-001
PDM: Rev:H
STATUS:Released
Printed: 2005
NUMBER
TITLE PAGE
GS-20-002
REVISION
Specification Requirements Cable Preparation, Wire Termination Assembly Connectors Using 72392-type Contacts
AUTHORIZED STATUS
DATE
J.R. Volstorf
UNRESTRICTED
Figure Unshielded Connector.5 Figure 4x12 Unshielded Connector.6 Figure 2x10 Unshielded Connector.6 Figure Cable Preparation Unshielded Connectors.7 Figure Wiring Diagram 72476 Unshielded Connectors Figure Wiring Diagram 72477 Unshielded Connectors Figure Dimensions Single Multiple Cables Unshielded Connector.9 Figure Dimensions Multiple Unshielded Connectors Cable.10 Figure Wire Insertion Visual Requirements Figure Wire Depth Gage Figure TL-230 AutomaticTerminator Figure BPY6737PC1xx AutomaticTerminator.16 Figure Hand Tool Terminator Figure Assembly Covers 72476 type Connectors.17 Figure Assembly Covers 72477 type Connectors.18 Figure Cover Assembly Fixture Figure Assembly Latch Finger.19 Figure Assembly Cable Figure Assembly Coding Keys Figure Checking Proper Contact Latching After Insertion.22 Figure Checking Damaged Terminal After Insertion.22 Figure Preparing Wire Reinsertion.23 Figure HT-0525 Wire Insertion Repair Tool Figure BPY75D37 Wire Insertion Repair Tool Figure Solder Repair Defective Insertion Figure Mating Headers Shrouds Figure Mating Retainers
Copyright 2005
Form E-3334 06/06/05 V05-0553
GS-01-001
PDM: Rev:H
STATUS:Released
Printed: 2005
NUMBER
TITLE PAGE
GS-20-002
REVISION
Specification Requirements Cable Preparation, Wire Termination Assembly Connectors Using 72392-type Contacts
AUTHORIZED STATUS
DATE
J.R. Volstorf
UNRESTRICTED
PURPOSE
This specification covers product workmanship requirements cable preparation, wire termination assembly following Metralconnectors using 72392 type insulation displacement contacts. 72476-type Metralunshielded cable connectors 72477-type 4x12 Metralunshielded cable connectors 88940-type 2x10 Metralunshielded cable connectors
SCOPE
Recommended cable preparation Recommendations wire types that terminated. deviation wire size, insulation type insulation thickness from those listed section "Recommended Wire Sizes Insulations" should used without approval engineering design group responsible this product. Please refer question your local representative. Recommended requirements completed termination Recommended repair procedures wire terminations Assembly components after wire termination
GENERAL
Method Specifying
cable assembly detail drawings should reference this specification when applicable. exceptions requirements this specification should clearly described notes cable assembly drawing. recommend exceptions unless approval obtained advance from engineering design group.
Workmanship
Workmanship shall level that indicates controlled conditions manufacture such that subsequent operations, functionality performance degraded.
Usage
connectors covered this instruction intended wide variety environments designed meet conditions specified Bellcore GR-1217-CORE IEC-61076-4-110. Banned/Restricted Substances product where part number ends `LF' meet European Union directives other country regulations described GS-22-008. part numbers that `LF' meet regulations except SnPb plating. Manufacturing Processability products covered this specification will withstand exposure convection, infra-red vapor phase reflow ovens. heat this product above 110°C.
Visual
Visual examinations shall performed with magnification 10x. recommended)
Copyright 2005
Form E-3334 06/06/05 V05-0553
GS-01-001
PDM: Rev:H
STATUS:Released
Printed: 2005
NUMBER
TITLE PAGE
GS-20-002
REVISION
Specification Requirements Cable Preparation, Wire Termination Assembly Connectors Using 72392-type Contacts
AUTHORIZED STATUS
DATE
J.R. Volstorf
UNRESTRICTED
Product Descriptions
72476 type 4-row MetralUnshielded Connector
This connector pitch cable connector with type contacts. connectors sold kits with following variations. 72476-wxy1 where specifies plating separable contact specifies latch finger type 0.8um Gold cable diameters 7.0mm 2.0um Gold cable diameters 11.0mm 1.3um Gold 0.8um specifies wire gage capacity 26-24 gage wire 30-28 gage wire Figure Unshielded Connector Product Number 72476-w1y1 Product Number 72476-w2y1
Standard Latch Finger
Short Latch Finger
difference between standard latch finger short latch finger that standard latch stands above cable easier access thus restricts maximum diameter cable that used. certain cases multiple cables stripping cable jacket above cable area connector will allow user overcome some restrictions.
Copyright 2005
Form E-3334 06/06/05 V05-0553
GS-01-001
PDM: Rev:H
STATUS:Released
Printed: 2005
NUMBER
TITLE PAGE
GS-20-002
REVISION
Specification Requirements Cable Preparation, Wire Termination Assembly Connectors Using 72392-type Contacts
AUTHORIZED STATUS
DATE
J.R. Volstorf
UNRESTRICTED
72477 type 4-row MetralUnshielded Connector
This connector 4x12 pitch cable connector with type contacts. connectors sold kits with same variations 72476 types adapt slightly larger cables 72477-wxy1 where cable diameters 9.5mm cable diameters 11.5mm Figure 4x12 Unshielded Connector Product Number 72477-w1y1 Standard Latch Finger Product Number 72477-w2y1 Short Latch Finger
88940 type 4-row MetralUnshielded Connector
These connectors come 2x10 pitch cable connector with type contacts. Please contact your representative obtain data cables that used with this connector. connectors sold only with 0.8um plating separable contacts gage wire sizes. Figure 2x10 Unshielded Connector 88940-001 88940-002
Copyright 2005
Form E-3334 06/06/05 V05-0553
GS-01-001
PDM: Rev:H
STATUS:Released
Printed: 2005
NUMBER
TITLE PAGE
GS-20-002
REVISION
Specification Requirements Cable Preparation, Wire Termination Assembly Connectors Using 72392-type Contacts
AUTHORIZED STATUS
DATE
J.R. Volstorf
UNRESTRICTED
Cable Preparation
"ASSEMBLY COMPONENTS AFTER WIRE INSERTION" restrictions cable diameters each connector. section "APPLICATION TOOLING" available wire insertion equipment.
72476, 72477 88940 type 4-row MetralUnshielded Connectors
following recommendations cable assemblies where more cables being terminated connector user wished cable jacket connector cover added strain relief. cases where more than connector being attached cable follow cable assembly drawing instructions. Figure Cable Preparation Unshielded Connectors
DESIGNING WIRING DIAGRAMS
connector sub-assemblies polarized with respect latch side connector. wiring diagrams this polarization feature must specified that when wire insertion operation performed, operator properly orient parts cable. addition, connectors using more than connector sub-assembly, cable assembly drawing wiring diagram must specify scheme identify which connector sub-assembly will occupy which position connector assembly. Figure Wiring Diagram 72476 Unshielded Connectors
Copyright 2005
Form E-3334 06/06/05 V05-0553
GS-01-001
PDM: Rev:H
STATUS:Released
Printed: 2005
NUMBER
TITLE PAGE
GS-20-002
REVISION
Specification Requirements Cable Preparation, Wire Termination Assembly Connectors Using 72392-type Contacts
AUTHORIZED STATUS
DATE
J.R. Volstorf
UNRESTRICTED
Figure Wiring Diagram 72477 Unshielded Connectors
standard wiring diagram exists 88940 type Connectors
RECOMMENDED WIRE SIZES INSULATIONS
Wire Insulation Materials
Semi-rigid FEP, DP-3, PVC/PE, PTFE, have been used.
Maximum Insulation Diameters Wire Sizes
Conductor Size gage solid .3mm solid gage solid .4mm solid gage solid .5mm solid gage solid Maximum Insulation Dimensions Insulation Thickness Insulation Diameter inch inch 0.27 0.011 0.80 0.032 0.28 0.011 0.86 0.034 0.32 0.013 0.96 0.038 0.30 0.012 1.00 0.040 0.30 0.012 1.00 0.040 0.25 0.010 1.00 0.040 0.245 0.010 1.00 0.040
Certain stranded wires successfully inserted contact must qualified individually. specification cable using stranded wire must have wire insulation type, wire insulation thickness, number strands, size strands twist strands controlled.
Copyright 2005
Form E-3334 06/06/05 V05-0553
GS-01-001
PDM: Rev:H
STATUS:Released
Printed: 2005
NUMBER
TITLE PAGE
GS-20-002
REVISION
Specification Requirements Cable Preparation, Wire Termination Assembly Connectors Using 72392-type Contacts
AUTHORIZED STATUS
DATE
J.R. Volstorf
UNRESTRICTED
Uninsulated Wires
Uninsulated wires sizes gage plus .5mm .4mm diameter have been successfully inserted contacts.
Conductor Materials
Bare copper wire plated copper wire plated copper wire
POSITION CONNECTOR SUB-ASSEMBLY CABLE
72476 72477 type 4-row MetralUnshielded Connectors
variety conditions exist after wire insertion depending cable size number cables used. following shows several cases where single multiple cables used connector. 18mm dimension represents distance range from connector sub-assembly cable jacket that allows cable fasten cable jacket. positioning cables insertion equipment controls final position cable jacket connector sub-assembly. Figure Dimensions Single Multiple Cables Unshielded Connector
different condition exists when multiple connectors assembled cable. this case cable jacket must stripped back point that cable ties only wrap around bundle wires. case hard wire insulation this method acceptable case soft insulation small piece heat shrink tubing needed area cable group wires prevent cable from penetrating wire insulation. However, each contacts wire strain relief most applications cable strain relief needed. cable assembly designer have specify that heat shrink tube slid each bundle wires before wire insertion depending size shrink rate tubing selected.
Copyright 2005
Form E-3334 06/06/05 V05-0553
GS-01-001
PDM: Rev:H
STATUS:Released
Printed: 2005
NUMBER
TITLE PAGE
GS-20-002
REVISION
Specification Requirements Cable Preparation, Wire Termination Assembly Connectors Using 72392-type Contacts
AUTHORIZED STATUS
DATE
J.R. Volstorf
UNRESTRICTED
Figure Dimensions Multiple Unshielded Connectors Cable
88940 type MetralUnshielded Connectors
These connectors have only wire strain relief each contact have cable jacket strain relief option. Therefore there requirement position cable jacket connector. Multiple connectors attached same cable.
ACCEPTABLE WIRE TERMINATION
Caution: wire strain relief each contact must closed wire insertion punch even wire inserted into contact! strain reliefs closed, short occur between contacts both shielded unshielded connectors between contact metal shields shielded connectors.
automatic wire terminators will unused contacts unless machine cycle interrupted. When using hand tools, operator must index connector subassembly unused positions activate hand tool.
Copyright 2005
Form E-3334 06/06/05 V05-0553
GS-01-001
PDM: Rev:H
STATUS:Released
Printed: 2005
NUMBER
TITLE PAGE
GS-20-002
REVISION
Specification Requirements Cable Preparation, Wire Termination Assembly Connectors Using 72392-type Contacts
AUTHORIZED STATUS
DATE
J.R. Volstorf
UNRESTRICTED
Termination Requirements, Visual
Requirements acceptable termination shown Figure well non-destructive visual inspection methods insure satisfactory terminations without removing wires.
9.1.1 Wire Location
copper conductor shall extend least .75mm beyond dimples. This requirement shall considered wire insulation extends least 1.00mmj beyond dimples. maximum insulation extend surface `D'. Figure
Figure Wire Insertion Visual Requirements
Copyright 2005
Form E-3334 06/06/05 V05-0553
GS-01-001
PDM: Rev:H
STATUS:Released
Printed: 2005
NUMBER
TITLE PAGE
GS-20-002
REVISION
Specification Requirements Cable Preparation, Wire Termination Assembly Connectors Using 72392-type Contacts
AUTHORIZED STATUS
DATE
J.R. Volstorf
UNRESTRICTED
9.1.2 Wire Depth
wire shall inserted into dimples that wire depth greater than equal "ab" measured from connector insulator wire insulation region Views Figure dial indicator depicted Figure used measure depth required. minimum "ab" based diameter wire being used. insulation diameters greater equal 0.6mm [0.0236 inch], "ab" determined from relation "ab" minimum [(1.48 O.D.) millimeters, (.058 O.D.) inches]; where O.D. actual outside diameter insulation wire question. insulation diameters below 0.6mm [0.0236 inch] minimum insertion depth 0.88mm [0.0346 inch]. case where different size wires being inserted same side insulator, "ab" shall calculated from largest wire insulation diameter. insertion punches available wire insulation diameter determines which used. section "Application Tooling" details. insulation diameters larger than 0.7mm [.0275 inch] possible push wire with such pressure that insulation spreads against side contact walls area opens contact. these diameters measure distance across channel either dimple shown view figure9 with wire inserted. Open wire strain relief gently remove inserted wire. Again measure distance same spot. measurement with wire removed should least .05mm [.002 inch] less than with wire inserted. This measurement should done when insertion equipment measurement less than specified, reduce depth insertion until meet. Contact representative wire selected cannot meet requirements. standard depth gage available measurement "ab" listed below. have observed that with some wire insulation types, insulation gradually lifts wire after insertion. this reason, measurement wire depth "ab" should made soon after insertion possible avoid incorrect readings. Dial Indicator Insertion Depth Gage Scale Travel Revolution Millimeters 1.00
Part 413395-001
Graduations 0.01
Figure Wire Depth Gage
Copyright 2005
Form E-3334 06/06/05 V05-0553
GS-01-001
PDM: Rev:H
STATUS:Released
Printed: 2005
NUMBER
TITLE PAGE
GS-20-002
REVISION
Specification Requirements Cable Preparation, Wire Termination Assembly Connectors Using 72392-type Contacts
AUTHORIZED STATUS
DATE
J.R. Volstorf
UNRESTRICTED
9.1.3 Strain Relief
strain relief tabs must crimped firmly against wire such that wire will dislodged with 8.9N lb.) minimum pull. wire shall pulled degrees axis terminated wire, direction opposite insertion direction. should considered major defect either contact strain relief tabs have been crimped over wire.
9.1.4 Terminal Damage
There should distortion metal terminal other than intended forming strain relief except that insertion punch into face dimple maximum millimeter (0.004 inches) during wire insertion.
9.1.5 Wire Damage
There shall breaks wire insulation expose center conductor below surface Figure View Marks dents insulation caused insertion equipment that expose conductor this area permitted.
Tool Setup Destructive Inspection Techniques
Techniques verify proper tool set-up further inspection suspected visual failures require wire removal. Wire removal shall done accordance with following instructions.
9.2.1 Wire Removal
Force open wire strain reliefs contact peel wire away form strain relief Figure View dimples, being careful damage contact.
9.2.2 Terminal Damage
Examine dimples. There shall visible damage other than that caused intended forming strain relief normal widening wire except that insertion punch into face dimple maximum 0.10 millimeters (0.004 inches) during wire insertion.
9.2.3 Acceptable Metallic Contact
removed wire shall show evidence metallic contact with four dimples.
10.0 CONNECTOR SUB-ASSEMBLIES GENERAL
10.1 Contact Retention
Contacts shall held securely insulator capable withstanding 13.4N (3.0 axial pull. contact which becomes dislodged axial force less than 8.9N (2.0 lb.) will considered major defect.
Copyright 2005
Form E-3334 06/06/05 V05-0553
GS-01-001
PDM: Rev:H
STATUS:Released
Printed: 2005
NUMBER
TITLE PAGE
GS-20-002
REVISION
Specification Requirements Cable Preparation, Wire Termination Assembly Connectors Using 72392-type Contacts
AUTHORIZED STATUS
DATE
J.R. Volstorf
UNRESTRICTED
10.2
Connector Insulator Damage 10.2.1 Termination Tool Misalignment
Slight misalignment between connector wire insertion blade will cause shaving plastic strain relief area connector Figure View Slight (0.1mm 0.004 inch) shaving insulator this region acceptable other requirements section "ACCEPTABLE WIRE TERMINATIONS" strain relief tabs crimped onto wire.
10.3
Wire Terminators
following coded wire termination tools available inserting wires into connectors.
Wire Insertion Equipment Part 413053-010 413053-011 BPY6737PC1xx BPY13836 Description TL-230 TL-230 Function Auto. Terminator Auto .Terminator Auto .Terminator Hand Tool Instructions 413054-001 413054-001 Comments Pistol grip
10.3.1 Automatic Terminators
terminators semi-automatic wire inserters that handle sizes connectors. terminators wire insertion punches adjusted meet depth requirements approved wire sizes insulation sizes types. terminators self indexing insert wires simultaneously. terminators programmed insert positions, insert side only skip positions. Multiple programs stored different cable assemblies terminator recalled program number. TL-230 automatic terminator uses different insertion punches. punch determined outside diameter wire insulation. case where bare drain wires being inserted along with insulated wires, punch used will depend diameter insulated wire. punches very similar identified part number etched sides. punches TL-230, punch 166981-005 replaces 166981-002. 166981-005 punch produces better connection wires with insulation diameters above 0.8mm
Insertion Equipment TL-230 TL-230
Insertion Punch 166981-005 166981-003
Wire Insulation Diameter 1.0mm [0.024 0.040inch] 0.7mm [0.016 0.028inch]
Copyright 2005
Form E-3334 06/06/05 V05-0553
GS-01-001
PDM: Rev:H
STATUS:Released
Printed: 2005
NUMBER
TITLE PAGE
GS-20-002
REVISION
Specification Requirements Cable Preparation, Wire Termination Assembly Connectors Using 72392-type Contacts
AUTHORIZED STATUS
DATE
J.R. Volstorf
UNRESTRICTED
Figure TL-230 AutomaticTerminator
BPY6737A3xx automatic terminator uses different adapter kits. Which depends cable connector using. `xx' terminator number specifies keyboard type. There three versions, `UK', `FR' `SW' Number BPY6736A1 Cable Connectors 72476 72477
Copyright 2005
Form E-3334 06/06/05 V05-0553
GS-01-001
PDM: Rev:H
STATUS:Released
Printed: 2005
NUMBER
TITLE PAGE
GS-20-002
REVISION
Specification Requirements Cable Preparation, Wire Termination Assembly Connectors Using 72392-type Contacts
AUTHORIZED STATUS
DATE
J.R. Volstorf
UNRESTRICTED
Figure BPY6737PC1xx AutomaticTerminator
10.3.2 Hand Tools
hand tool pistol grip ratchet type manual inserter. insertion punch hand tool adjusted controlling insertion depth once activated must complete entire insertion cycle before returning. punch mechanically advanced spring returned connector sub-assembly manually advanced retracted from tool. hand tool inserts wire time. Figure Hand Tool Terminator
Copyright 2005
Form E-3334 06/06/05 V05-0553
GS-01-001
PDM: Rev:H
STATUS:Released
Printed: 2005
NUMBER
TITLE PAGE
GS-20-002
REVISION
Specification Requirements Cable Preparation, Wire Termination Assembly Connectors Using 72392-type Contacts
AUTHORIZED STATUS
DATE
J.R. Volstorf
UNRESTRICTED
11.0 ASSEMBLY COMPONENTS AFTER WIRE INSERTION
11.1 72476 72477 type MetralUnshielded Connectors 11.1.1 Assembly Covers Connector Sub-Assemblies
cover halves pressed together trapping connector sub-assemblies with inserted cable wires between halves. connector sub-assemblies must aligned that side with smaller diameter longer stud faces latch side cover. force required press halves together such that fixture needed. covers disassembled reassembled three times repairs needed. After assembly check that small separator ribs covers that between insulators connector subassemblies actually between insulators smashed down under side insulators. Part HT-0520 Drawing 415810-001 Description Cover Assembly Fixture Instructions 415835-001
Figure Assembly Covers 72476 type Connectors
Copyright 2005
Form E-3334 06/06/05 V05-0553
GS-01-001
PDM: Rev:H
STATUS:Released
Printed: 2005
NUMBER
TITLE PAGE
GS-20-002
REVISION
Specification Requirements Cable Preparation, Wire Termination Assembly Connectors Using 72392-type Contacts
AUTHORIZED STATUS
DATE
J.R. Volstorf
UNRESTRICTED
Figure Assembly Covers 72477 type Connectors
Figure Cover Assembly Fixture
Copyright 2005
Form E-3334 06/06/05 V05-0553
GS-01-001
PDM: Rev:H
STATUS:Released
Printed: 2005
NUMBER
TITLE PAGE
GS-20-002
REVISION
Specification Requirements Cable Preparation, Wire Termination Assembly Connectors Using 72392-type Contacts
AUTHORIZED STATUS
DATE
J.R. Volstorf
UNRESTRICTED
11.1.2 Assembly Latch Finger Covers
assembly latch finger cover show drawn below. latch finger also assembled before after assembly optional coding keys. Figure Assembly Latch Finger
11.1.3 Assembly Cable
band cable threaded through holes non-latch side cover around cable shown. Then pull band tight excess band flush head. Position head that remains within projected area covers that does block insertion adjacent connectors. case cable assemblies specifying connectors with regular latch finger, head must positioned that does interfere with action latch finger. Figure Assembly Cable
Copyright 2005
Form E-3334 06/06/05 V05-0553
GS-01-001
PDM: Rev:H
STATUS:Released
Printed: 2005
NUMBER
TITLE PAGE
GS-20-002
REVISION
Specification Requirements Cable Preparation, Wire Termination Assembly Connectors Using 72392-type Contacts
AUTHORIZED STATUS
DATE
J.R. Volstorf
UNRESTRICTED
11.1.4 Assembly Optional Coding Keys Covers
assembly 72388 type coding keys connector assembly shown below. cable shown. coding keys also inserted latch side cover before latch finger connector final assembly. 72388 coding designed work with 5-row MetralHeader coding 70274. There coding variations. Thus cable connector variations 4x12 cable connector have 18x18 variations. keys match part dash number 72388-004 works with 70274-004. Figure Assembly Coding Keys
11.2
88940 type MetralUnshielded Connectors
additional assembly required after wire insertion.
Copyright 2005
Form E-3334 06/06/05 V05-0553
GS-01-001
PDM: Rev:H
STATUS:Released
Printed: 2005
NUMBER
TITLE PAGE
GS-20-002
REVISION
Specification Requirements Cable Preparation, Wire Termination Assembly Connectors Using 72392-type Contacts
AUTHORIZED STATUS
DATE
J.R. Volstorf
UNRESTRICTED
12.0 REPAIR PROCEDURES
12.1 Repair Tooling
HT-0522 contact removal contains HT-0523 contact removal tool holding fixture. holding fixture needed remove contacts connector sub-assembly positions with exposed contact latch fingers. There these positions connector sub-assembly unshielded cable connectors. shielded cable connectors require holding fixture need only HT-0522 contact removal tool. HT-0525 wire insertion repair tool will insert wire with only short remaining lead into unused contact. contact into which wire inserted been used previously, then must replaced with unused contact before insertion. HT-0517 latch finger removal tool removes already installed latch finger from connector assembly. Part HT-0522 HT-0523 HT-0524 HT-0517 Drawing 415832-001 415826-001 415821-001 415709-001 Description Contact Removal Contact Removal Hand Tool Wire Insertion repair Tool Latch Finger Removal Tool Instructions 415837-001 415837-001 415838-001 415708-001
12.2
Wire Replacement
testing been done reliability contacts that have been repaired wire removed replaced Contacts with improperly inserted incorrect wires should removed replaced.
12.3 12.4
Damaged Contacts Completed Connector
Damaged contacts must removed from connector replaced.
Removing Contacts from Insulator
Contacts removed inserting contact removal tool, HT-0523 into lock window insulator deforming lock Figure View away from window. This allows contact slide through back insulator down Figure View contact reinserted, then contact must remove carefully bend deform contact. contact must also protected from damage until reinserted.
12.5
Inserting Contacts into Insulator
Carefully insert contact into desire insulator position. Check orientation other contacts insulator orient contact inserted same before beginning insertion. Replacement contacts obtained removing contact from identical connector sub-assembly match part numbers printed connector sub-assembly) following special replacement contacts. Part 84899-401 84899-402 Description 4-row Contact, 2.0um 4-row Contact, 2.0um Wire Gages 26-24 30-26
Copyright 2005
Form E-3334 06/06/05 V05-0553
GS-01-001
PDM: Rev:H
STATUS:Released
Printed: 2005
NUMBER
TITLE PAGE
GS-20-002
REVISION
Specification Requirements Cable Preparation, Wire Termination Assembly Connectors Using 72392-type Contacts
AUTHORIZED STATUS
DATE
J.R. Volstorf
UNRESTRICTED
contact must fully seated that latch finger snaps into locking window holds contact place. following figure shows visual inspection needed determine that contact properly latched insulator. Figure Checking Proper Contact Latching After Insertion
following figure demonstrates visual inspection procedure check that contact properly aligned insulator. This visual inspection requires least magnification lens. reason shown defect named "blackeye' that prevents light from passing through from side insulator window side. good contact, insertion light pass through contact gap. Figure Checking Damaged Terminal After Insertion
12.6
Wires Inserted Wrong Position Defective Insertion 12.6.1 Preferred Method Repair
preferred method repair cutoff defective connector sub-assemblies from cable just above connectors, strip cable insert wires into connector subassemblies.
Copyright 2005
Form E-3334 06/06/05 V05-0553
GS-01-001
PDM: Rev:H
STATUS:Released
Printed: 2005
NUMBER
TITLE PAGE
GS-20-002
REVISION
Specification Requirements Cable Preparation, Wire Termination Assembly Connectors Using 72392-type Contacts
AUTHORIZED STATUS
DATE
J.R. Volstorf
UNRESTRICTED
12.6.2 Alternate Methods Repair 12.6.2.1 Wires Inserted Wrong Position
Remove inserted contact using contact removal HT-0522 being careful damage contact disturb wire IDC's. some cases amount free wire between connector sub-assembly cable jacket short back contact insulator. this case cable jacket will have slit higher free more wire length accomplish task. After removal carefully reinsert contacts correct positions. Another method would remove contacts insulator same time which does require slitting cable jacket reinserting contacts also same time. This latter method recommended since very hard properly reinsert contacts same time.
12.6.2.2
Defective Insertions
12.6.2.2.1 Reinsertion Wire Contact
Remove inserted contact with contact removal HT-0522. Replace contact with contact. preferred method wire outside contact this does leave long enough wire reinsertion then strain relief contact opened wire removed. After removal wire wire just before were first dimple contacted wire shown following figure. Reinsert wire using wire insertion repair tool HT-05254 reinserted wire must meet requirements listed normal wire insertion. Figure Preparing Wire Reinsertion
Copyright 2005
Form E-3334 06/06/05 V05-0553
GS-01-001
PDM: Rev:H
STATUS:Released
Printed: 2005
NUMBER
TITLE PAGE
GS-20-002
REVISION
Specification Requirements Cable Preparation, Wire Termination Assembly Connectors Using 72392-type Contacts
AUTHORIZED STATUS
DATE
J.R. Volstorf
UNRESTRICTED
Figure HT-0525 Wire Insertion Repair Tool
Figure BPY75D37 Wire Insertion Repair Tool
Copyright 2005
Form E-3334 06/06/05 V05-0553
GS-01-001
PDM: Rev:H
STATUS:Released
Printed: 2005
NUMBER
TITLE PAGE
GS-20-002
REVISION
Specification Requirements Cable Preparation, Wire Termination Assembly Connectors Using 72392-type Contacts
AUTHORIZED STATUS
DATE
J.R. Volstorf
UNRESTRICTED
12.6.2.2.2 Soldering Wire Contact
Remove inserted contact with contact removal HT-0522. Replace contact with contact. preferred method wire outside contact this does leave long enough wire reinsertion then strain relief contact opened wire removed. After removal wire wire just before were first dimple contacted wire shown above figure. Remove insulation from wire such that after reinsertion wire positioned contact shown following figure. Reinsert wire using contact wire insertion repair tool HT-0524 setting strain relief carefully solder wire contact channel first dimples between sets dimples. soldering operation must done quickly possible prevent damage insulator. allow solder protrude above contact shown following figure. Only certified soldering operators should used make these repairs. Figure Solder Repair Defective Insertion
Copyright 2005
Form E-3334 06/06/05 V05-0553
GS-01-001
PDM: Rev:H
STATUS:Released
Printed: 2005
NUMBER
TITLE PAGE
GS-20-002
REVISION
Specification Requirements Cable Preparation, Wire Termination Assembly Connectors Using 72392-type Contacts
AUTHORIZED STATUS
DATE
J.R. Volstorf
UNRESTRICTED
12.7
Replacing Latches
This procedure covers both replacement broken defective latch fingers well wrong latch finger having been assembled. both cases latch finger destroyed process cannot reused. Remove latch finger using latch finger removal tool, HT-0517. After latch finger removed, check latch finger track latch side covers damage cover remaining pieces latch finger. Remove remaining pieces latch fingers present. Assemble latch finger instructions section component assembly.
12.8
Replacing Removing Covers
covers apart taking care damage cable connector sub-assemblies. undamaged, covers reused three times. more covers damaged, replace with covers. Reassemble covers instructions section component assembly. repair having made remote location, feasible have cover assembly fixture (HT-0520), covers pressed together using small vise mallet great care must taken align connector sub-assemblies covers good assembly.
13.0 Connectors with Mating Products
13.1 72476 72477 type MetralUnshielded Connectors
cable connectors mate with standard Metral4-row headers shrouds. Multiple cable connectors plugged into header case 72477, cable connector plugged into headers. cable connectors end-to-end stackable spaced within 16mm side-to-side. connectors mate with following range heights. Figure Mating Headers Shrouds
13.2
88940 type MetralUnshielded Connectors
These connectors used only rear plug-up straight Metralfour headers. Three varieties press-on retainers available this purpose. retainers press onto header pins extra features required board. cases connectors must placed side-to-side retainers effect latching. retainers thus connectors end-to-end stackable. connector mate with following range heights.
Copyright 2005
Form E-3334 06/06/05 V05-0553
GS-01-001
PDM: Rev:H
STATUS:Released
Printed: 2005
NUMBER
TITLE PAGE
GS-20-002
REVISION
Specification Requirements Cable Preparation, Wire Termination Assembly Connectors Using 72392-type Contacts
AUTHORIZED STATUS
DATE
J.R. Volstorf
UNRESTRICTED
Figure Mating Retainers
Copyright 2005
Form E-3334 06/06/05 V05-0553
GS-01-001
PDM: Rev:H
STATUS:Released
Printed: 2005
NUMBER
TITLE PAGE
GS-20-002
REVISION
Specification Requirements Cable Preparation, Wire Termination Assembly Connectors Using 72392-type Contacts
AUTHORIZED STATUS
DATE
J.R. Volstorf
UNRESTRICTED
14.0 NOTES
following table lists files imported into this document. Figure Autocad File G20002_A.DWG G20002_B.DWG G20002_C.DWG G20002_D.DWG G20002_E.DWG G20002_F.DWG G20002_G.DWG G20002_H.DWG G20002_J.DWG G20002_K.DWG G20003_T.JPG G20003_U.JPG G20003_V.JPG G20002_L.DWG G20002_M.DWG G20003_Y.JPG G20002_N.DWG G20002_P.DWG G20002_R.DWG G20002_S.DWG G20002_T.DWG G20002_U.DWG G20003AH.JPG G20003AJ.JPG G20002_V.DWG G20002_W.DWG G20002_X.DWG
15.0 NOTES
following table lists files pictures imported into this document.
16.0 REFERENCE DOCUMENTS
Bellcore GR-1217-CORE, IEC-1076-4-110
Copyright 2005
Form E-3334 06/06/05 V05-0553
GS-01-001
PDM: Rev:H
STATUS:Released
Printed: 2005
NUMBER
TITLE PAGE
GS-20-002
REVISION
Specification Requirements Cable Preparation, Wire Termination Assembly Connectors Using 72392-type Contacts
AUTHORIZED STATUS
DATE
J.R. Volstorf
UNRESTRICTED
REVISION RECORD PAGE DESCRIPTION DOCUMENT SPRING BACK REQUIREMENTS VISUAL AIDS CONTACT REPLACEMENT CAMS REPAIR INFORMATION CHANGE 10.3 APP. TOOLING WIRE INSERT EQUIP. CHART UPDATE INFO HAND TOOLS ALTERNATE AUTO-INSERTER LEAD FREE INFORMATION V-71213 V-80308 V-81232 V-90139 V12111 V03-1138 V05-0944 DATE 09-03-97 02-12-98 06-19-98 01-29-99 08/23/01 10-20-03 10-31-05
Copyright 2005
Form E-3334 06/06/05 V05-0553
GS-01-001
PDM: Rev:H
STATUS:Released
Printed: 2005

TITLE PAGE GS-20-002 REVISION Specification Requirement

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