Maintenance

WIRE HARNESS REPAIR

PART NO. 524223769 2200 YRM 1128

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the
load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the
weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks.
Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK
ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use APPROVED parts when making repairs. Replacement parts must meet or exceed the
specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs
repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable.
Be sure to follow the necessary safety precautions when handling these fuels and when working on these
fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area.
Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this man-
ual:

WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
 Table of Contents

TABLE OF CONTENTS
Series Code / Model Designation Reference Table................................................................................................ 1
General....................................................................................................................................................................3
Deutsch Crimping Tool............................................................................................................................................ 3
How to Strip a Wire for Use With Deutsch Crimping Tool.....................................................................................3
How to Crimp With the Deutsch Crimping Tool.....................................................................................................5
Calibration Test for the Deutsch Crimping Tool.....................................................................................................6
Deutsch Connectors................................................................................................................................................8
DT, DTM, and DTP Series Connectors.................................................................................................................8
Connector Receptacle Replacement............................................................................................................... 17
Connector Plug Replacement.......................................................................................................................... 25
Connector Receptacle Pin Replacement......................................................................................................... 33
Connector Plug Socket Replacement.............................................................................................................. 42
HD Series Connectors........................................................................................................................................50
Connector Receptacle Replacement............................................................................................................... 53
Connector Plug Replacement.......................................................................................................................... 57
Connector Receptacle Pin Replacement......................................................................................................... 60
Connector Plug Socket Replacement.............................................................................................................. 66
Sealing Plugs......................................................................................................................................................70
Metri-Pack Connectors..........................................................................................................................................72
Remove and Install.............................................................................................................................................72
Micro-Pack Connectors.........................................................................................................................................74
Weather-Pack Connectors.................................................................................................................................... 75
Weather-Pack Terminal Repair...........................................................................................................................75
AMPSEAL Crimping Tools.....................................................................................................................................76
AMP Hand Crimping Tool With Certi-Crimp........................................................................................................76
Description....................................................................................................................................................... 76
Stripping Wire for Use with AMP Hand Crimping Tool..................................................................................... 77
Insulation Crimp Adjustment............................................................................................................................ 78
Maintenance and Inspection for AMP Hand Crimping Tool............................................................................. 78
AMP Hand Crimping Tool.............................................................................................................................. 78
Crimp Height Inspection................................................................................................................................ 78
How to use AMP Hand Crimping Tool................................................................................................................ 79
AMP Pro-Crimper II Tool.....................................................................................................................................80
Description....................................................................................................................................................... 80
Remove and Install Die Set and Locator Assembly...................................................................................... 80
Stripping Wire for Use With AMP PRO-CRIMPER II Tool................................................................................81
Contact Support Adjustment............................................................................................................................ 82
Crimp Height Adjustment................................................................................................................................. 82
Maintenance and Inspection Procedures.........................................................................................................83
PRO-CRIMPER II Tool.................................................................................................................................. 83
Crimp Height Inspection................................................................................................................................ 83
How to Use AMP PRO-CRIMPER II Tool........................................................................................................... 83
AMPSEAL Connector Assemblies........................................................................................................................ 84
Description for Plug Connector Assembly.......................................................................................................... 84
Seal Plug..........................................................................................................................................................85
Contact Crimping............................................................................................................................................. 85
Contact Removal..............................................................................................................................................86
Contact Insertion..............................................................................................................................................87
Description for Plug Connector and Header Assembly...................................................................................... 89
Voltage Reading...............................................................................................................................................91
Seal Plug..........................................................................................................................................................91
Contact Crimping............................................................................................................................................. 92

©2020 Yale Materials Handling Corp. i

Table of Contents

TABLE OF CONTENTS (Continued)

Contact Removal..............................................................................................................................................94
Contact Insertion..............................................................................................................................................96
AMP Superseal 1.5 Crimping Tools...................................................................................................................... 99
Mini Mic Receptacle and Tab Contacts...............................................................................................................99
Description....................................................................................................................................................... 99
Crimping Conditions and Measurements.........................................................................................................99
Insertion of Rubber Seal on Cable.................................................................................................................101
Correction or Replacement of Parts...............................................................................................................101
AMP Hand Application Tool.............................................................................................................................. 106
Description..................................................................................................................................................... 106
Maintenance and Inspection.......................................................................................................................... 106
Crimp Height Inspection.............................................................................................................................. 106
Crimp Height Adjustment............................................................................................................................... 106
How to Use AMP Hand Application Tool.......................................................................................................... 107
AMP Pro-Crimper II Tool...................................................................................................................................108
Description..................................................................................................................................................... 108
Remove and Install Die Set and Locator Assembly.................................................................................... 108
Adjustments................................................................................................................................................... 109
Contact Support...........................................................................................................................................109
Crimp Height................................................................................................................................................110
Inspections and Maintenance.........................................................................................................................111
Crimp Height Inspection...............................................................................................................................111
Visual Inspection..........................................................................................................................................111
Maintenance................................................................................................................................................ 112
How to Use Pro-Crimper II Tool........................................................................................................................ 112
AMP Superseal 1.5 Connector Assemblies.........................................................................................................112
Description........................................................................................................................................................ 112
Harness Assembly......................................................................................................................................... 112
Positioning of Anti-Backout Device..............................................................................................................113
Removal of Contacts................................................................................................................................... 115
Repair and Maintenance...................................................................................................................................119
Panel Mount Option.......................................................................................................................................... 119
AMP Fastin-Faston Hand Tools...........................................................................................................................119
Description - AMP Double Action Hand Tool.................................................................................................... 119
Maintenance and Inspection Procedures......................................................................................................... 120
Daily Maintenance..........................................................................................................................................120
Periodic Tool Inspection................................................................................................................................. 121
Lubrication...................................................................................................................................................121
Visual Inspection......................................................................................................................................... 121
Crimp Height Inspection.................................................................................................................................121
Certi-Crimp Ratchet Inspection......................................................................................................................122
How to Use AMP Double Action Hand Tool......................................................................................................123
Description - AMP Extraction Tool.................................................................................................................... 124
Maintenance and Inspection.............................................................................................................................124
How to Use AMP Extraction Tool......................................................................................................................125
AMP Fastin-Faston Receptacles and Housings..................................................................................................126
Description........................................................................................................................................................126
Wire Repair......................................................................................................................................................... 134
Wire Splicing Requirements............................................................................................................................. 134
Deutsch Jiffy Splice.......................................................................................................................................... 135
Assemble....................................................................................................................................................... 135
Disassemble...................................................................................................................................................137

ii
 Table of Contents

TABLE OF CONTENTS (Continued)

Del-City Crimp-Solder-Shrink Splice.................................................................................................................138
Twisted/Shielded Cable and Leads Repair......................................................................................................... 140
Twisted/Shielded Cable Repair........................................................................................................................ 140
Twisted Leads Repair....................................................................................................................................... 141
Special Tools....................................................................................................................................................... 142

iii
2200 YRM 1128 Series Code / Model Designation Reference Table

Series Code / Model Designation Reference Table

This table consist of the following Series Codes used
in this manual.

Series European Model Americas Model

Code
A390 GP20-30MX GP040-060MX
A410 ERP70SVNL, ERP80SVNL, ERP80VNL9, ERP90VNL ERP155SVNL, ERP170SVNL,
ERP175VNL, ERP190VNL
A909 GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX GLP/GDP170VX, GLP/
GDP175VX36, GLP/GDP190VX
A910 GLC20-35VX GC/GLC040-070VX, GC/
GLC055SVX
A938 ERC40-55VH, ERC50VHS ERC80-120VH, ERC100VHS
A955 ERP16-20VF ERP30-40VF
A964 GP30MX --
A967 -- GLC050LX
A968 ERC22-35VG ERC045-070VG
A969 ERC16-20VA ERC030-040VA
A974 GLP/GDP20-25LX GLP/GDP050LX
A976 ERP22-35VL ERP045-070VL
A985 ERP40-50VM, ERP50-55VM6 ERP080-120VM, ERP100VML
B295 -- NR035-40DB, NDR030DB
B875 GLP/GDP20-35VX GP/GLP/GDP040-070VX
B883 -- ESC030AC, ESC035AC,
ESC040AC
B888 ERP13-15VC ERP025-030VC
B909 GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX GLP/GDP170VX, GLP/
GDP175VX36, GLP/GDP190VX
B910 GLC20-35VX GC/GLC040-070VX, GC/
GLC055SVX
B967 -- GLC050LX, GLC050LX2
B974 GLP/GDP20-25LX GLP/GDP050LX
C295 -- NDR030DC, NR035DC, NR040DC
C809 -- GC/GLC030-035VX, GC/
GLC040SVX
C810 GLP/GDP16-18VX, GLP/GDP020SVX GP/GLP/GDP030-035VX, GP/GLP/
GDP040SVX
C875 GLP/GDP20-35VX GP/GLP/GDP040-070VX
C878 GLP/GDP60-70VX GP/GLP/GDP135-155VX
C879 GLC/GDC60-70VX GC/GLC/GDC135-155VX

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Series Code / Model Designation Reference Table 2200 YRM 1128

Series European Model Americas Model

Code
C883 -- ESC030AD, ESC035AD,
ESC040AD
C909 GDP80VX, GDP80VX9, GDP90VX GLP/GDP170VX, GLP/
GDP175VX36, GLP/GDP190VX
C910 GLC20-35VX GC/GLC040-070VX, GC/
GLC055SVX
D809 -- GC/GLC030-035VX, GC/
GLC040SVX
D810 GLP/GDP16-18VX, GLP/GDP020SVX GP/GLP/GDP030-035VX, GP/GLP/
GDP040SVX
D861 -- NDR035EB, NR045EB
D875 GLP/GDP20-35VX GP/GLP/GDP040-070VX
D878 GLP/GDP60-70VX GP/GLP/GDP135-155VX
D879 GLC/GDC60-70VX GC/GLC/GDC135-155VX
D909 GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX GDP170VX, GDP175VX36,
GDP190VX
E815 -- NR035-40EB, NDR030EB
E818 GLC40-55VX, GLC55SVX GC/GLC080-120VX, GC/
GLC080-100VXBCS, GC/
GLC120SVX, GC/GLC120VXPRS
E861 -- NR035EC, NR040EC, NR045EC,
NDR030EC, NDR035EC
E878 GLP/GDP60-70VX GP/GLP/GDP135-155VX
E879 GLC/GDC60-70VX GC/GLC/GDC135-155VX
F813 GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GP/GLP/GDP080-120VX
GLP/GDP50-55VX
F818 GLC40-55VX, GLC55SVX GC/GLC080-120VX, GC/
GLC080-100VXBCS, GC/
GLC120SVX, GC/GLC120VXPRS
F878 GLP/GDP60-70VX GP/GLP/GDP135-155VX
F879 GLC/GDC60-70VX GC/GLC/GDC135-155VX
G807 ERP15-20VT ERP030-040VT
G813 GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GP/GLP/GDP080-120VX
GLP/GDP50-55VX
G818 GLC40-55VX, GLC55SVX GC/GLC080-120VX, GC/
GLC080-100VXBCS, GC/
GLC120SVX, GC/GLC120VXPRS
G878 GLP/GDP60VX, GLP/GDP70VX, GP70VXS6, GP70VXS9 GLP/GDP135VX. GLP/GDP155VX,
GP155VXS

2
2200 YRM 1128 General

Series European Model Americas Model

Code
H813 GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GP/GLP/GDP080-120VX
GLP/GDP50-55VX
J813 GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GP/GLP/GDP080-120VX
GLP/GDP50-55VX
K813 GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GP/GLP/GDP080-120VX
GLP/GDP50-55VX

General
This section covers the repair of the wire harness
connectors, pins, sockets, and splicing of wires.

Deutsch Crimping Tool

HOW TO STRIP A WIRE FOR USE WITH
DEUTSCH CRIMPING TOOL
1. Choose Metri-Pack Connectorsthe correct AWG
for the contact being used. See Table 15.

2. See Table 15 for recommended strip length for

contact size. Measure strip length from end of
wire as shown in Figure 1.

Figure 2. Stripped Wire

4. Check for any broken strands or for a nick in the

wire. If either exists, the wires are damaged and
should be cut and stripped again.

5. Measure the exposed strands to verify strip length

is correct. See Figure 3.

Figure 1. Strip Length Measurement

3. Strip the wire to the recommended strip length. A

small piece of insulation should come off the wire
after stripping. See Figure 2.

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Deutsch Crimping Tool 2200 YRM 1128

Figure 3. Strip Length Measurement Verification

Table 1. Wire Strip Length Specifications

Contact Part Number Type Wire Gauge Range Recommended Strip Length
580039516 Pin 20 AWG (0.5 mm2) 3.96 to 5.54 mm (0.156 to 0.218 in.)
580039517 Socket 20 AWG (0.5 mm2) 3.96 to 5.54 mm (0.156 to 0.218 in.)
580094445 Pin 20 AWG (0.5 mm2) 4.0 to 5.5 mm (0.157 to 0.217 in.)
505972554 Pin 16 to 20 AWG (1.0 to 0.5 6.35 to 7.92 mm (0.250 to 0.312 in.)
mm2)
505064713 Socket 16 to 20 AWG (1.0 to 0.5 6.35 to 7.92 mm (0.250 to 0.312 in.)
mm2)
580082335 Pin 16 to 20 AWG (1.0 to 0.5 6.4 to 7.9 mm (0.252 to 0.311 in.)
mm2)
580082337 Socket 16 to 20 AWG (1.0 to 0.5 6.4 to 7.9 mm (0.252 to 0.311 in.)
mm2)
520038865 Pin 14 AWG (2.0 mm2) 6.35 to 7.92 mm (0.250 to 0.312 in.)
505064747 Socket 14 AWG (2.0 mm2) 6.35 to 7.92 mm (0.250 to 0.312 in.)
580079525 Socket 14 AWG (2.0 mm2) 6.4 to 7.9 mm (0.252 to 0.311 in.)
15021835 Pin 12 to 14 AWG (3.0 to 2.0 5.64 to 7.21 mm (0.222 to 0.284 in.)
mm2)
580050627 Socket 12 to 14 AWG (3.0 to 2.0 5.64 to 7.21 mm (0.222 to 0.284 in.)
mm2)

4
2200 YRM 1128 Deutsch Crimping Tool

HOW TO CRIMP WITH THE DEUTSCH 4. Insert the contact into the crimping tool; for pin
CRIMPING TOOL contacts, insert short end into crimping tool; for
socket contacts, insert long end into crimping tool.
1. Strip the insulation from the wire. See How to See Figure 6.
Strip a Wire for Use With Deutsch Crimping Tool.

2. Raise the selector knob and rotate until arrow is

aligned with wire gauge to be crimped. See
Figure 4.

1. INSERTION POINT
2. INDENTER COVER

Figure 6. Insertion Point

5. Turn the adjusting screw clockwise until the

contact is flush or slightly above flush with the
indenter cover (cover around insertion point). See
Figure 6. Tighten the lock nut.

6. Insert the wire into the contact. There should be

Figure 4. Selector Knob no loose strands. All strands should be contained
in the contact barrel. The contact must be
3. Loosen lock nut and turn adjusting screw until it centered between indicators. See Figure 7.
stops. See Figure 5.

Figure 7. Wire Insertion

1. LOCK NUT
2. ADJUSTING SCREW 7. Close handles until handles stop.

Figure 5. Adjusting Screw and Lock Nut 8. Release handles and remove crimped contact.

9. Visually check the crimped contact for the

following:

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Deutsch Crimping Tool 2200 YRM 1128

a. The conductor is inserted to the proper depth

and is visible through the inspection hole. See
Figure 8.

b. There is about
0.635 to 2.54 mm (0.025 to 0.100 in.) of
conductor between the contact and the
insulator.

c. There are no damaged wire strands.

d. There are no frayed wires or wires not entering

the contact barrel.
1. GO END (GREEN)
2. NO-GO END (RED)

Figure 9. G454 Testing Tool

NOTE: Testing for all wire sizes should be #20 wire

size, selector number 4. This ensures proper
calibration for all settings and further testing is not
needed for the other selections.
1. Set the Deutsch hand crimp tool to #20 wire size,
selector number 4. See Figure 10.

1. INSPECTION HOLE
2. CRIMP
3. INSULATION GAP,
0.635 TO 2.54 mm (0.025 TO 0.100 in.)

Figure 8. Proper Crimp

10. If any of the conditions in Step 9 are not met,

discard the contact, re-cut and strip the wire, and
start the crimping process over.

CALIBRATION TEST FOR THE DEUTSCH

CRIMPING TOOL
The G454 testing tool is needed for the following
procedures. The G454 testing tool is for use with the
Deutsch hand crimping tool only. See Figure 9.

1. SELECTOR SET AT #20 WIRE SIZE, SELECTOR

NUMBER 4

Figure 10. Selector Test Setting

2. Squeeze the handles of the crimp tool completely

together. See Figure 11.

6
2200 YRM 1128 Deutsch Crimping Tool

4. Insert the No-Go end (red) of the G454 testing

tool into the insertion point of the crimp tool while
the handles are still completely closed. The No-
Go end (red) should not insert. If it does insert,
the calibration is incorrect and the crimp tool must
be replaced. See Figure 13.

1. INSERTION POINT

Figure 11. Insertion Point

3. Insert the Go end (green) of the G454 testing tool

into the insertion point of the crimp tool while the
handles are completely closed. The Go end
(green) should insert easily. If it does not insert,
the calibration is incorrect and the crimp tool must
be replaced. See Figure 12.

1. NO-GO END (RED)

2. NO-GO END SHOULD NOT INSERT ANY
FURTHER

Figure 13. No-Go End Test

1. GO END (GREEN)
2. GO END COMPLETELY INSERTED

Figure 12. Go End Test

7
Deutsch Connectors 2200 YRM 1128

Deutsch Connectors
DT, DTM, AND DTP SERIES For examples of the DT connector receptacles, see
CONNECTORS Figure 15. See Figure 16 for the different connector
receptacle secondary locks, Figure 17 for the different
All Deutsch DT, DTM, and DTP series pin- and socket- connector plugs, and Figure 18 for the different
type connectors are repaired in the same manner. See connector plug secondary locks.
Figure 14.
For examples of the DTM and DTP connectors, see
Figure 19 for the different connector receptacles,
Figure 20 for the different connector receptacle
secondary locks, Figure 21 for the different connector
plugs, and Figure 22 for the different connector plug
secondary locks.

1. PLUG TYPE BODY

2. SOCKET TERMINAL
3. SECONDARY LOCK
4. PIN TERMINAL
5. CAVITY PLUG
6. RECEPTACLE CONNECTOR BODY

Figure 14. Typical Deutsch Series Connector

8
2200 YRM 1128 Deutsch Connectors

Figure 15. DT Connector Receptacles

9
Deutsch Connectors 2200 YRM 1128

Legend for Figure 15.

NOTE: ALL CONNECTOR RECEPTACLES ARE SHOWN WITH THE SECONDARY LOCK INSTALLED.

A. CONNECTOR TYPE AA I. CONNECTOR TYPE AB-C (SIMILAR TO TYPE AB)

B. CONNECTOR TYPE AB J. CONNECTOR TYPE AG (2-PINS)
C. CONNECTOR TYPE AC K. CONNECTOR TYPE AH (4-PINS)
D. CONNECTOR TYPE AD L. CONNECTOR TYPE AI
E. CONNECTOR TYPE AE M. CONNECTOR TYPE AG (12-PINS)
F. CONNECTOR TYPE AF N. CONNECTOR TYPE AH (12-PINS)
G. CONNECTOR TYPE AB-A (SIMILAR TO TYPE O. CONNECTOR TYPE AJ
AB) P. CONNECTOR TYPE AL
H. CONNECTOR TYPE AB-B (SIMILAR TO TYPE
AB)

A. SECONDARY LOCK TYPE BA F. SECONDARY LOCK TYPE BD

B. SECONDARY LOCK TYPE BC G. SECONDARY LOCK TYPE BF
C. SECONDARY LOCK TYPE BE H. SECONDARY LOCK TYPE BH
D. SECONDARY LOCK TYPE BG I. SECONDARY LOCK TYPE BJ
E. SECONDARY LOCK TYPE BB J. SECONDARY LOCK TYPE BK

Figure 16. DT Connector Receptacle Secondary Locks

10
2200 YRM 1128 Deutsch Connectors

NOTE: ALL CONNECTOR PLUGS ARE SHOWN WITH THE SECONDARY LOCK INSTALLED.

A. CONNECTOR TYPE CA F. CONNECTOR TYPE CF

B. CONNECTOR TYPE CB G. CONNECTOR TYPE CH (SIMILAR TO TYPE CB)
C. CONNECTOR TYPE CC H. CONNECTOR TYPE CG
D. CONNECTOR TYPE CD I. CONNECTOR TYPE CL
E. CONNECTOR TYPE CE

Figure 17. DT Connector Plugs

11
Deutsch Connectors 2200 YRM 1128

A. SECONDARY LOCK TYPE DA E. SECONDARY LOCK TYPE DE

B. SECONDARY LOCK TYPE DB F. SECONDARY LOCK TYPE DF
C. SECONDARY LOCK TYPE DC G. SECONDARY LOCK TYPE DG
D. SECONDARY LOCK TYPE DD H. SECONDARY LOCK TYPE DH

Figure 18. DT Connector Plug Secondary Locks

12
2200 YRM 1128 Deutsch Connectors

Figure 19. DTM and DTP Connector Receptacles

13
Deutsch Connectors 2200 YRM 1128

Legend for Figure 19.

A. DTP CONNECTOR TYPE EA E. DTP CONNECTOR TYPE ED

B. DTM CONNECTOR TYPE EB F. DTM CONNECTOR TYPE EE
C. DTM CONNECTOR TYPE EC G. DTM CONNECTOR TYPE EF
D. DTM CONNECTOR TYPE EJ

A. DTP SECONDARY LOCK TYPE FA E. DTP SECONDARY LOCK TYPE FD

B. DTM SECONDARY LOCK TYPE FB F. DTM SECONDARY LOCK TYPE FH
C. DTM SECONDARY LOCK TYPE FG G. DTM SECONDARY LOCK TYPE FE
D. DTM SECONDARY LOCK TYPE FC H. DTM SECONDARY LOCK TYPE FF

Figure 20. DTM and DTP Connector Receptacle Secondary Locks

14
2200 YRM 1128 Deutsch Connectors

A. DTM CONNECTOR TYPE GA F. DTM CONNECTOR TYPE GE

B. DTM CONNECTOR TYPE GB G. DTP CONNECTOR TYPE GG
C. DTM CONNECTOR TYPE GC H. DTM CONNECTOR TYPE GH
D. DTP CONNECTOR TYPE GD I. DTM CONNECTOR TYPE GJ
E. DTM CONNECTOR TYPE GF

Figure 21. DTM and DTP Connector Plugs

15
Deutsch Connectors 2200 YRM 1128

A. DTM SECONDARY LOCK TYPE HA F. DTM SECONDARY LOCK TYPE HF

B. DTM SECONDARY LOCK TYPE HB G. DTM SECONDARY LOCK TYPE HG
C. DTM SECONDARY LOCK TYPE HC H. DTP SECONDARY LOCK TYPE HH
D. DTP SECONDARY LOCK TYPE HD I. DTM SECONDARY LOCK TYPE HJ
E. DTM SECONDARY LOCK TYPE HE

Figure 22. DTM and DTP Connector Plug Secondary Locks

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2200 YRM 1128 Deutsch Connectors

Connector Receptacle Replacement

STEP 1.
Release the external locking clip(s) and separate
the connector plug from the connector receptacle.

17
Deutsch Connectors 2200 YRM 1128

STEP 2.
Using a small hook end tool (Yale Part No.
150121838) , or needle nose pliers, remove the
secondary lock from the connector receptacle.

18
2200 YRM 1128 Deutsch Connectors

STEP 3.
Using a small, flat-blade screwdriver (Yale P/N
150121838) , release the locking finger by moving
it away from the pin.

19
Deutsch Connectors 2200 YRM 1128

STEP 4.
Gently pull the wire backward while, at the same
time, releasing the locking finger with the small,
flat-blade screwdriver (Yale P/N 150121838) .

20
2200 YRM 1128 Deutsch Connectors

STEP 5.
Tag the wire and mark it with the corresponding
number or letter on the back of the connector
from which the wire was removed.

STEP 6.
Repeat Step 3 through Step 5 for the removal of
the remaining wires.

21
Deutsch Connectors 2200 YRM 1128

STEP 7.
Insert the wires into the new connector receptacle
according to the number or letter on the tag and
connector receptacle. Push the wires straight into
the back of the receptacle until a click is felt.
Slightly tug each wire to verify the wire is properly
locked in place. Remove tags.

NOTE: Verify that the seal is in place on the connector plug before installing the secondary lock.

22
2200 YRM 1128 Deutsch Connectors

STEP 8.
Install the secondary lock. Push the lock straight
in until the lock snaps into place.

23
Deutsch Connectors 2200 YRM 1128

STEP 9.
Push the connector plug into the connector
receptacle until the external locking mechanism(s)
snap(s) into place.

24
2200 YRM 1128 Deutsch Connectors

Connector Plug Replacement

STEP 1.
Release the external locking clip(s) and separate
the connector plug from the connector receptacle.

25
Deutsch Connectors 2200 YRM 1128

STEP 2.
Using a small, flat-blade screwdriver (Yale P/N
150121838) , remove the secondary lock from the
connector plug.

26
2200 YRM 1128 Deutsch Connectors

STEP 3.
Using a small, flat-blade screwdriver (Yale P/N
150121838) , release the locking finger by moving
it away from the socket.

27
Deutsch Connectors 2200 YRM 1128

STEP 4.
Gently pull the wire backward while, at the same
time, releasing the locking finger with the small,
flat-blade screwdriver (Yale P/N 150121838) .

28
2200 YRM 1128 Deutsch Connectors

STEP 5.
Tag the wire and mark it with the corresponding
number or letter on the back of the connector
from which the wire was removed.

STEP 6.
Repeat Step 3 through Step 5 for the removal of
the remaining wires.

29
Deutsch Connectors 2200 YRM 1128

STEP 7.
Insert the wires into the back of the new
connector plug according to the number or letter
on the tag and connector plug. Push the wires
straight into the back of the plug until a click is
felt. Slightly tug each wire to verify the wire is
properly locked in place. Remove tags.

NOTE: Verify that the seal is in place on the connector plug before installing the secondary lock.

30
2200 YRM 1128 Deutsch Connectors

STEP 8.
Install the secondary lock. Push the lock straight
in until the lock snaps into place. On 3-way
secondary locks, the arrow on the lock must be
oriented toward the exterior locking mechanism.

1. SEAL

1. SEAL

31
Deutsch Connectors 2200 YRM 1128

STEP 9.
Push the connector plug into the connector
receptacle until the external locking mechanism(s)
snap(s) into place.

32
2200 YRM 1128 Deutsch Connectors

Connector Receptacle Pin Replacement

STEP 1.
Release the external locking clip(s) and separate
the connector plug from the connector receptacle.

33
Deutsch Connectors 2200 YRM 1128

STEP 2.
Using a small hook end tool (Yale P/N
150121838) , or needle nose pliers, remove the
secondary lock from the connector receptacle.

34
2200 YRM 1128 Deutsch Connectors

STEP 3.
Using a small, flat-blade screwdriver (Yale P/N
150121838) , release the locking finger by moving
it away from the pin.

35
Deutsch Connectors 2200 YRM 1128

STEP 4.
Gently pull the wire backward while, at the same
time, releasing the locking finger with the small,
flat-blade screwdriver (Yale P/N 150121838) .

36
2200 YRM 1128 Deutsch Connectors

STEP 5.
If more than one pin is being replaced, tag the
wire and mark it with the corresponding number
or letter on the back of the connector from which
the wire was removed.

STEP 6.
Using wire cutters, cut the wire behind the old pin
and discard old pin.

37
Deutsch Connectors 2200 YRM 1128

STEP 7.
Using wire strippers (Yale P/N 150121841) , strip
the wire to the recommended length shown in
Table 15.

STEP 8.
Using the Deutsch Crimping Tool (Yale P/N
150121900) , crimp the new pin on the wire as
shown in How to Crimp With the Deutsch
Crimping Tool.

38
2200 YRM 1128 Deutsch Connectors

STEP 9.
Insert the wire into the connector receptacle
according to the number or letter on the tag and
connector receptacle. Push the wire straight into
the back of the receptacle until a click is felt.
Slightly tug the wire to verify the wire is properly
locked in place. Remove tag.

NOTE: Verify that the seal is in place on the connector plug before installing the secondary lock.

39
Deutsch Connectors 2200 YRM 1128

STEP 10.
Install the secondary lock. Push the lock straight
in until the lock snaps into place.

40
2200 YRM 1128 Deutsch Connectors

STEP 11.
Push the connector plug into the connector
receptacle until the external locking mechanism(s)
snap(s) into place.

41
Deutsch Connectors 2200 YRM 1128

Connector Plug Socket Replacement

STEP 1.
Release the external locking clip(s) and separate
the connector plug from the connector receptacle.

42
2200 YRM 1128 Deutsch Connectors

STEP 2.
Using a small, flat-blade screwdriver (Yale P/N
150121838) , remove the secondary lock from the
connector plug.

43
Deutsch Connectors 2200 YRM 1128

STEP 3.
Using a small, flat-blade screwdriver (Yale P/N
150121838) , release the locking finger by moving
it away from the socket.

44
2200 YRM 1128 Deutsch Connectors

STEP 4.
Gently pull the wire backward while, at the same
time, releasing the locking finger with the small,
flat-blade screwdriver (Yale P/N 150121838) .

45
Deutsch Connectors 2200 YRM 1128

STEP 5.
If more than one socket is being removed, tag the
wire and mark it with the corresponding number
or letter on the back of the connector from which
the wire was removed.

STEP 6.
Using wire cutters, cut the wire behind the old
socket and discard old socket.

46
2200 YRM 1128 Deutsch Connectors

STEP 7.
Using wire strippers, (Yale P/N 150121841) , strip
the wire to the recommended length shown in
Table 15.

STEP 8.
Using the Deutsch Crimping Tool (Yale P/N
150121900) , crimp the new socket on the wire as
shown in How to Crimp With the Deutsch
Crimping Tool.

47
Deutsch Connectors 2200 YRM 1128

STEP 9.
Insert the wire into the back of the new connector
plug according to the number or letter on the tag
and connector plug. Push the wire straight into
the back of the plug until a click is felt. Slightly tug
the wire to verify the wire is properly locked in
place. Remove tag.

NOTE: Verify that the seal is in place on the connector plug before installing the secondary lock.

48
2200 YRM 1128 Deutsch Connectors

STEP 10.
Install the secondary lock. Push the lock straight
in until the lock snaps into place. On 3-way
secondary locks, the arrow on the lock must be
oriented toward the exterior locking mechanism.

1. SEAL

1. SEAL

49
Deutsch Connectors 2200 YRM 1128

STEP 11.
Push the connector plug into the connector
receptacle until the external locking mechanism(s)
snap(s) into place.

HD SERIES CONNECTORS For examples of the HD connectors, see Figure 23 for

the different connector receptacles and Figure 24 for
All Deutsch HD series pin-type connectors are the different connector plugs.
repaired in the same manner.

50
2200 YRM 1128 Deutsch Connectors

A. TYPE A B. TYPE B

Figure 23. HD Connector Receptacles

51
Deutsch Connectors 2200 YRM 1128

A. TYPE 1 B. TYPE 2

Figure 24. HD Connector Plugs

52
2200 YRM 1128 Deutsch Connectors

Connector Receptacle Replacement

STEP 1.
Separate the connector plug from the connector
receptacle.

STEP 2.
Remove the lock nut and washer retaining the
receptacle to the mounting structure. Remove
receptacle from mounting structure.

NOTE: Be sure to use correct extraction tool; see Special Tools section of this manual.

53
Deutsch Connectors 2200 YRM 1128

STEP 3.
Insert a Deutsch extraction tool over the wire
being removed.

NOTE: Do not twist the tool or insert the tool at an angle.

STEP 4.
Push the tool into the connector about
25 mm (1 in.) until it bottoms on the contact
flange.

NOTE: If pin is difficult to remove, remove the extraction tool, turn the extraction tool 90 degrees, and reinsert the
tool into the connector.

54
2200 YRM 1128 Deutsch Connectors

STEP 5.
Hold the tool on the contact flange and pull the
wire and the connection pin out of the connector.

STEP 6.
Tag the wire and mark it with the corresponding
number or letter on the back of the connector
from which the wire was removed.

55
Deutsch Connectors 2200 YRM 1128

STEP 7.
Repeat Step 3 through Step 6 for the removal of
the remaining wires.

STEP 8.
Insert the wires into the back of the new
connector receptacle according to the number or
letter on the tag and connector receptacle. Push
the wire straight into the back of the receptacle
until a click is felt. Slightly tug each wire to verify
the wire is properly locked in place. Remove tags.

STEP 9.
Install receptacle into mounting structure. Install
the lock nut and washer to retain the receptacle to
the mounting structure.

STEP 10.
Connect the connector plug to the connector
receptacle.

56
2200 YRM 1128 Deutsch Connectors

Connector Plug Replacement

STEP 1.
Separate the connector plug from the connector
receptacle.

NOTE: Be sure to use correct extraction tool; see Special Tools section of this manual.

STEP 2.
Insert a Deutsch extraction tool over the wire
being removed.

NOTE: Do not twist the tool or insert the tool at an angle.

57
Deutsch Connectors 2200 YRM 1128

STEP 3.
Push the tool into the connector about
25 mm (1 in.) until it bottoms on the contact
flange.

NOTE: If pin is difficult to remove, remove the extraction tool, turn the extraction tool 90 degrees, and reinsert the
tool into the connector.

STEP 4.
Hold the tool on the contact flange and pull the
wire and the connection socket out of the
connector.

58
2200 YRM 1128 Deutsch Connectors

STEP 5.
Tag the wire and mark it with the corresponding
number or letter on the back of the connector
from which the wire was removed.

STEP 6.
Repeat Step 2 through Step 5 for the removal of
the remaining wires.

59
Deutsch Connectors 2200 YRM 1128

STEP 7.
Insert the wires into the back of the new
connector plug according to the number or letter
on the tag and connector plug. Push the wire
straight into the back of the plug until a click is
felt. Slightly tug each wire to verify the wire is
properly locked in place. Remove tags.

STEP 8.
Connect the connector plug to the connector
receptacle.

Connector Receptacle Pin Replacement

STEP 1.
Separate the connector plug from the connector
receptacle.

60
2200 YRM 1128 Deutsch Connectors

STEP 2.
Remove the lock nut and washer retaining the
receptacle to the mounting structure. Remove
receptacle from mounting structure.

NOTE: Be sure to use correct extraction tool; see Special Tools section of this manual.

STEP 3.
Insert a Deutsch extraction tool over the wire
being removed.

NOTE: Do not twist the tool or insert the tool at an angle.

61
Deutsch Connectors 2200 YRM 1128

STEP 4.
Push the tool into the connector about
25 mm (1 in.) until it bottoms on the contact
flange.

STEP 5.
Hold the tool on the contact flange and pull the
wire and the connection pin out of the connector.

62
2200 YRM 1128 Deutsch Connectors

STEP 6.
If more than one wire is being removed, tag the
wire and mark it with the corresponding number
or letter on the back of the connector from which
the wire was removed.

63
Deutsch Connectors 2200 YRM 1128

STEP 7.
Using wire cutters, cut the wire behind the old pin
and discard old pin.

STEP 8.
Using wire strippers, Yale P/N 150121841 , strip
the wire to the recommended length shown in
Table 15.

STEP 9.
Using the Deutsch Crimping Tool (Yale P/N
150121900) , crimp the new pin on the wire as
shown in How to Crimp With the Deutsch
Crimping Tool.

NOTE: The rear seal/grommet must be seated properly before inserting wires.

64
2200 YRM 1128 Deutsch Connectors

STEP 10.
Insert the wires into the back of the new
connector receptacle according to the number or
letter on the tag and connector receptacle. Push
the wire straight into the back of the receptacle
until a click is felt. Slightly tug each wire to verify
the wire is properly locked in place. Remove tags.

STEP 11.
Install receptacle into mounting structure. Install
the lock nut and washer to retain the receptacle to
the mounting structure.

STEP 12.
Connect the connector plug to the connector
receptacle.

65
Deutsch Connectors 2200 YRM 1128

Connector Plug Socket Replacement

STEP 1.
Separate the connector plug from the connector
receptacle.

NOTE: Be sure to use correct extraction tool; see Special Tools section of this manual.

STEP 2.
Insert a Deutsch extraction tool over the wire
being removed.

NOTE: Do not twist the tool or insert the tool at an angle.

66
2200 YRM 1128 Deutsch Connectors

STEP 3.
Push the tool into the connector about
25 mm (1 in.) until it bottoms on the contact
flange.

STEP 4.
Hold the tool on the contact flange and pull the
wire and the connection socket out of the
connector.

67
Deutsch Connectors 2200 YRM 1128

STEP 5.
If more than one wire is being removed, tag the
wire and mark it with the corresponding number
or letter on the back of the connector from which
the wire was removed.

68
2200 YRM 1128 Deutsch Connectors

STEP 6.
Using wire cutters, cut the wire behind the old
socket and discard old socket.

STEP 7.
Using wire strippers, Yale P/N 150121841 , strip
the wire to the recommended length shown in
Table 15.

STEP 8.
Using the Deutsch Crimping Tool (Yale P/N
150121900) , crimp the new socket on the wire as
shown in How to Crimp With the Deutsch
Crimping Tool.

NOTE: The rear seal/grommet must be seated properly before inserting wires.

69
Deutsch Connectors 2200 YRM 1128

STEP 9.
Insert the wires into the back of the new
connector plug according to the number or letter
on the tag and connector plug. Push the wire
straight into the back of the plug until a click is
felt. Slightly tug wire to verify the wire is properly
locked in place. Remove tags.

STEP 10.
Connect the connector plug to the connector
receptacle.

SEALING PLUGS
STEP 1.
All empty contact cavities must be filled with a
sealing plug.

A. 6 AWG (DARK RED)

B. 8 AWG (CLEAR WHITE)
C. 12 TO 18 AWG (WHITE)
D. 20 AWG (RED)

70
2200 YRM 1128 Deutsch Connectors

STEP 2.
Hold the sealing plug with the large diameter end
away from the connector.

STEP 3.
Insert the sealing plug into the connector contact
cavity. Gently apply downward pressure to force
the sealing plug into the cavity.

71
Metri-Pack Connectors 2200 YRM 1128

STEP 4.
Apply pressure until sealing plug is forced to stop
by the connector rear grommet. Visually inspect
the sealing plug to ensure it is flush with the cavity
opening.

Metri-Pack Connectors
Some connectors use terminals called Metri-Pack REMOVE AND INSTALL
Series 150. These may be used at the coolant sensor
and TBI units on ICE lift trucks. 1. Slide the seal back on the wire.

They are also called push-to-seat terminals because to 2. Hold the wire and use it to push the terminal to its
install a terminal on a wire, the wire is first inserted forward position in the connector body. Hold the
through the seal and connector. The terminal is then terminal in this position. See Figure 25.
crimped on the wire and the terminal pulled back into
the connector to seat it in place.
NOTE: DO NOT cut contacts from reel, use loose
contacts only.

1. FEMALE TERMINAL 4. CONNECTOR BODY

2. LOCKING TAB 5. SEAL
3. TOOL KIT

Figure 25. Metri-Pack Terminal Removal

72
2200 YRM 1128 Metri-Pack Connectors

3. Find the lock tab for the terminal in the connector

channel. Push a removal tool (pick), (Yale P/N
150121850) , of the correct size into the
connector channel. See Figure 26 and Figure 27.

1. TOOL (PICK)
2. LOCK TAB
3. TERMINAL
4. CONNECTOR BODY

Figure 26. Metri-Pack Push-to-Seat Connector

1. TERMINAL
2. LOCK TAB
3. TOOL KIT
4. CONNECTOR BODY
5. SEAL

Figure 28. Metri-Pack Pull-to-Seat Terminal

Removal

CAUTION
1. TOOL (PICK) Work carefully and do not use enough force to
2. LOCK TAB damage the terminal or the connector.
3. TERMINAL
4. CONNECTOR BODY 5. Inspect the terminal and connector for damage.
See Figure 29.
Figure 27. Metri-Pack Pull-to-Seat Connector

4. Use the removal tool, (Yale P/N 150121850) , to

move the lock tab to release the terminal from its
seat.
Push-to-Seat - Gently pull the wire to remove the
terminal from the back of the connector.
Pull-to-Seat - Gently push the wire to remove the
terminal through the front of the connector. See
Figure 28.

73
Micro-Pack Connectors 2200 YRM 1128

NOTE: THE GREATER DISTANCE D, A FAULT CAN

OCCUR IN THE CONNECTION.

1. CONTACT TAB

Figure 29. Metri-Pack Terminal Inspection

NOTE: If reusing the terminal, reshape the locking

tab.
6. If the terminal will be used again, make sure the
lock tab is correctly bent so that the terminal will
be locked in the connector again.

7. Push the terminal into the connector channel.

Make sure that the lock tab correctly locks the
terminal in position.

8. Push the seals into their position and install any

secondary locks.

Micro-Pack Connectors
The Micro-Pack connector is shown in Figure 30. This
connector is normally used to connect the wire
harness to the ECM. The repair procedures for the
Micro-Pack connectors are the same as the Metri-
Pack connectors. Refer to the section Metri-Pack
Connectors for the repair procedures.

1. CABLE
2. TERMINAL
3. LOCKING TAB
4. TOOL KIT (YALE P/N 150121852

Figure 30. Micro-Pack Connector

74
2200 YRM 1128 Weather-Pack Connectors

Weather-Pack Connectors
A Weather-Pack connector can be identified by a deformed. Unlike standard blade-type terminals, these
rubber seal at the rear of the connector. This terminals cannot be straightened once they are bent.
connector, which is used in the engine compartment,
Make certain that the connectors are properly seated
protects against moisture and dirt which could create
and all of the sealing rings are in place when
oxidation and deposits on the terminals. This
connecting leads. The hinge-type flap provides a
protection is important because of the very low voltage
backup or secondary locking feature for the connector.
and current levels found in the electronic system.
They are used to improve the connector reliability by
Repair of a Weather-Pack terminal is shown in retaining the terminals if the small terminal lock tabs
Weather-Pack Terminal Repair. Use the tool kit to are not positioned properly.
remove the pin and sleeve terminals. See Special
Weather-Pack connections cannot be replaced with
Tools.
standard connections. Instructions are provided with
If removal is attempted with an ordinary pick, there is a Weather-Pack connector and terminal packages.
good chance that the terminal will be bent or

WEATHER-PACK TERMINAL REPAIR

STEP 1.
Open secondary lock hinge on connector.

1. FEMALE CONNECTOR
2. MALE CONNECTOR
3. SECONDARY LOCK HINGE

STEP 2.
Remove terminal, using tool YALE P/N
150121851 .

1. TERMINAL
2. TOOL

75
AMPSEAL Crimping Tools 2200 YRM 1128

STEP 3.
Cut wire immediately behind cable seal.

1. WIRE
2. SEAL

STEP 4.
Replace terminal.

STEP 1.
Slip new seal onto wire.

STEP 2.
Strip 5 mm (0.2 in.) of insulation from wire.

STEP 3.
Crimp terminal over wire and seal.

STEP 5.
Push terminal and connector onto wire and
engage locking tabs.

STEP 6.
Close secondary lock hinge.

1. SEAL

AMPSEAL Crimping Tools

AMP HAND CRIMPING TOOL WITH CERTI-
CRIMP
Description
The hand crimping tool, Yale P/N 580093883 ,
features two upper inserts, two anvils, an insulation
crimp adjustment lever, a contact support, a locator, an
ejector, and a CERTI-CRIMP ratchet. The contact is
inserted into the FRONT of the tool. The wire is
inserted into the BACK of the tool. See Figure 31.

76
2200 YRM 1128 AMPSEAL Crimping Tools

Legend for Figure 31.

A. FRONT OF TOOL
B. BACK OF TOOL

1. UPPER INSERT
2. ANVIL
3. INSULATION CRIMP ADJUSTMENT LEVER
4. CONTACT SUPPORT
5. LOCATOR
6. CERTI-CRIMP RATCHET
7. STRIPPED WIRE

The insulation adjust lever regulates the crimp height.

See Insulation Crimp Adjustment.
The contact support prevents the contact from bending
during crimping.
The locator functions two ways:
• position the contact between the upper insert
and the anvil before crimping
• limits the insertion distance of the stripped wire
into the contact.
The ejector pulls the locator down, and ejects the
crimped contact when the tool handles are fully
opened.

CAUTION
The crimping jaws bottom before the CERTI-
CRIMP ratchet releases. This is a design feature
that ensures maximum electrical and tensile
performance of the crimp DO NOT readjust the
ratchet.

The CERTI-CRIMP ratchet assures full crimping of the

contact. Once engaged, the ratchet will not release
until the handles have been fully closed.

Stripping Wire for Use with AMP Hand

Crimping Tool
1. Choose the correct AWG for the contact being
used.
Figure 31. AMP Hand Crimping Tool
2. See Table 2 for recommended strip length.

77
AMPSEAL Crimping Tools 2200 YRM 1128

Table 2. Wire Size (AWG)

Wire Size Insulation Diameter Tool Wire Contact Wire Strip Length
(AWG) Range Size
Marking
16 1.7 to 2.7 mm (0.067 16 Yale P/N 520202601 5.5 mm (0.215 in.)
20 - 18 to 0.106 in.) 20 - 18 4.7 mm (0.185 in.)

setting, test crimp a contact using the setting which

CAUTION approximates the insulation size: 1) small, 2) medium,
DO NOT cut or nick the wire strands. or 3) large. If the crimped insulation barrel is too tight
or too loose, change the setting accordingly. The crimp
3. Strip wire to recommended strip length. A small should hold the insulation firmly without cutting into it.
piece of insulation should come off the wire after
stripping. See Figure 32. Maintenance and Inspection for AMP
Hand Crimping Tool
AMP Hand Crimping Tool
1. Perform maintenance and inspections as
specified by AMP.

Crimp Height Inspection

1. This inspection requires the use of a micrometer
with a modified anvil as shown in Figure 33.

NOTE: SEE TABLE 2 FOR WIRE STRIP LENGTH. 2. Refer to Table 3 and select contact and wire
(maximum size) for each crimp section listed.
1. STRIPPED WIRE
2. LOCATOR SLOT 3. Crimp a contact on to the wire according to How
to use AMP Hand Crimping Tool procedure.
Figure 32. Strip Length
4. Using a modified micrometer, measure wire barrel
Insulation Crimp Adjustment crimp height as shown in Figure 33. If the crimp
height conforms to measurement in Table 3 the
The insulation barrel crimp height is regulated by the tool is correct. If not, replace tool.
insulation adjustment lever. To determine the proper

78
2200 YRM 1128 AMPSEAL Crimping Tools

Legend for Figure 33.

A. CRIMP HEIGHT - SEE TABLE 3

1. TOOL CRIMP SECTION MARKING

2. WIRE SLOT IN LOCATOR
3. WIRE BARREL
4. LOCATOR SLOT IN CONTACT
5. MODIFIED ANVIL ON MICROMETER

Figure 33. AMP Crimp Tool Inspection

Table 3. Crimp Height

Contact Part No Wire Size (AWG) Tool Crimp Section Crimp Height
Marking
20 20-18 1.22 ±0.05 mm

(0.048 ±0.002 in.)

18 20-18 1.22 ±0.05 mm
Yale P/N 520202601
(0.048 ±0.002 in.)
16 16 1.40 ±0.05 mm

(0.055 ±0.002 in.)

HOW TO USE AMP HAND CRIMPING 3. Release tool ratchet by squeezing tool handles
TOOL then allowing them to open.

1. Strip insulation from wire. See Stripping Wire for 4. Holding contact by its mating portion and looking
Use with AMP Hand Crimping Tool. straight into crimp section, insert contact from the
FRONT of tool into BACK of crimp section.
2. Hold tool so BACK side (wire side) faces you. Position contact as shown in Figure 34.

79
AMPSEAL Crimping Tools 2200 YRM 1128

The locator assembly, on the outside of the frame,

contains a locator, a spring retainer, and a contact
support.
The dies are secured to the frame with retaining pins
and retaining screws. A nut on the upper retaining
screw holds the locator assembly in place.

1. BACK OF TOOL
2. STRIPPED WIRE
3. WIRE BARREL
4. CONTACT
5. LOCATOR

Figure 34. Crimp Contact to Wire

A. TOOL FRONT
NOTE: Make sure wire barrel is not deformed during B. TOOL BACK
crimping procedure.
1. STATIONARY JAW
5. Holding contact in this position, squeeze tool 2. STATIONARY HANDLE
handles together. 3. MOVING JAW
4. MOVING HANDLE
6. Insert properly stripped wire through locator and 5. DIE ASSEMBLY
into wire barrel of contact. 6. LOCATOR ASSEMBLY

7. Crimp contact onto wire while holding wire in Figure 35. AMP PRO-CRIMPER II Tool
place by squeezing tool handles together until
ratchet releases. Remove and Install Die Set and Locator
Assembly
8. Allow tool handles to open fully and remove
NOTE: Perform Step 1 through Step 3 for removal of
crimped contact from tool.
die set and locator assembly. Follow Step 4 through
Step 12 for installation of die set and locator assembly.
AMP PRO-CRIMPER II TOOL
1. Close tool handles until ratchet releases.
Description
This tool has a tool frame with stationary jaw and 2. Remove nut, locator assembly, upper and lower
handle, a moving jaw and handle, and an adjustable die retaining screws, and upper and lower die
ratchet to ensure full contact crimping. The tool frame retaining pins. See Figure 36.
contains a die assembly with two crimping sections.
3. Slide wire anvil, insulation anvil, wire crimper, and
The die assembly contains a wire anvil, an insulation insulation crimper out of tool frame. See
anvil, a wire crimper and an insulation crimper. See Figure 36.
Figure 35.

80
2200 YRM 1128 AMPSEAL Crimping Tools

4. Install wire anvil and insulation anvil into moving

jaw of tool frame, with chamfered sides and
marked surfaces facing outward. See Figure 36.

5. Insert lower die retaining pins. See Figure 36.

6. Insert lower die retaining screw through moving

jaw and both anvils. Tighten screw enough to
hold the anvils in place, but DO NOT tighten
completely. See Figure 36.

7. Insert wire crimper and insulation crimper into

stationary jaw, with chamfered sides and marked
surfaces facing outward. See Figure 36.
1. UPPER DIE RETAINING SCREW
2. LOWER DIE RETAINING SCREW
8. Insert upper die retaining pins. See Figure 36. 3. WIRE ANVIL
4. INSULATION ANVIL
9. Insert upper die retaining screw through 5. LOWER DIE RETAINING PIN
stationary jaw and both crimpers. See Figure 36. 6. WIRE CRIMPER
Tighten screw enough to hold crimpers in place, 7. INSULATION CRIMPER
but DO NOT tighten completely. 8. UPPER DIE RETAINING PIN
9. LOCATOR ASSEMBLY
10. NUT
10. Carefully close tool handles. Make sure anvils 11. LOCATOR
and crimpers align properly. Completely close tool 12. TOOL FRAME
handles until ratchet is engaged enough to hold
anvils and crimpers in position. Tighten upper and Figure 36. Die Set and Locator Assembly
lower die retaining screws.
Stripping Wire for Use With AMP PRO-
11. Install locator assembly over the end of upper die CRIMPER II Tool
retaining screw and position against the side of
the tool jaw. See Figure 36. 1. Choose the correct AWG for the contact being
used.
12. Install nut onto the end of upper die retaining
screw and tighten enough to hold locator 2. See Table 4 for recommended strip length.
assembly in place while allowing the locator to
Table 4. Strip Length for PRO-CRIMPER II Tool
slide up and down. See Figure 36.
Wire Size Wire Insulation Strip Length
(AWG) Diameter
16 1.7 to 2.7 mm (0.07 5.1 ±0.4 mm (0.20
18-20 to 0.11 in.) ±0.02 in.)

CAUTION
DO NOT cut or nick the wire strands.

3. Strip wire to recommended strip length. See

Figure 37.

81
AMPSEAL Crimping Tools 2200 YRM 1128

1. CONTACT
2. LOCATOR (IN WIRE STOP SLOT) 1. ADJUSTMENT SCREW
3. WIRE (INSERTED TO STOP) 2. CONTACT SUPPORT
4. STRIP LENGTH 3. LOCATOR
4. WIRE
Figure 37. Contact and Wire Strip 5. BACK OF TOOL

Contact Support Adjustment Figure 38. Contact Support Adjustment

1. Make a sample crimp. Determine if contact is
Crimp Height Adjustment
straight, bent upward or downward.
1. Remove lockscrew from ratchet adjustment
2. If adjustment is required, loosen adjustment wheel. See Figure 39.
screw, DO NOT remove screw. See Figure 38.
2. Using screwdriver, adjust ratchet wheel as
3. Insert contact and wire into tool as shown in indicated in Step 3 or Step 4.
Figure 37. Close tool handles until the ratchet
reaches the sixth clip or the contact support 3. To tighten crimp, rotate ratchet adjustment wheel
touches the contact. COUNTERCLOCKWISE. See Figure 39.

4. Loosen the nut, slightly, that holds the locator 4. To loosen crimp, rotate ratchet adjustment wheel
assembly onto the tool frame. See Figure 38. CLOCKWISE. See Figure 39.

5. Move the contact support to eliminate bending the 5. Replace lockscrew onto ratchet adjustment
contact. wheel. See Figure 39.

6. Tighten the nut and squeeze handles until ratchet 6. Make a sample crimp and measure the crimp
releases. height.

7. Remove and inspect the contact.

8. Make another sample crimp. If the contact is

straight, tighten the adjustment screw. If the
contact is bent, repeat Step 2 through Step 8.

82
2200 YRM 1128 AMPSEAL Crimping Tools

A. POSITION POINT ON CENTER OF WIRE

BARREL OPPOSITE SEAM.

1. MODIFIED ANVIL ON MICROMETER

2. CRIMP HEIGHT, SEE TABLE 5

1. LOCKSCREW Figure 40. Crimp Height

2. RATCHET ADJUSTMENT WHEEL
3. SCREWDRIVER 2. Refer to Table 5 to select wire for each crimp
section listed.
Figure 39. Ratchet Adjustment Wheel
Table 5. Crimp Measurement
Maintenance and Inspection Procedures
Wire Size (AWG) Crimp Height
PRO-CRIMPER II Tool 16 1.41 ±0.05 mm
1. Make sure the tool and dies are clean by wiping
them with a clean, soft cloth. If debris is present, (0.056 ±0.002 in.)
clear away with a soft brush. Keep handles 18 1.22 ±0.05 mm
closed when not in use to prevent objects from
becoming stuck in crimping dies. Store in clean, (0.048 ±0.002 in.)
dry area.
3. Crimp a contact onto the selected wire according
2. Inspect the crimping dies on a regular basis to
to How to Use AMP PRO-CRIMPER II Tool
ensure they are not worn or damaged. If crimp
procedure.
sections are flattened, chipped, worn or broken
replace tool.
4. Using a modified micrometer, measure wire barrel
height as shown in Figure 40. If the crimp height
Crimp Height Inspection matches measurement shown in Table 5 the tool
1. This inspection requires the use of a micrometer is correct. If not, follow Crimp Height Adjustment
with a modified anvil as shown in Figure 40. procedure.

HOW TO USE AMP PRO-CRIMPER II TOOL

1. Strip insulation from wire. See Stripping Wire for
Use With AMP PRO-CRIMPER II Tool procedure.

2. Hold PRO-CRIMPER II tool so BACK side (wire

side) is facing you.

3. Squeeze tool handles together, then allow to fully

open.

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AMPSEAL Connector Assemblies 2200 YRM 1128

4. Holding contact by mating end, insulation barrel 7. Insert stripped wire into contact insulation and
first, insert contact through front of tool and into wire barrels until butted against wire stop.
appropriate crimp section.
8. Squeeze tool handles, while holding wire in
5. Mating end of contact should be on locator side of position, until ratchet releases.
tool; the open "U" of wire barrel and insulation
barrel should face the top of the tool. The contact 9. Allow tool handles to open and remove crimped
to be placed to that movable locator drips into slot contact from tool.
in the contact. Butt the front end of the wire barrel
against locator. 10. Check crimp height as described in Crimp Height
Inspection.
NOTE: Make sure neither wire barrel nor insulation
barrel are damaged.
6. Hold contact in position and squeeze tool handles
until ratchet engages enough to hold contact.

AMPSEAL Connector Assemblies

DESCRIPTION FOR PLUG CONNECTOR
ASSEMBLY
The plug assembly consists of a housing, a wedge
lock, a wire seal, and a mating seal. See Figure 41.

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2200 YRM 1128 AMPSEAL Connector Assemblies

Table 6. Current Rating

Single Wire Size Current Rating
Circuit (AWG) (Max.)
Plating
Tin 16, 18, and 20 8A
Gold 16 14.5A
18 13A
20 11.5A

Seal Plug
All circuits are sealed by a diaphragm in the rubber
wire seal. When assembling the connector, the
diaphragm is pierced as the contact passes through it.
Unused circuit cavities will remain sealed unless
perforated by accidental insertion and removal of
contact in the wrong cavity. The seal plug is designed
to keep out contaminants if the diaphragm is pierced.

1. Insert the seal plug, large end first, into the circuit
cavity as far as it will go. No insertion tool is
usually required for this procedure. See
Figure 42.

1. HOUSING
2. WEDGE LOCK
3. WIRE SEAL
4. MATING SEAL
5. DIAPHRAGM
6. CONTACT 1. PLUG CONNECTOR
7. RETENTION FINGERS 2. SEAL PLUG
3. CIRCUIT CAVITY
Figure 41. AMPSEAL Plug Connector
Figure 42. Seal Plug
For current ratings of special use connectors,
AMPSEAL, refer to Table 6. Contact Crimping
Information on contact crimping can be found in
AMPSEAL Crimping Tools.

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AMPSEAL Connector Assemblies 2200 YRM 1128

Contact Removal
NOTE: The wedge lock should never be removed from the housing for insertion or removal of the contacts.

STEP 1.
Insert a screwdriver blade between the mating
seal and one of the red wedge lock tabs. Pry
open the wedge lock to the OPEN position.

NOTE: SCREWDRIVER TO BE MOVED IN

DIRECTION OF ARROW.

A. CLOSED POSITION
B. OPEN POSITION

1. WEDGE LOCK TAB

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2200 YRM 1128 AMPSEAL Connector Assemblies

STEP 2.
While rotating the wire back and forth over a half
turn (1/4 turn each direction), gently pull the wire
until the contact is removed.

STEP 3.
Tag the wire and mark it with the corresponding
number or letter on the back of the connector
from which the wire was removed.

STEP 4.
Repeat Step 2 and Step 3 to remove remaining
wires.

Contact Insertion
NOTE: The wedge lock should never be removed from the housing for insertion or removal of the contacts.
NOTE: Check to be sure the wedge lock is in the OPEN position. Perform Step 1 if wedge lock is closed.

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AMPSEAL Connector Assemblies 2200 YRM 1128

STEP 1.
Insert a screwdriver blade between the mating
seal and one of the red wedge lock tabs. Pry
open the wedge lock to the OPEN position.

NOTE: SCREWDRIVER TO BE MOVED IN

DIRECTION OF ARROW.

A. CLOSED POSITION
B. OPEN POSITION

1. WEDGE LOCK TAB

STEP 2.
Insert contact by pushing it straight into the
appropriate circuit cavity as far as it will go.

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2200 YRM 1128 AMPSEAL Connector Assemblies

STEP 3.
Pull back on the contact wire with a force of
4 to 9 N (1 to 2 lbf) to be sure the retention fingers
are holding the contact.

NOTE: PULL WIRE IN DIRECTION OF ARROW.

1. RETENTION FINGERS

STEP 4.
After all required contacts have been inserted, the
wedge lock must be closed to its LOCKED
position. Release the locking latches by
squeezing them inward.

1. LOCKING LATCHES

STEP 5.
Slide the wedge lock into the housing until it is
flush with the housing.

1. WEDGE LOCK

DESCRIPTION FOR PLUG CONNECTOR

AND HEADER ASSEMBLY
The plug assembly will accept multiple socket
contacts. See Figure 43. The head assembly is
designed to be fastened to the enclosure by four self-
tapping screws. The screw length will depend on panel
thickness.

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AMPSEAL Connector Assemblies 2200 YRM 1128

Legend for Figure 43.

NOTE: PLUG AND HEADER ASSEMBLY COLORS
ARE MECHANICALLY KEYED TO MATE ONLY WITH
IDENTICAL COLORS.

A. PLUG ASSEMBLY
B. HEADER ASSEMBLY

1. MATING SEAL
2. HOUSING
3. WEDGE LOCK
4. RETENTION LEG

Panel mounting cutout requirements shown in

Figure 44. Maximum panel thickness to be
2 mm (0.08 in.) for proper clearance.

Figure 43. AMPSEAL Plug and Header Assembly

Figure 44. AMPSEAL Plug and Header Assembly Panel Mounting

Use screwdriver slot to lift latch for unmating. To mate, fasten the locking latch when mating plug and header.
the plug and head must be identical in color. Securely See Figure 45.

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2200 YRM 1128 AMPSEAL Connector Assemblies

A. WIRE STRANDS MUST BE VISIBLE IN THIS C. CUTOFF TAB MUST BE VISIBLE

AREA
B. WIRE STRANDS AND INSULATION MUST
BOTH BE VISIBLE IN THIS AREA

1. SCREWDRIVER SLOT 3. PLUG AND HEADER

2. LOCKING LATCH

Figure 45. Contact, Plug, and Header

The wedge lock has slotted openings in the mating, When using AMPSEAL plug assembly DO NOT pierce
forward, end. The slots are for circuit test tabs wire insulation with a sharp point. Pin holes in the
approximately 3.3 × 0.6 mm (0.13 × 0.02 in.), which insulation allow moisture to invade the sealed
prevent damage to the receptacle. Circuit testing in the connector system nullifying effectiveness and resulting
field to be done by a flat probe, DO NOT use a sharp in possible system failure.
point.
Seal Plug
Voltage Reading All circuits are sealed by a diaphragm in the rubber
wire seal. This diaphragm is pierced when the contact
CAUTION is pressed through it. Unused circuit cavities will
remain sealed unless perforated by accidental
DO NOT pierce wire insulation to take voltage
insertion and removal of contact in the wrong cavity.
readings.

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AMPSEAL Connector Assemblies 2200 YRM 1128

The seal plug is designed to keep out contaminants if Contact Crimping

the diaphragm is accidentally pierced.
1. Information on contact crimping can be found in
1. Insert the seal plug, large end first, into the circuit AMPSEAL Crimping Tools.
cavity as far as it will go. No insertion tool is
required for this procedure. See Figure 46. NOTE: DO NOT cut contacts from "reel", use loose
contacts only.

2. Crimped contacts to meet conditions shown in

Figure 47 and Table 7.

1. PLUG CONNECTOR
2. SEAL PLUG
3. CIRCUIT CAVITY

Figure 46. Seal Plug

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2200 YRM 1128 AMPSEAL Connector Assemblies

A. WIRE STRAND ENDS MUST BE VISIBLE IN THIS AREA

B. WIRE BARREL SHALL BE CLOSED AT SEAM WITH NO STRANDS PROTRUDING OR SHOWING
C. WIRE STRANDS AND INSULATION SHALL BOTH BE VISIBLE
D. FRONT BELLMOUTH SHALL BE 0.25 mm (0.01 in.)MAX; 0.13 mm (0.005 in.)MIN
E. REAR BELLMOUTH SHALL BE 0.13 TO 0.75 mm (0.005 TO 0.03 in.)
F. CUTOFF TAB SHALL BE 0.25 mm (0.01 in.)MAX

Figure 47. Crimp Conditions

Table 7. Crimp Conditions

Wire Wire Barrel Insulation Barrel
Size Insulation Strip Crimp Height Crimp Width Crimp Crimp Width
(AWG) Diameter Length (Nom) Height Max ±0.1
Range
20 1.17 ±0.08
18 1.7 to 2.7 5.1 1.27 ±0.05 2.03 3.2 3.1
16 1.40 ±0.05

are present at the wire seal, leakage can occur.

CAUTION Insulation surface within 26 mm (1.02 in.) of contact tip
Cable far end to be sealed or isolated from the must be smooth and free of indentations. Ensure wire
environment. DO NOT damage insulation. insulation is not damaged during crimping procedure.
The insulation bars to be wrapped around the wire
NOTE: Wire stripping tools may leave indentations on insulation, leaving not sharp points to damage rubber
the surface of the wire insulation. If these indentations wire seal.

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AMPSEAL Connector Assemblies 2200 YRM 1128

3. The crimped contact to be a 2 mm (.08 in.)

diameter cylinder. See Figure 48.

A. CENTERLINE B. DIA 2 mm (0.08 in.)

1. CONTACT (PARTIALLY INSERTED) 4. DIAPHRAGM

2. WIRE SEAL 5. MATING SEAL
3. RETENTION FINGERS 6. WEDGE LOCK (OPEN POSITION)

Figure 48. Contact Concentricity

Contact Removal
NOTE: The wedge lock should never be removed from the housing for insertion or removal of the contacts.

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2200 YRM 1128 AMPSEAL Connector Assemblies

STEP 1.
Insert a screwdriver blade between the mating
seal and one of the red wedge lock tabs. Pry
open the wedge lock to the OPEN position.

NOTE: SCREWDRIVER TO BE MOVED IN

DIRECTION OF ARROW.

A. CLOSED POSITION
B. OPEN POSITION

1. WEDGE LOCK TAB

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AMPSEAL Connector Assemblies 2200 YRM 1128

STEP 2.
While rotating the wire back and forth over a half
turn (1/4 turn each direction), gently pull the wire
until the contact is removed.

STEP 3.
Repeat Step 2 to remove remaining wires.

Contact Insertion
NOTE: The wedge lock should never be removed from the housing for insertion or removal of the contacts.
NOTE: Check to be sure the wedge lock is in the OPEN position. Perform Step 1 if wedge lock is closed.

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2200 YRM 1128 AMPSEAL Connector Assemblies

STEP 1.
Insert a screw driver blade between the mating
seal and one of the red wedge lock tabs. Pry
open the wedge lock to the OPEN position.

NOTE: SCREWDRIVER TO BE MOVED IN

DIRECTION OF ARROW.

A. CLOSED POSITION
B. OPEN POSITION

1. WEDGE LOCK TAB

STEP 2.
Insert contact straight into circuit cavity as far as it
will go.

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AMPSEAL Connector Assemblies 2200 YRM 1128

STEP 3.
Pull back on contact wire with 4 to 9 N (1 to 2 lbf)
to be sure the retention fingers are holding the
contact.

1. RETENTION FINGERS

STEP 4.
After all required contacts have been inserted, the
wedge lock must be closed to the LOCKED
position. Release the locking latches by
squeezing them inward.

1. LOCKING LATCHES

STEP 5.
Slide the wedge lock into the housing until it is
flush with the housing.

1. WEDGE LOCK

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2200 YRM 1128 AMP Superseal 1.5 Crimping Tools

AMP Superseal 1.5 Crimping Tools

MINI MIC RECEPTACLE AND TAB 4. Bend up = 5° max. See Figure 51.
CONTACTS
5. Bend down = 5° max. See Figure 51.
Description
6. Bend right = 5° max. See Figure 50.
Contacts are for 16-22 AWG wire, with single wire
seals. Each wire is inserted into a discrete wire seal 7. Bend left = 5° max. See Figure 50.
before crimping into contact. Insulation barrel is
crimped so wire seal is gripped to avoid any 8. Rolling = 5° max. See Figure 50.
movement of seal. Contacts are suitable for single
wires only. 9. Cable end protrusion =
0.2 to 0.7 mm (0.008 to 0.03 in.). See Figure 49.
Crimping Conditions and Measurements
10. Insulation stripping length =
1. Cut-off tab length = 0.3 mm (0.01 in.) max. See
3.0 to 3.5 mm (0.12 to 0.14 in.).
Figure 49.
11. Wire barrel seam must be neatly closed. See
2. Front bellmouth = 0.10 mm (0.004 in.) × 45° max.
Figure 49.
See Figure 49.

3. Rear bellmouth = 0.25 mm (0.009 in.) × 45° max.

See Figure 49.

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AMP Superseal 1.5 Crimping Tools 2200 YRM 1128

A. TOP VIEW B. SIDE VIEW

1. WIRE BARREL SEAM 8. INSULATION BARREL

2. WIRE BARREL 9. FRONT BELLMOUTH
3. CABLE END PROTRUSION LENGTH 10. REAR BELLMOUTH
4. WIRE BARREL CRIMP WIDTH 11. INSULATION BARREL CRIMP HEIGHT
5. INSULATION BARREL CRIMP WIDTH 12. CUT-OFF TAB LENGTH
6. RUBBER SEAL 13. WIRE BARREL CRIMP HEIGHT
7. CABLE

Figure 49. Crimping Conditions

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2200 YRM 1128 AMP Superseal 1.5 Crimping Tools

1. BEND RIGHT 3. ROLLING

2. BEND LEFT 4. DATUM LINE

Figure 50. Crimping Conditions Bend Right/Left

1. BEND UP 2. BEND DOWN 3. DATUM LINE

Figure 51. Crimping Conditions Bend Up/Down

Insertion of Rubber Seal on Cable

NOTE: Rubber seals are lubricated, lubrication must
not be removed.
The end of cable insulation to be positioned from edge
of rubber seal when rubber seal is installed on cable.
See Figure 52.

A. 0.5 mm (0.02 in.)MAX

1. WIRE INSULATION 2. RUBBER SEAL

Figure 52. Rubber Seal Installed on Cable

Correction or Replacement of Parts

STEP 1.
When defects or improper applications are found
on parts to be installed, rework or replace with
new parts.

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AMP Superseal 1.5 Crimping Tools 2200 YRM 1128

STEP 2.
Cut end of wire shall appear neat without any
bend or stranded conductor.

STEP 3.
Conductor shall be free from nick, cut or scrape.

STEP 4.
Wire insulation must have smooth surface in a
round form without damage, groove, or recessed
surface.

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2200 YRM 1128 AMP Superseal 1.5 Crimping Tools

STEP 5.
wire end shall be straight without bend or
untidiness after insertion of rubber seal.

STEP 6.
Flanges of rubber seal to be free of cuts or
damage.

STEP 7.
Insertion of rubber seal to be done straight and
even. If flanges are tilted, plug must be corrected
so flanges are perpendicular to contact center
line.

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AMP Superseal 1.5 Crimping Tools 2200 YRM 1128

STEP 8.
After crimping, cable insulation inside rubber seal
to be in good condition and within requirements
as specified in Crimping Conditions and
Measurements in this section.

A. 0.2 TO 0.7 mm (0.008 TO 0.03 in.)

B. 0.2 mm (0.008 in.)

STEP 9.
Rubber seal must protrude from insulation crimp
without damage. Check by visual inspection in the
transition area (between wire and insulation
barrel) as shown.

1. RUBBER SEAL

STEP 10.
No parts of insulation or rubber are allowed in the
wire crimp, after crimping.

STEP 11.
Part of rubber seal must stick out of transition
hole.

1. RUBBER SEAL

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2200 YRM 1128 AMP Superseal 1.5 Crimping Tools

STEP 12.
Tilt shape of rubber seal is unacceptable.

A. 8° MAX

STEP 13.
Crimped contacts should appear as shown.

A. TOP VIEW B. SIDE VIEW

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AMP Superseal 1.5 Crimping Tools 2200 YRM 1128

AMP HAND APPLICATION TOOL

Description
This tool is designed for use with AMP Superseal 1.5
series contacts. The tool has two crimp sections,
contact locator, wire stop, and ratchet. See Figure 53.

A. POSITION POINT ON CENTER OF WIRE

BARREL OPPOSITE SEAM.

1. MODIFIED ANVIL
2. CRIMP HEIGHT (SEE TABLE 8)

Figure 54. Crimp Height

2. Use Table 8 to select wire for crimp height

inspection.

Table 8. Wire Strip Lengths

Wire Size Strip Length Crimp Height
1. FRONT OF TOOL (LOCATOR SIDE) (AWG) ±0.05 mm
2. BACK OF TOOL (WIRE SIDE) (0.002 in.)
3. DIE SET
4. MOVABLE LOCATOR 3.0 to 3.5 mm 1.12 mm (0.044 in.)
5. RATCHET ADJUSTMENT WHEEL 20
(0.12 to 0.13 in.)
6. PIVOT PIN
3.0 to 3.5 mm 1.30 mm (0.051 in.)
18
Figure 53. AMP Hand Application Tool for AMP (0.12 to 0.13 in.)
Superseal 1.5 Contacts 3.0 to 3.5 mm 1.45 mm (0.057 in.)
16
(0.12 to 0.13 in.)
Maintenance and Inspection
1. Ensure tool and dies are clean by wiping with a 3. Crimp a contact onto the selected wire according
clean, soft cloth. Remove any debris with clean, to How to use AMP Hand Application Tool
soft brush. DO NOT use objects that could procedure.
damage tool. When not in use, keep handles
closed to prevent debris from lodging in dies. 4. Using crimp height comparator, measure wire
Store in clean, dry area. barrel crimp height as shown in Figure 54. If
crimp height matches that shown in Table 8, the
2. Crimping dies to be inspected on a regular basis tool is considered dimensionally correct. If not,
for wear or damage. Inspect crimp sections for follow Crimp Height Adjustment procedure.
flattened, chipped, worn, or broken areas.
Replace tool if damaged. Crimp Height Adjustment
1. Remove lockscrew from ratchet adjustment
Crimp Height Inspection wheel. See Figure 55.
1. This inspection requires the use of a micrometer
with a modified anvil. See Figure 54.

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2200 YRM 1128 AMP Superseal 1.5 Crimping Tools

1. RATCHET ADJUSTMENT WHEEL

2. LOCKSCREW
3. LOOSEN-TIGHTEN
4. BACK OF TOOL
5. FRONT OF TOOL
6. SCREWDRIVER

Figure 55. Ratchet Wheel Adjustment 1. WIRE STRIP LENGTH

2. WIRE SEAL
3. INSULATION BARREL
2. Using a screwdriver, adjust ratchet wheel from 4. WIRE BARREL
front of tool. See Figure 55. 5. WIRE STOP SLOT
6. MATING END
3. To tighten crimp, rotate ratchet adjustment wheel
COUNTERCLOCKWISE. See Figure 55. Figure 56. Wire and Receptacle

4. To loosen crimp, rotate ratchet adjustment wheel Table 9. Wire Strip Lengths
CLOCKWISE. See Figure 55.
Wire Size Insulation Strip Length
5. Make a sample crimp and measure crimp height. (AWG) Diameter
If crimp height is acceptable, replace and tighten 1.7 to 2.4 mm 3.0 to 3.5 mm
lockscrew. If crimp height is unacceptable, follow 20-16 (0.07 to (0.12 to 0.13 in.)
Step 3 or Step 4 until acceptable crimp height is 0.09 in.)
achieved.
1.7 to 2.4 mm 3.0 to 3.5 mm
22-20 (0.07 to (0.12 to 0.13 in.)
HOW TO USE AMP HAND APPLICATION 0.09 in.)
TOOL
1. Strip insulation from wire. See Figure 56 and 2. Hold tool so BACK (wire side) faces you.
Table 9.
3. Release tool handles by squeezing them together
then allowing them to open fully.

NOTE: Insert contact with open side of insulation and

wire barrel toward movable crimping jaw.
4. Holding contact by insulation barrel, insert it
through back of tool into appropriate crimp
section, receptacle/tab end first.

NOTE: Ensure both sides of insulation barrel are

started evenly into the crimper jaws. DO NOT attempt
to crimp improperly positioned contacts.

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AMP Superseal 1.5 Crimping Tools 2200 YRM 1128

5. Align contact wire stop slot with the wire stop in used on upper retaining screw to hold locator
the crimping jaws. Contact insulation and wire assembly in place. See Figure 58.
barrels must be position in crimp section as
shown in Figure 57.

1. WIRE INSERTED TO STOP

2. STRIP LENGTH (SEE TABLE 9)

Figure 57. Wire Stop Slot

6. Squeeze handles together until ratchet engages A. FRONT OF TOOL (LOCATOR SIDE)
sufficiently to hold contact in position. DO NOT B. BACK OF TOOL (WIRE SIDE)
deform insulation or wire barrel.
1. LOCATOR ASSEMBLY
2. STATIONARY JAW
7. Insert stripped wire into contact insulation and 3. DIE ASSEMBLY
wire barrels until butted against wire stop. See 4. MOVING JAW
Figure 57. 5. RATCHET ADJUSTMENT WHEEL
6. PIVOT PIN
8. Holding wire in position, squeeze tool handles 7. STATIONARY HANDLE
8. MOVING HANDLE
together until ratchet releases. Allow tool handles
to open and remove crimped contact. Figure 58. AMP PRO-CRIMPER II Tool and Die

AMP PRO-CRIMPER II TOOL Remove and Install Die Set and Locator
Description Assembly
This tool has a tool frame with stationary jaw and 1. Close tool handles until ratchet releases, remove
handle, a moving jaw and handle, and an adjustable the nut, locator assembly, upper retaining screw,
ratchet to endure full contact crimping. The tool frame lower retaining screw and four die retaining pins
contains a die assembly with three crimping sections. from tool frame. See Figure 59.
The die assembly contains a wire anvil, an insulation 2. Slide wire anvil, insulation anvil, wire crimper, and
anvil, a wire crimper and an insulation crimper. See insulation crimper out of tool frame. See
Figure 58. Figure 59.
Die retaining pins and retaining screws are used to
position and secure the dies in the tool frame. A nut is

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2200 YRM 1128 AMP Superseal 1.5 Crimping Tools

3. Install wire anvil and insulation anvil, with

chamfered sides and marked surfaces facing
outward, into moving jaw. See Figure 59.

4. Insert two die retaining pins. See Figure 59.

5. Insert lower retaining screw through moving jaw,

insulation anvil, and wire anvil. Tighten lower
retaining screw just enough to hold anvils in
position. DO NOT tighten lower retaining screw
completely. See Figure 59.

6. Install wire crimper and insulation crimper, with

chamfered sides and marked surfaces facing
1. TOOL FRAME
outward, into stationary jaw. See Figure 59. 2. LOCATOR ASSEMBLY
3. NUT
7. Insert two die retaining pins. See Figure 59. 4. DIE RETAINING PIN
5. UPPER RETAINING SCREW
8. Install upper die retaining screw through 6. LOWER RETAINING SCREW
stationary jaw, insulation crimper, and wire 7. WIRE CRIMPER
crimper. Tighten upper retaining screw just 8. WIRE ANVIL
9. CHAMFER
enough to hold crimpers in position. DO NOT 10. OFFSET
tighten upper retaining screw completely. See 11. INSULATION CRIMPER
Figure 59. 12. INSULATION ANVIL
13. CHAMFER
9. Carefully close tool handles making sure anvils 14. MOVING JAW
15. STATIONARY JAW
and crimpers align properly. Continue closing tool
handles until ratchet in tool frame engages Figure 59. Die Set and Locator Assembly
enough to hold anvils and crimpers in position.
Tighten upper and lower retaining screws. Adjustments
10. Install locator assembly over the end of upper Contact Support
retaining screw and position against tool frame.
NOTE: Contact support is preset prior to shipment but
See Figure 59.
minor adjustment may be necessary.
11. Install nut onto end of upper retaining screw and
1. Make a sample crimp and determine if the contact
tighten enough to hold locator assembly in
is straight, bending upward, or bending
position while allowing locator to slide up and
downward.
down. See Figure 59.
2. If adjustment is required, loosen the adjustment
screw holding contact support onto locator
assembly. See Figure 60.

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AMP Superseal 1.5 Crimping Tools 2200 YRM 1128

A. BACK OF TOOL B. STRIP LENGTH

1. LOCATOR 5. WIRE SEAL

2. CONTACT SUPPORT 6. CONTACT
3. ADJUSTMENT SCREW 7. LOCATOR IN WIRE STOP SLOT
4. WIRE 8. WIRE INSERTED TO STOP

Figure 60. Contact Support and Wire Strip

NOTE: The ratchet has detents that create audible 8. Make another sample crimp. If the contact is
clicks as the tool handles are closed. straight, tighten the adjustment screw. If the
contact is still being bent during crimping, repeat
3. Position contact with wire in the proper nest and
adjustment procedure.
close the tool handles until the ratchet reaches
the sixth click, or until the contact support touches
the contact. Crimp Height
1. Remove lockscrew from ratchet adjustment
4. Slightly loosen the nut holding the locator wheel. See Figure 61.
assembly onto the tool frame.
2. Using a screwdriver, adjust the ratchet wheel from
5. Move the contact support as needed to eliminate locator side of tool. See Figure 61. Observe
the bending of the contact. ratchet adjustment wheel.

6. Tighten the nut and close the handles until the 3. If a tighter crimp is required, rotate ratchet
ratchet releases. adjustment wheel COUNTERCLOCKWISE to a
higher-numbered setting.
7. Remove and inspect the contact.
4. If a looser crimp is required, rotate ratchet
adjustment wheel CLOCKWISE to a lower-
numbered setting.

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2200 YRM 1128 AMP Superseal 1.5 Crimping Tools

5. Replace lockscrew. See Figure 61.

6. Make a sample crimp and measure the crimp

height as specified in Crimp Height Inspection
section. If the dimension is acceptable, secure
lockscrew. If the dimension is unacceptable,
continue to adjust the ratchet and measure a
sample crimp.

1. POSITION POINT ON CENTER OF WIRE

BARREL OPPOSITE SEAM
2. MODIFIED ANVIL
3. CRIMP HEIGHT (SEE TABLE 10)

Figure 62. Crimp Height

2. See Table 10 and select a wire (maximum size)

for each crimping chamber listed.

Table 10. Crimp Height - Dimension "3" in

Figure 62
Wire Size Crimping Crimp Height
AWG Chamber (Wire ± 0.05 mm (0.002 in.)
1. LOCKSCREW Size Marking)
2. RATCHET ADJUSTMENT WHEEL 20 20 1.12 mm (0.044 in.)
3. SCREWDRIVER
18 18 1.30 mm (0.051 in.)
Figure 61. Ratchet Adjustment Wheel 16 16 1.45 mm (0.057 in.)
Inspections and Maintenance 3. See How to Use AMP Pro-Crimper II Tool section
Crimp Height Inspection and crimp contact accordingly.
1. This inspection requires the use of a micrometer 4. Using crimp height comparator, measure the wire
with a modifier anvil as shown in Figure 62 barrel crimp height as shown in Figure 62. If
crimp height conforms to dimensions shown in
Table 10 the tool is considered dimensionally
correct. If not, the tool must be adjusted; see
Crimp Height section.

Visual Inspection
The crimping dies should be inspected on a regular
basis to ensure they have not become worn or
damaged. Inspect the crimping chamfers for flattened,
chipped, worn or broken areas. If damage or abnormal
wear is present, replace tool.

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AMP Superseal 1.5 Connector Assemblies 2200 YRM 1128

Maintenance 5. Position the contact tho that the mating end of

contact is on locator side of tool and the open "U"
1. Wipe tool and dies with clean, soft cloth. Remove of the wire and insulation barrels face the top of
any debris with a clean, soft brush. DO NOT use the tool. Fit the contact into the nest so the
objects that could damage the tool. When not in movable locator drops into the slot in the contact.
use, keep handles closed to prevent debris from See Figure 60. Butt front end of wire barrel
becoming lodged in the crimping dies, and store against movable locator.
in a clean, dry area.
NOTE: Make sure both sides of insulation barrel are
HOW TO USE PRO-CRIMPER II TOOL started evenly into the crimping chamber. DO NOT
NOTE: This tool is provided with a crimp adjustment attempt to crimp and improperly positioned contact.
feature. Initially the crimp height should be verified as 6. Hold contact in position and squeeze the tool
stipulated in Crimp Height Inspection and Crimp handles together until ratchet engages enough to
Height Adjustment sections to verify height before hold contact in position. DO NOT deform
using the tool to crimp desired contacts and wire sizes. insulation barrel or wire barrel.

1. Using Table 9 select wire of specified size and 7. Insert stripped wire, with wire seal, into insulation
insulation diameter. Assemble wire seal onto wire and wire barrels until it is butted against wire stop.
as specified in Mini Mic Receptacle and Tab See Figure 60.
Contact section.
NOTE: The crimped contact may stick in the crimping
2. Strip wire to the length indicated in Table 9 taking area, but the contact can be easily removed by
care not to nick or cut wire strands. Select contact pushing downward on the top of the locator. See
and identify appropriate crimping chamber Figure 60.
according to the wire size markings on the tool.
8. Holding wire in position, squeeze tool handles
3. Hold tool so that the back (wire side) is facing together until ratchet releases. Allow tool handles
you. Squeeze tool handles together and allow to open and remove crimped contact.
them to open fully.
9. Check contact crimp height as described in Crimp
4. Holding contact by mating end, insert the contact, Height Inspection section. If necessary, adjust the
insulation barrel first, through the front of the tool crimp height as specified in Crimp Height section.
and into the appropriate crimping chamber.

AMP Superseal 1.5 Connector Assemblies

DESCRIPTION field. The following information is intended as a
general guide for the best use of the connectors for
The AMP Superseal 1.5 connectors are designed to wire harnesses and their maintenance.
meet the performance requirements in the automotive

Harness Assembly
STEP 1.
Contacts can only be inserted into housing
cavities in one position. The correct placing is
shown. After insertion of a contact, pull back
lightly on the wire to check that the contact is
securely locked in position.

112
2200 YRM 1128 AMP Superseal 1.5 Connector Assemblies

STEP 2.
Cavity plug, Yale P/N 580050847 , must be used
when a cavity is not loaded with a contact. This
prevents the ingress of water. Insert cavity plug
deeply into the cavity by means of a pin as
shown. If necessary, the cavity plug can be
removed by a pin point.

1. CAVITY PLUG

Positioning of Anti-Backout Device

STEP 1.
These connectors are supplied with an anti-
backout device for both receptacle and tab
housings. After loading all of the crimped
contacts, these devices must be pushed into
CLOSED position. If one contact is not properly
seated in the cavity, the plastic locking lance
remains deflected and the anti-backout device
cannot be closed. This serves as a warning for
the user. If the anti-backout device is not closed,
the mating with a counterpart cannot be
completed.

A. CONTACT NOT PROPERLY SEATED

1. TAB HOUSING
2. PLUG HOUSING
3. ANTI-BACK OUT DEVICE
4. ANTI-BACK OUT DEVICE

NOTE: Perform Step 2 for manually operated, position 2 to 6 plugs.

113
AMP Superseal 1.5 Connector Assemblies 2200 YRM 1128

STEP 2.
Rotate the anti-back out device to deflect the
central lances inward then push until the side
arms lock.

1. ANTI-BACK OUT DEVICE

NOTE: Perform Step 3 for position 2 to 6 plugs inserted by a harness maker machine.

STEP 3.
Push the two lances for position 2 housing, the
central lance for positions 3 and 5 housing, and
the two central lances for positions 4 and 6
housing inward. Then push until the side arms
lock.

1. ANTI-BACK OUT DEVICE

STEP 4.
For position 1, manually or machine operated,
push the anti-backout device until its upper end is
the same level as the housing mating face.

1. ANTI-BACK OUT DEVICE

NOTE: Different jigs are needed for position 1 and 2 housings and position 3 to 6 housings.

114
2200 YRM 1128 AMP Superseal 1.5 Connector Assemblies

STEP 5.
To close the anti-backout device for tab housings,
either manually or by machine, push the device in
with a jig until it meets the stop.

1. ANTI-BACK OUT DEVICE

Removal of Contacts
Since the locking lance of contacts can be reached from the mating side of the housings, it is necessary to
remove the anti-backout device first.
NOTE: Perform Step 1 and Step 2 for removal of receptacle contact.

STEP 1.
Deflect the side arms of the anti-back out device
and pull it away.

1. ANTI-BACK OUT DEVICE

2. EXTRACTION TOOL

115
AMP Superseal 1.5 Connector Assemblies 2200 YRM 1128

CAUTION
Be careful not to insert the extraction tool in the
contacting area of the receptacle.

STEP 2.
Insert the contact extraction tool, Yale P/N
580093887 , between contact and lance nose,
then rotate slightly as shown. Pull the wire.

1. CONTACT
2. CONTACT EXTRACTION TOOL

NOTE: Perform Step 3 and Step 4 for removal of tab contact.

116
2200 YRM 1128 AMP Superseal 1.5 Connector Assemblies

STEP 3.
Insert the extraction tool, Yale P/N 58093886 , in
one of the central holes of the anti-backout device
and pull it away.

NOTE: Pull extraction tool in direction of arrow.

1. EXTRACTION TOOL

117
AMP Superseal 1.5 Connector Assemblies 2200 YRM 1128

CAUTION
When rotating the extraction tool, be careful not to
deform the tab.

STEP 4.
Insert the contact extraction tool, Yale P/N
580093887 , between contact and lance note,
then rotate slightly as shown. Pull the wire up as
shown.

1. CONTACT EXTRACTION TOOL

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2200 YRM 1128 AMP Fastin-Faston Hand Tools

REPAIR AND MAINTENANCE mounting of the connector. The clip can be different
shape according to the requirements. See example in
During repair and maintenance operation for wiring, Figure 63.
replacement of contacts may be required. Following is
the recommended procedure.

1. Cut the wire of the defective contact.

2. Strip the wire insulation to appropriate length.

3. Slide a new wire seal onto the wire.

4. Crimp the new contact on the wire using a hand

crimping tool.

PANEL MOUNT OPTION

NOTE: SLIDE CLIP IN DIRECTION OF ARROW.
The tab housings come with two "L" shaped guides for
the insertion of a special elastic clip, allowing panel Figure 63. Panel Mount Clip Example

AMP Fastin-Faston Hand Tools

DESCRIPTION - AMP DOUBLE ACTION consisting of an anvil and a crimper. When jaws are
HAND TOOL closed they form two crimping chambers, marked on
BACK of tool as "A" and "B". Crimping jaws "bottom"
Hand-crimping tools that accommodate full wire size before ratchet releases. This is a design feature to
range are designed for repair applications. This tool is assure maximum electrical and tensile performance of
designed for use with AMP micro and mini relay crimp; DO NOT readjust ratchet. See Figure 64.
receptacles. The tool has two crimping jaws, each

119
AMP Fastin-Faston Hand Tools 2200 YRM 1128

1. CRIMPER 5. INSULATION CRIMPING JAWS

2. ANVIL 6. BACK OF TOOL
3. CRIMPING CHAMBER MARKINGS 7. CERTI-CRIMP RATCHET
4. WIRE CRIMPING JAW 8. LINK

Figure 64. AMP Double Action Hand Tool

MAINTENANCE AND INSPECTION 2. Ensure retaining pins are in place and secured
PROCEDURES with retaining rings. See Figure 65.

Daily Maintenance 3. When not in use, keep handles closed to prevent

debris from lodging in jaws. Store in clean dry
1. Immerse tool, with handles partially closed, in
area.
reliable commercial de-greasing compound to
remove accumulated debris. If de-greasing
compound is not available, wipe tool with soft lint-
free cloth. DO NOT use objects that could
damage tool.

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2200 YRM 1128 AMP Fastin-Faston Hand Tools

1. RETAINING RING 3. HANDLE SPRING

2. RETAINING PIN

Figure 65. Tool Inspection

Periodic Tool Inspection Crimp Height Inspection

Lubrication 1. This inspections requires the use of a modified
micrometer with modified anvil and spindle.
1. Coat all pins, pivot points, and bearing surfaces Modified micrometer to be used when crimp
with thin layer of SAE 20 motor oil per schedule height is specified. See Figure 66.
below:
1 Tool used daily: lubricate weekly
2 Tool used weekly: lubricate monthly

2. Wipe excess oil from tool paying close attention

to crimp area. Oil transferred from crimping area
onto terminations can affect electrical
characteristics of application.

Visual Inspection
NOTE: Manufacturer's replacement and repair
procedures included in documentation received with
tool.
1. Close handles until ratchet releases and handles
open freely. If handles DO NOT open quickly and
fully, the spring is defective and must be replaced.
See Figure 65. If spring is defective, follow
manufacturers' replacement and repair
procedures.

2. Inspect tool for worn, cracked, or broken jaws. If

jaws are damaged follow manufacturers'
replacement and repair procedures.

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AMP Fastin-Faston Hand Tools 2200 YRM 1128

4. Using modified micrometer, measure wire barrel

crimp height as shown in Figure 67. If crimp
height matches measurement in Table 11, the tool
is considered dimensionally correct. If not, follow
manufacturers' replacement and repair
procedure.

NOTE: SAMPLE READING SHOWN IN ILLUSTRA-

TION EQUALS 3.489 mm (0.1374 in.).
1. POSITION POINT ON CENTER OF WIRE
1. ANVIL BARREL OPPOSITE SEAM
2. SPINDLE 2. MODIFIED ANVIL
3. STATIONARY HANDLE 3. CRIMP HEIGHT (SEE TABLE 11)
4. MOVABLE HANDLE
5. TYPICAL CONTACT Figure 67. Crimp Height

Figure 66. Modified Micrometer Certi-Crimp Ratchet Inspection

2. Use Table 11 to select maximum size wire for The ratchet on this tool should be checked to ensure it
each crimping chamber. does not release prematurely, allowing jaws to open
before they have fully bottomed. Use a
Table 11. Wire Size and Crimp Height 0.025 mm (0.001 in.) shim suitable for checking
clearance between bottoming surfaces of crimping
Crimp Wire Size Crimp Height jaws.
Chamber (AWG)
1.27 ±0.076 mm (0.05 1. Select receptacle and maximum size wire for
A 18-20 tool.
±0.003 in.)
1.65 ±0.076 mm 2. Position receptacle and wire between jaws as
B 14-16
(0.065 ±0.003 in.) shown in Figure 68.

3. Crimp receptacle onto selected wire according to

How to Use AMP Double Action Hand Tool
procedure.

122
2200 YRM 1128 AMP Fastin-Faston Hand Tools

Legend for Figure 68.

A. RECEPTACLE BARREL ALIGNMENT

1. RECEPTACLE CRIMPING BARREL

2. STRIPPED WIRE
3. WIRE CRIMPING JAW
4. INSULATION CRIMPING JAW
5. BACK SIDE OF TOOL

3. While holding wire in position, squeeze tool

handles together until ratchet releases. Hold
handles in closed position.

4. Check clearance between bottoming surfaces of

crimping jaws. If clearance is
0.025 mm (0.001 in.) or less, the ratchet is
satisfactory. If clearance exceeds
0.025 mm (0.001 in.) follow manufacturers'
replacement and repair procedure.

HOW TO USE AMP DOUBLE ACTION

HAND TOOL
NOTE: Wire size and insulation diameter must be
Figure 68. Crimp Alignment within specified range for receptacle. See Table 12.

1. Strip insulation from wire. See Table 12 and

Figure 69.

Table 12. Wire Strip Length

Crimp Wire Size Strip Insulation
Chamber (AWG) Length Diameter
20-16 4.2 to 5.2 mm (0.16 to 0.20 in.)
B 2.2 to 3.1 mm (0.09 to 0.12 in.)
18-14 5.1 to 6.1 mm (0.20 to 0.24 in.)

123
AMP Fastin-Faston Hand Tools 2200 YRM 1128

4. Insert receptacle barrel into crimping area as

shown in Figure 68.

5. Squeeze tool handles together just enough to

hold receptacle in place.

NOTE: Make sure insulation DOES NOT enter wire

barrel.
6. Insert stripped wire into receptacle crimping barrel
from BACK of tool.

7. While holding wire position, squeeze tool handles

together until ratchet releases. Open tool handles
and remove crimped receptacle.
1. WIRE BARREL
2. INSULATION BARREL DESCRIPTION - AMP EXTRACTION TOOL
3. LOCATOR SLOT Extraction tools are designed to release locking lance
4. WIRE STRIP LENGTH (SEE TABLE 12)
inside connector housing without damaging housing or
Figure 69. Wire and Receptacle connectors. The extraction tip is used with the
universal handle as shown in Figure 70. Extraction tip,
2. Hold tool so BACK side is facing you. installed, is aligned with mating face of connector
housing to depress locking lance of receptacle holding
3. Release tool handles by squeezing them together it in housing.
until ratchet releases.

1. UNIVERSAL HANDLE 2. EXTRACTION TIP 3. DRIVE SCREW

Figure 70. AMP Extraction Tool With Tip

MAINTENANCE AND INSPECTION regular intervals, refer to manufacturers data for

specifics.
For proper operation, tool to conform to measurements
indicated in Figure 71. Inspections to be performed at

124
2200 YRM 1128 AMP Fastin-Faston Hand Tools

A. TOP VIEW B. SIDE VIEW

Figure 71. Tool Tip Inspection

Clean extraction tool with clean, soft, lint-free cloth and 3. Push wire from BACK of housing TOWARD tool
store in clean, dry place. and depress locking lance. See view C of
Figure 72.
HOW TO USE AMP EXTRACTION TOOL
4. Pull BACK on wire and remove receptacle from
It is necessary to depress locking lance of receptacle housing. See view D of Figure 72.
from its cavity inside connector housing. Procedure
below describes steps of extraction. 5. Remove extraction tool from housing.
1. Orient extraction tool tip with mating face of
connector. See view A of Figure 72.

2. Insert tip of extraction tool, aligned in center of

housing cavity where locking lance is located.
See view B of Figure 72.

125
AMP Fastin-Faston Receptacles and Housings 2200 YRM 1128

A. EXTRACTION TOOL ORIENTATION C. WIRE DEPRESSIONS

B. TOOL TIP ALIGNMENT D. RECEPTACLE REMOVAL

1. EXTRACTION TOOL 3. RECEPTACLE

2. HOUSING 4. LOCKING LANCE

Figure 72. Contact Extraction

AMP Fastin-Faston Receptacles and Housings

DESCRIPTION
This manual section covers FASTIN-FASTON
receptacle installation. These connectors are the
multiple circuit connectors use primarily as wire
harness connectors.

CAUTION
DO NOT nick, scrape, or cut the wire conductor
during the striping operation.

1. Install receptacles as specified in How to Use

AMP Double Action Hand Tool. See Figure 73 for
tool image.

Figure 73. AMP Double Action Hand Tool

2. Receptacle contact should appear as shown in

Figure 74.

126
2200 YRM 1128 AMP Fastin-Faston Receptacles and Housings

A. WIRE CONDUCTORS AND INSULATION BOTH C. INSULATION BARREL CRIMP WIDTH

VISIBLE IN THIS AREA
B. CONDUCTOR VISIBLE

1. FRONT BELLMOUTH 5. WIRE BARREL CRIMP HEIGHT

2. CRIMP LENGTH 6. WIRE BARREL FLASH
3. REAR BELLMOUTH 7. CUTOFF TAB
4. WIRE BARREL CRIMP WIDTH 8. MAX BURR

Figure 74. Typical Crimped Receptacle

a. The most critical and compressed area is the

crimp applied to the wire portion of the contact
to ensure optimum electrical and mechanical
performance of crimped receptacle. See
Figure 75 and Table 13.

127
AMP Fastin-Faston Receptacles and Housings 2200 YRM 1128

Legend for Figure 75.

1. WIRE INSULATION
2. STRIP LENGTH (SEE TABLE 13)

Figure 75. Wire Strip Length

Table 13. Wire Strip Length and Crimp Measurements

Insulation Wire Barrel Insulation Barrel

Wire Size (AWG) Strip Length
Diameter Crimp Width Crimp Height Crimp Width
1.52 to 2.54 mm 2.49 to 2.59 mm
(0.06 to 0.10 in.) (0.98 to
5.82 to 6.48 mm 2.24 to 2.34 mm 1.07 to 1.32 mm 0.102 in.)
20 (0.229 to (0.088 to (0.042 to
2.16 to 3.18 mm 0.255 in.) 0.092 in.) 0.052 in.) 3.5 to 3.61 mm
(0.085 to (0.138 to
0.125 in.) 0.142 in.)

128
2200 YRM 1128 AMP Fastin-Faston Receptacles and Housings

Table 13. Wire Strip Length and Crimp Measurements (Continued)

Insulation Wire Barrel Insulation Barrel

Wire Size (AWG) Strip Length
Diameter Crimp Width Crimp Height Crimp Width
3.05 to 4.32 mm 6.23 to 6.48 mm
(0.120 to (0.245 to
0.170 in.) 0.255 in.)
3.05 to 4.06 mm 1.5 to 1.6 mm 4.01 to 4.11 mm
(0.120 to (0.059 to (0.158 to
0.160 in.) 0.063 in.) 0.162 in.)
3.5 to 3.68 mm 2.74 to 2.84 mm
(0.120 to (0.108 to
0.145 in.) 5.41 to 5.66 mm 0.112 in.)
(0.213 to
0.223 in.) 1.37 to 1.42 mm 4.52 to 4.62 mm
(0.054 to (0.178 to
2.54 to 4.42 mm 0.058 in.) 0.182 in.)
(0.100 to
0.170 in.) 1.47 to 1.57 mm 4.01 to 4.11 mm
(0.054 to (0.158 to
0.062 in.) 0.162 in.)
18
6.22 to 6.48 mm 1.35 to 1.45 mm
(0.245 to (0.053 to
2.16 to 3.18 mm 0.255 in.) 0.057 in.) 3.5 to 3.61 mm
(0.085 to (0.138 to
0.125 in.) 5.82 to 6.07 mm 1.17 to 1.27 mm 0.142 in.)
(0.229 to (0.046 to
0.239 in.) 2.24 to 2.34 mm 0.050 in.)
(0.088 to
6.22 to 6.48 mm 0.092 in.) 1.35 to 1.45 mm
(0.245 to (0.053 to
1.52 to 2.54 mm 0.255 in.) 0.057 in.) 2.49 to 2.59 mm
(0.060 to (0.098 to
0.100 in.) 5.82 to 6.07 mm 1.17 to 1.27 mm 0.102 in.)
(0.229 to (0.046 to
0.239 in.) 0.050 in.)
2.2 to 4.44 mm 5.1 to 6.1 mm 2.74 to 2.84 mm 1.42 to 1.52 mm 4.52 to 4.62 mm
(0.090 to (0.200 to (0.108 to (0.056 to (0.178 to
0.175 in.) 0.240 in.) 0.112 in.) 0.060 in.) 0.182 in.)

129
AMP Fastin-Faston Receptacles and Housings 2200 YRM 1128

Table 13. Wire Strip Length and Crimp Measurements (Continued)

Insulation Wire Barrel Insulation Barrel

Wire Size (AWG) Strip Length
Diameter Crimp Width Crimp Height Crimp Width
4.06 to 5.33 mm 1.5 to 1.83 mm 6.3 to 6.4 mm
(0.160 to (0.059 to (0.248 to
0.210 in.) 0.072 in.) 0.252 in.)
3.81 to 4.83 mm 5.82 to 6.07 mm 3.0 to 3.11 mm 1.73 to 1.83 mm 5.28 to 5.38 mm
(0.150 to (0.229 to (0.118 to (0.068 to (0.208 to
0.190 in.) 0.239 in.) 0.122 in.) 0.072 in.) 0.212 in.)
3.3 mm 1.85 to 2.18 mm 6.3 to 6.4 mm
(0.130 in.)MAX (0.073 to (0.248 to
(2 Wires) 0.086 in.) 0.252 in.)
3.05 to 4.32 mm 6.22 to 6.48 mm
(0.120 to (0.245 to
0.170 in.) 0.255 in.)
3.05 to 4.06 mm 1.65 to 1.75 mm 4.01 to 4.11 mm
16 (0.120 to (0.065 to (0.158 to
0.160 in.) 0.069 in.) 0.162 in.)
3.05 to 3.68 mm
(0.120 to
0.145 in.) 5.41 to 5.66 mm 2.74 to 2.84 mm
(0.213 to (0.108 to
0.223 in.) 0.112 in.) 1.32 to 1.42 mm 4.52 to 4.62 mm
(0.052 to (0.178 to
2.54 to 4.32 mm 0.056 in.) 0.182 in.)
(0.100 to
0.170 in.) 1.6 to 1.7 mm 4.01 to 4.11 mm
(0.063 to (0.158 to
0.067 in.) 0.162 in.)
2.2 to 4.44 mm 5.1 to 6.1 mm 1.57 to 1.68 mm 4.52 to 4.62 mm
(0.090 to (0.200 to (0.062 to (0.178 to
0.175 in.) 0.240 in.) 0.066 in.) 0.182 in.)

130
2200 YRM 1128 AMP Fastin-Faston Receptacles and Housings

Table 13. Wire Strip Length and Crimp Measurements (Continued)

Insulation Wire Barrel Insulation Barrel

Wire Size (AWG) Strip Length
Diameter Crimp Width Crimp Height Crimp Width
4.06 to 5.33 mm 1.7 to 2.03 mm 6.3 to 6.4 mm
(0.106 to (0.067 to (0.248 to
0.210 in.) 6.22 to 6.45 mm 3.0 to 3.1 mm 0.080 in.) 0.252 in.)
(0.245 to (0.118 to
3.81 to 4.83 mm 0.255 in.) 0.122 in.) 1.93 to 2.03 mm 5.28 to 5.38 mm
(0.150 to (0.076 to (0.208 to
0.190 in.) 0.080 in.) 0.212 in.)
7.01 to 7.26 mm 2.74 to 2.84 mm 1.88 to 1.98 mm 4.01 to 4.11 mm
(0.276 to (0.108 to (0.074 to (0.158 to
3.05 to 4.32 mm 0.286 in.) 0.112 in.) 0.078 in.) 0.162 in.)
(0.120 to
0.170 in.) 6.60 to 6.86 mm 3.25 to 3.35 mm 1.78 to 1.88 mm 4.52 to 4.62 mm
(0.260 to (0.128 to (0.070 to (0.178 to
0.270 in.) 0.132 in.) 0.074 in.) 0.182 in.)
3.05 to 4.06 mm 4.01 to 4.62 mm
14 (0.120 to (0.158 to
0.160 in.) 1.88 to 1.98 mm 0.182 in.)
(0.074 to
3.05 to 3.68 mm 0.078 in.) 4.01 to 4.11 mm
(0.120 to (0.158 to
0.145 in.) 5.82 to 6.07 mm 0.162 in.)
(0.229 to
0.239 in.) 2.74 to 2.84 mm 1.55 to 1.65 mm 4.52 to 4.62 mm
(0.108 to (0.061 to (0.178 to
2.54 to 4.32 mm 0.112 in.) 0.065 in.) 0.182 in.)
(0.100 to
0.170 in.) 1.83 to 1.93 mm 4.01 to 4.11 mm
(0.072 to (0.158 to
0.076 in.) 0.162 in.)
2.2 to 4.44 mm 5.1 to 6.1 mm 1.8 to 1.9 mm 4.52 to 4.62 mm
(0.090 to (0.201 to (0.071 to (0.178 to
0.175 in.) 0.240 in.) 0.075 in.) 0.182 in.)

b. Crimp length must be within dimensions c. Front and rear bellmouths to match images
indicated in Table 13. and dimensions shown in Figure 76.

131
AMP Fastin-Faston Receptacles and Housings 2200 YRM 1128

A. WIRE CONDUCTORS AND INSULATION BOTH C. INSULATION BARREL CRIMP WIDTH

VISIBLE IN THIS AREA
B. CONDUCTOR VISIBLE

1. FRONT BELLMOUTH 5. WIRE BARREL CRIMP HEIGHT (SEE TABLE 13)

2. CRIMP LENGTH (SEE TABLE 13) 6. WIRE BARREL FLASH
3. REAR BELLMOUTH 7. CUTOFF TAB
4. WIRE BARREL CRIMP WIDTH (SEE TABLE 13) 8. MAX BURR

Figure 76. Typical Crimp - Fastin-Faston Receptacle

d. The cutoff tab to be cut as shown in Figure 76. h. Conductor may extend beyond wire barrel to
maximum dimension shown in Figure 76.
e. Max burr on cutoff tab shall not exceed
dimensions indicated in enlarged view of i. Wire barrel seam to be closed, no loose wire
Figure 76. strands visible.

f. Acceptable dimensions for wire barrel flash j. There shall be no twist, roll, deformation, or
shown in section A-A, Figure 76. other damage to mating portion of crimped
receptacle that will prevent proper mating. See
g. After crimping, wire conductor and insulation to Figure 77.
be visible in areas shown in Figure 76.

132
2200 YRM 1128 AMP Fastin-Faston Receptacles and Housings

3. Crimped receptacle should hold wire firmly and

have a pull-test tensile value as specified in
Table 14.

Table 14. Crimp Pull-Out Test

Wire Size Minimum Force

(AWG) Newtons Pounds
20 57.8 13
18 89.0 20
16 133.4 30
14 222.4 50
1. FRONT OF RECEPTACLE
2. WIRE BARREL 4. Damaged crimped receptacles or housings must
be removed, discarded, and replaced with new
Figure 77. Mating Portion components. See Figure 79 and Figure 80 for
tools used during removal.
k. Force applied during crimping can cause
bending between the crimped wire barrel and
mating portion of receptacle. Bending is
acceptable within limits shown in Figure 78.

Figure 79. AMP Extraction Tool Universal Handle

NOTE: ANGLES DRAWN FOR CLARIFICATION ON-

LY, NOT TO SCALE. ANGLES ARE MAXIMUM DIS-
TANCE FROM DATUM LINE.

A. UP AND DOWN B. SIDE TO SIDE

1. DATUM LINE

Figure 78. Receptacle Bending Limits

133
Wire Repair 2200 YRM 1128

5. For procedure to remove receptacles for

connector housings, see How to Use AMP
Extraction Tool section.

Figure 80. AMP Extraction Tool Tip

Wire Repair
WIRE SPLICING REQUIREMENTS 4. 12 to 14 Gauge wire in area allowing
12.7 mm (0.5 in.) diameter × 63.5 mm (2.5 in.)
Refer to the following for determining which procedure long splice - use Deutsch jiffy splice.
to use for wire repairs.
5. 14 to 20 Gauge wire in area allowing
1. 8 Gauge or heavier wire - no splicing, replace full 9.78 mm (0.385 in.) diameter ×
length of wire or replace harness. 62.74 mm (2.47 in.) long splice - use Deutsch jiffy
splice.
2. Wires not meeting requirements of Step 3 through
Step 5 - no splicing, replace full length of wire or
replace harness.

3. 10 to 20 Gauge wire in area allowing use of a

heat gun - repair using Del-City crimp-solder-
shrink splice.

Table 15. Wire Strip Length Specifications

Contact Part Number Type Wire Gauge Range Recommended Strip Length
580039516 Pin 20 AWG (0.5 mm ) 2 3.96 to 5.54 mm (0.156 to 0.218 in.)
580039517 Socket 20 AWG (0.5 mm2) 3.96 to 5.54 mm (0.156 to 0.218 in.)
580094445 Pin 20 AWG (0.5 mm2) 4.0 to 5.5 mm (0.157 to 0.217 in.)
505972554 Pin 16 to 20 AWG (1.0 to 0.5 6.35 to 7.92 mm (0.250 to 0.312 in.)
mm2)
505064713 Socket 16 to 20 AWG (1.0 to 0.5 6.35 to 7.92 mm (0.250 to 0.312 in.)
mm2)
580082335 Pin 16 to 20 AWG (1.0 to 0.5 6.4 to 7.9 mm (0.252 to 0.311 in.)
mm2)
580082337 Socket 16 to 20 AWG (1.0 to 0.5 6.4 to 7.9 mm (0.252 to 0.311 in.)
mm2)
520038865 Pin 14 AWG (2.0 mm2) 6.35 to 7.92 mm (0.250 to 0.312 in.)

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Table 15. Wire Strip Length Specifications (Continued)

Contact Part Number Type Wire Gauge Range Recommended Strip Length
505064747 Socket 14 AWG (2.0 mm2) 6.35 to 7.92 mm (0.250 to 0.312 in.)
580079525 Socket 14 AWG (2.0 mm2) 6.4 to 7.9 mm (0.252 to 0.311 in.)
150121835 Pin 12 to 14 AWG (3.0 to 2.0 5.64 to 7.21 mm (0.222 to 0.284 in.)
mm2)
580050627 Socket 12 to 14 AWG (3.0 to 2.0 5.64 to 7.21 mm (0.222 to 0.284 in.)
mm2)

DEUTSCH JIFFY SPLICE

This splicing procedure adds 19.05 mm (0.75 in.) to
the length of the wire and may be used when slight
lengthening of the wire is desired.

Assemble
STEP 1.
Strip both wire ends to the specifications in
Table 15.

STEP 2.
On one wire, crimp the appropriate pin onto the
wire using the Deutsch Crimping Tool (Yale P/N
150121900 ). See How to Crimp With the Deutsch
Crimping Tool.

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Wire Repair 2200 YRM 1128

STEP 3.
On second wire, crimp the appropriate socket
onto the wire using the Deutsch Crimping Tool
(Yale P/N 150121900 ). See How to Crimp With
the Deutsch Crimping Tool.

STEP 4.
Insert the wire with the socket contact into one
end of the jiffy splice.

STEP 5.
Push the contact into the jiffy splice until a
positive stop is felt. An audible snap will occur
when correctly installed. Slightly tug the wire to
verify the wire is properly locked in place.

STEP 6.
Insert the wire with the pin contact into opposite
end of the jiffy splice.

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2200 YRM 1128 Wire Repair

STEP 7.
Push the contact into the jiffy splice until a
positive stop is felt. An audible snap will occur
when correctly installed. Slightly tug the wire to
verify the wire is properly locked in place.

Disassemble
STEP 1.
Insert appropriate Deutsch extraction tool over the
wire being removed.

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Wire Repair 2200 YRM 1128

NOTE: Do not twist the tool or insert the tool at an

angle.
STEP 2.
Push the tool into the splice connector about
25 mm (1 in.), until it bottoms on the contact
flange.

NOTE: If pin is difficult to remove, remove the extraction tool, turn the extraction tool 90 degrees and reinsert the
tool into the connector.

STEP 3.
Hold the tool on the contact flange and pull the
wire and the connection socket or pin out of the
connector.

STEP 4.
Repeat Step 1 through Step 3 on opposite end.

DEL-CITY CRIMP-SOLDER-SHRINK SPLICE

Refer to Table 16 for the correct splice part number for the wire gauge being repaired.

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2200 YRM 1128 Wire Repair

Table 16. Wire Splice Size

Part Number Wire Gauge Range
150121847 10 to 12 AWG (5.0 to 3.0 mm2)
150121848 14 to 16 AWG (2.0 to 1.0 mm2)
150121849 18 to 20 AWG (0.8 to 0.5 mm2)

STEP 1.
Strip approximately 9.525 mm (0.375 in.) from
both wire ends.

CAUTION
Do not crimp solder sleeve in the center of the
connector. This will make the connector
unserviceable.

STEP 2.
Insert one wire into the connector. Make sure wire
is properly seated and crimp the connector using
an insulated connector crimping tool nest that
matches the color or gauge of the connector.
1. SOLDER SLEEVE 2. CRIMP POINT

CAUTION
Do not crimp solder sleeve in the center of the
connector. This will make the connector
unserviceable.

STEP 3.
Insert the second wire into the opposite end of the
connector. Make sure wire is properly seated and 1. CRIMP POINT
crimp the connector using an insulated connector
crimping tool nest that matches the color or gauge
of the connector.

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Twisted/Shielded Cable and Leads Repair 2200 YRM 1128

STEP 4.
Using a heat gun, apply heat evenly, to
approximately 135°C (275°F), around the length
of the tubing (including the crimp area) from the
center out to the ends until the tubing fully
recovers and adhesive flows.
Continue distributing the heat over the solder
sleeve until solder flows into the terminal barrel.
Remove from the heat and let cool for ultimate
connection performance.

1. EXPOSED NOTCHES AFTER SOLDER BAND

MELTS

Twisted/Shielded Cable and Leads Repair

TWISTED/SHIELDED CABLE REPAIR

STEP 1.
Remove outer jacket.

STEP 2.
Unwrap aluminum mylar tape. Do not remove
mylar tape.

1. DRAIN WIRE
2. OUTER JACKET
3. MYLAR

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2200 YRM 1128 Twisted/Shielded Cable and Leads Repair

STEP 3.
Untwist conductors and strip insulation as
necessary.

STEP 4.
Splice wires using splice clips and rosin core
solder. Wrap each splice to insulate.

1. SPLICE AND SOLDER

STEP 5.
Splice the drain (uninsulated) wire using splice
clip and rosin core solder.

STEP 6.
Wrap with mylar and drain (uninsulated) wire.

1. DRAIN WIRE

STEP 7.
Apply electrical tape over whole bundle to secure.

TWISTED LEADS REPAIR

STEP 1.
Locate damaged wire and remove insulation as
required.

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Special Tools 2200 YRM 1128

STEP 2.
Splice the two wires using splice clips and rosin
core solder.

1. SPLICE AND SOLDER

STEP 3.
Cover splice with electrical tape to insulate from
other wires.

STEP 4.
Twist and tape with electrical tape.

Special Tools

Illustration Tool Description

Not Illustrated Deutsch Connector Kit - Yale P/N 150121833
Not Illustrated Deutsch Connector/ Crimp/ Stripper Kit - Yale
P/N 150121822
Wire Stripper - Yale P/N 150121841. Used for
stripping wires.

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2200 YRM 1128 Special Tools

Illustration Tool Description

Wire Stop for Wire Stripper - Yale P/N 150121842

Wire Crimping Pliers - Used for crimping

connectors (except Deutsch and AMP connectors)

Deutsch Hand Crimping Tool - Yale P/N

150121900. Used for crimping pins and sockets for
Deutsch connectors.

Deutsch Wedge Removal Tool - Yale P/N

150121838. Used to remove secondary lock for
Deutsch connectors.

Yellow Extracting Tool - Yale P/N 150121836.

Used to repair Deutsch HD 12 to 14 AWG
connectors.

Orange Extracting Tool (E-Seal) - Yale P/N

150121843. Extra thin wall tool. Used to repair
Deutsch HD 12 to 14 AWG connectors.

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Special Tools 2200 YRM 1128

Illustration Tool Description

Light Blue Extracting Tool - Yale P/N 150121834.
Used to repair Deutsch HD 16 to 18 AWG
connectors.

Dark Blue Extracting Tool (E-Seal) - Yale P/N

150121844. Extra thin wall tool. Used to repair
Deutsch HD 16 to 18 AWG connectors.

Red Extracting Tool - Yale P/N 150121845. Used

to repair Deutsch HD 20 to 24 AWG connectors.

Deutsch G454 Testing Tool - Yale P/N

150121846. Used to check calibration of Deutsch
Hand Crimping Tool

Flat Blade Screwdriver - Used to open wedge lock

for AMP plug connectors

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2200 YRM 1128 Special Tools

Illustration Tool Description

AMP Hand Crimping Tool - Yale P/N 580093883,
(AMP P/N 58440-1). Use for crimping AMPSEAL
contacts

AMP Pro-Crimper II - Yale P/N 580096885. With

Die Set, Yale P/N 580093884. Use for crimping
AMPSEAL contacts

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Special Tools 2200 YRM 1128

Illustration Tool Description

AMP Extracting Tool - Yale P/N 580093887. AMP
Receptacle and Tab Contact Extraction Tool for
AMPSeal connectors

AMP Extracting Tool - Yale P/N 580093886. AMP

Tab Contact Extraction Tool for AMPSeal
connectors

AMP Hand Application Tool - Yale P/N

580093888. With Die Set, Yale P/N 580093889.
Use for crimping AMP Superseal 1.5 Series
Contacts

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2200 YRM 1128 Special Tools

Illustration Tool Description

AMP Pro-Crimper II - Yale P/N 580093890. With
Die Set, Yale P/N 580093891. Used for crimping
AMP Superseal 1.5 Series Contacts

Heat Gun - Used to repair connector wires.

Tool Kit for Terminal Repair - Terminals cannot be

removed from their connectors or repaired without
special tools. This kit has the special removal and
installation tools and crimping tools required to
make repairs in Micro-Pack, Metri-Pack, and
Weather-Pack connectors. This repair kit does not
have the terminals or the connectors.

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Special Tools 2200 YRM 1128

Illustration Tool Description

AMP Double Action Hand Tool - Yale P/N
580094770. Use for crimping Fastin-Faston
receptacle connectors.

AMP Universal Handle Assembly with Strap -

Yale P/N 580094772. Use with Extraction Tool Tip
for Fastin-Faston receptacle connector extraction
from connector housings.

AMP Extraction Tool Tip - Yale P/N 580094771.

Use with Universal Handle Assembly for Fastin-
Faston receptacle connector extractions.

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2200 YRM 1128 3/20 (11/19)(6/19)(6/18)(4/18)(12/17)