FOR M-23A AND M-238 SWITCH MACHINES WIRE HARNESS ASSEMBLY PROCEDURE TRAINING MANUAL AUGUST, 1989 ID0236F/DN0079F A-8/

Transcription

1 TRAINING MANUAL WIRE HARNESS ASSEMBLY PROCEDURE FOR M-23A AND M-238 SWITCH MACHINES AUGUST, 1989 ID0236F/DN0079F A-8/ tiuoo COR.POl1A1E DlllVl PlnSBlJRGH, PA l~;!:ii' COPYRIGHT 1!Hl!l, UNION SWITCH ti. SIGNAL INC PRINTED IN USA

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3 ( TRAINING MANUAL WIRE HARNESS ASSEMBLY PROCEDURE I FOR M-23A AND M-23B SWITCH MACHINES AUGUST,1989 ID0236F/DN0079F A-8/ CORPORATE DRIVE PlTISBURGIL. PA COPYRIGHT Hltl9, UNION SWITCH;. SIGNAL INC PRINlED IN USA

4 REVISION INDEX Revised pages of this manual are listed below by page number and date of revision. ( Page Number Date of Revision Revision Number ( i ;

5 CONTENTS Section Page I, GENERAL 1.1 PURPOSE 1 II, SUBASSEMBLIES GENERAL INDIVIDUAL WIRE LEAD ASSEMBLY AND TEST Lead A Assembly Lead A Test III, FINAL ASSEMBLY 3. 1 ASSEMBLY OF HARNESS COMPLETE 6 IV, TOOLS AND MATERIAL REQUIRED GENERAL TOOLS AND TEST EQUIPMENT REQUIRED MATERIALS REQUIRED APPENDIX A A,l HARNESS ASSEMBLY N A,2 HARNESS ASSEMBLY N A,3 HARNESS ASSEMBLY N A,4 HARNESS ASSEMBLY N A2 A4 A6 AB APPENDIX B APPENDIX C WIRE PREPARATION GUIDELINES SOLDERLESS CRIMP TERMINAL GUIDELINES Bl Cl iii

6 LIST OF ILLUSTRATIONS M23A AND M23B SWITCH MACHINE WIRE HARNESS, Figure Title Page 2-1 Marker Card J /4 3-1 N Harness Assembly 7 A-1 N Harness Assembly A3 A-2 N Harness Assembly AS A-3 N Harness Assembly A7 A-4 N Harness Assembly A9 ( iv

7 SECTION I GENERAL 1,1 PURPOSE The purpose of this Training Manual is to describe the procedure for assembling Harness Pc. No. N required for a L,H, M23A Switch Machine Pc, No, N Harness assembly N is shown on Dwg, C9190 Sh, 79, For assembly details of other switch machine Harnesses, refer to the previously mentioned drawing, the switch machine Bill of Material, and the Tables provided in Appendix A,

8 SECTION II SUBASSEMBLIES 2, l GENERAL This section will describe the assembly procedure for the Individual Wire Leads required for Harness assembly N ,2 INDIVIDUAL WIRE LEAD ASSEMBLY AND TEST Assemble and test each of the 22 leads, A thru x, in the order listed in Table 2-1 by completing the steps outlined below for Lead A, Letters I and o have purposely been omitted from the wire lead tabulation in Table 2-1, NOTE USE SPEC, M BLACK WIRE A and A FOR #14 AWG AND #12 AWG WIRE LEADS RESPECTIVELY, FOR LEADS B THRU X REFER TO TABLE 2-1 FOR SPECIFIC WIRE SIZE AND LENGTH, A, Lead A Assembly From a reel of #14 AWG Black wire A , cut off a 24-1/2 inch length of wire as called for in Table 2-1 for Lead A, NOTE PRIOR TO PERFORMING STEP B, REFER TO APPENDICES BAND C FOR WIRE STRIPPING AND SOLDERLESS CRIMP TERMINATION GUIDELINES, B, Using a certified wire stripping tool, remove only the proper amount of insulation from both ends of the 24-1/2 inch length of wire and apply an AMP PIDG terminal J to each end of the wire using AMP Tool 47387, NOTE WHEN HARNESS LEAD IS TO BE MADE WITH #12 AWG BLACK WIRE A , APPLY AMP TERMINAL J TO EACH END OF THE WIRE USING AMP TOOL # , C, Using the markers provided on cards J and J shown in Figure 2-1, apply marker with the 12 nomenclature to one end of Lead A, and marker with the 25 nomenclature to the other end of Lead A, Wire markers are to be positioned adjacent the AMP Terminals on each end of Lead A, NOTE FOR LEADS B THRU X, THE NOMENCLATURE APPLIED TO THE ENDS OF EACH LEAD SHOULD lle AS SHOWN IN TABLE 2-1, D, This completes the assembly of Lean A, }

9 UNION SWITCH & SIGNAL m LEAD STEP WIRE SIZE NUMBER A 14 B 14 c 14 D 12 E 14 F 14 G 14 H 14 J 14 K 12 L 14 M 14 N 14 p 14 Q 14 R 14 s 14 T 12 u 14 v 12 w 14 x 12 * REFER TO TEXT & FIGURE 3-1 TABLE 2-1 HARNESS ASSEMBLY N la * STEP lb * AMP. LENGTH TERMINAL (inches) PC. NUMBER 24-1/2 J /4 J J J /2 J J /2 J /4 J /2 J /4 J /4 J J J /4 J /4 J /4 J /4 J /2 J J /4 J J /4 J STEP lc * LEAD NOMENCLATURE TERM BRD. CIR CON. END END H2 37 Hl UJ I i J S. & LMOVT. ( ~~~~~~ M-2,M-W M , ' HI H2 I A ~... PJ'I Pl'2. ~... ~ I ~~~"')~rt') N,J f\lnn(u \ -... J Figure 2-1 3/4

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11 Lead A Test Lead A is to be tested in accordance with the following, then placed on Cable Form Board (Tl2002) prior to proceeding with the assembly of Lead B, NOTE INTEGRITY OF EACH LEAD IS TO BE VERIFIED USING EITHER A BATTERY/BUZZER UNIT OR A SIMPSON 260 OHMMETER, IF AN OHMMETER IS USED, THE RESISTANCE SCALE SELECTED SHOULD BE THE LOWEST SCALE AVAILABLE WHICH, IN THE CASE OF THE SIMPSON 260, IS THE RX 1 SCALE, A, With the leads of the test device applied to the AMP Terminals of Lead A, the integrity of Lead A may be considered verified if a normal buzzer tone is heard or a zero reading is obtained with the ohmmeter. The application of the AMP Terminal should be checked on each end of Lead A if there is any deviation in the buzzer tone or the ohmmeter reading described in the preceeding paragraph, B, With the integrity verified, Lead A is complete and should be placed on the Cable Form Board (T#2002), C, Repeat Sections 2,2,1 and 2,2,2 for the remaining leads, B thru X,

12 SECTION III FINAL ASSEMBLY 3,1 HARNESS ASSEMBLY N DWG, C9190 SH, 79 1, As each lead is completed and tested, it should be placed on Cable Form Board (T#2002) in the order tabulated, i.e., A, B, c, etc,, AS EACH LEAD IS PLACED ON THE CABLE FORM BOARD, CARE MUST BE TAKEN TO ENSURE THE TERMINAL BOARD AND CIRCUIT CONTROLLER NOMENCLATURE ON THE ENDS OF THE LEAD CORRESPOND WITH THE TERMINAL BOARD AND CIRCUIT CONTROLLER LOCATIONS DESIGNATED ON THE CABLE FORM BOARD, 2, With all 22 leads properly placed on the Cable Form Board, securely bind the leads together using Electrical Tape A (black) spirally wrapped and overlapped one-half turn as shown in Figure , This completes the assembly of Harness N which may now be removed from the Cable Form Board, 4. Fill out and wire a tag to harness indicating piece number. 6

13 <,: i "' 0: h, u t, v ~ v N <l. ~., J t :,( ~ '<) ~ ~ 0 "l ~ 1 ' ~..; K Figure 3-1 7

14 SECTION IV TOOLS AND MATERIAL REQUIRED 4,1 GENERAL The tools and material required to assemble the Individual Wire Leads and Harness N are provided in the paragraphs that follow, 4.2 TOOLS AND TEST EQUIPMENT REQUIRED 1. AMP Tool # AMP Tool # , Cable Form Board (T#2002) 4. Battery/buzzer unit or Simpson 260 Multimeter (or equivalent) 4,3 MATERIAL REQUIRED 1, #14 AWG Black wire A (Spec M ) 2, #12 AWG wire A (Spec M ) 3. #14-16 AWG AMP Terminals J , #10-12 AWG AMP Terminals J , Black Electrical Tape A ( 8

15 APPENDIX A Al

16 APPENDIX A INFORMATION FOR OTHER HARNESS ASSEMBLIES A,l HARNESS ASSEMBLY N281550, DRAWING C9190-SH,80 STEP la * STEP lb * STEP lc * WIRE AMP, LEAD NOMENCLATURE LEAD SIZE LENGTH TERMINAL TERM BRO, CIR CON, NUMBER (inches) PC, NUMBER END END A 14 tl-5/8 J B J c /4 J D /4 J u E /4 J F /4 J G /4 J7-rn H J J /4 J H2 K /4 J Hl L J7 < M J N J p J Q J R J s J A 50 T J PJl u J73uu 4 33 PJ2 * REFER TO TEXT & Figure A-1 ( A2

17 "' 0... l/l 0 "' 0 I( 0 "'... < i " ~... FigUrP A-1 A3

18 APPENDIX A (can't) A.2 HARNESS ASSEMBLY N320067, C9190-SH.114 STEP la * STEP 18 * STEP lc * WIRE AMP. LEAD NOMENCLATURE LEAD SIZE LENGTH TERMINAL TERM BRD. CIR CON. NUMBER (inches) PC. NUMBER END END A J07<1 no B /4 J c /2 J D /2 J E J F 14 ~b-1/2 J G J H 14 ~4-1/4 JU/ lb J J K 12 55=1/4 J L /4 J H2 M /2 J Hl N /2 J p /4 J Q /4 J R 14 oq-3/4 J s /4 J T J u /2 J07:Jl v /4 J w /2 J x /4 J * REFER TO TEXT & Figure A-2 NOTE AMP TOOL REQUIRED TO APPLY FLAG TERMINALS TO LEADS AS FOLLOWS: TERMINAL J J TOOL AMP #48040 AMP #48049 A4

19 ( Figur,, A-2

20 APPENDIX A (con't) A.3 HARNESS ASSEMBLY N320069, C9190-SH.115 STEP la * STEP 18 * STEP lc * WIRE AMP. LEAD NOMENCLATURE LEAD SIZE LENGTH TERMINAL TERM BRD. CIR CON. NUMBER (inches) PC. NUMBER END END A /2 J B J c /4 J D /4 J E /4 J F /4 J G /4 J H J J /4 J H2 K /4 J Hl L J M J N J p J Q J R J s J A 50 *REFER TO TEXT & FIGURE A-3 NOTE AMP TOOL REQUIRED TO APPLY FLAG TERMINALS TO LEADS IS AS FOLLOWS: TERMINAL J J TOOL AMP #48040 AMP #48049 A6

21 '...I.. :, ",::t 'r '...~1 :: 6-) t re.., ~ ; ~ ~ ~ h ~ J Figure A-3 A7

22 APPENDIX A (con't) A.4 HARNESS ASSEMBLY N , DRAWING SH.63 STEP la * STEP lb * STEP lc * WIRE AMP. LEAD NOMENCLATURE LEAD SIZE LENGTH TERMINAL TERM BRO. CIR CON. NUMBER (inches) PC. NUMBER END END A /2 J B /4 J c J D J E /2 J F J G /2 J H /4 J J /2 J K /4 J L /4 J H2 M J H2 N J p /4 J Q /4 J R /4 J s /4 J T /2 J u J v /4 J w J y J z /4 J zz /4 J * REFER TO TEXT & Figure A-4 NOTES 1. USED ON LOW VOLTAGE SWITCH MACHINES WITH SPLIT FIELD MOTORS ARRANGED FOR FIVE WIRE CONTROL AND SUITABLE FOR THREE WIRE CONTROL. 2. USE SPEC M BLACK WIRE A WHERE THE TABULATION CALLS FOR #10 AWG. WIRE. 3. NOMENCLATURE TO BE APPLIED TO 'rhe ENDS OF THE INDIVIDUAL LEADS IS ACCOMPLISHED USING THE FOLLOWING CAHDS: Piece No. J J Remarks For 1 thru 33 nomenclature For 34 thru 66 nomenclature ( A8

23 00 ~ "' c...j ' u t :, v u Figure A-4 A9

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25 APPENDIX B WIRE PREPARATION GUIDELINES Prior to making a solderless crimp termination, the end of the wire to be terminated must be properly prepared, i,e,, a portion of the wire insulation must be removed from the end of the wire. Guidelines describing the method for preparing a wire for the application of a solderless crimp terminal are as follows: NOTE ONLY WIRE STRIPPING TOOLS THAT HAVE BEEN QC INSPECTED AND CERTIFIED FOR PRODUCTION ARE TO BE USED TO REMOVE INSULATION FROM THE END(S) OF A WIRE, WIRE STRIPPERS MAY BE EITHER OF THE MULITCONDUCTOR OR ADJUSTABLE TYPE, 1, Remove only the proper amount of insulation from the end of the wire to be terminated, The amount of insulation to be removed is specified in the Instruction Sheet (IS) provided with each AMP Crimp Tool, however, the following may be used as general guidelines: A. Crimp Terminal Without Insulation Support (1) Insulation should be within l/32nd of an inch from the end of the wire barrel into which the wire is inserted, (2) The tip of the bare wire should project no more than l/32nd to l/16th of an inch beyond the wire barrel end opposite the end into which the wire is inserted, B. Crimp Terminal With Insulation Support (1) With the bare end of the wire inserted in the wire barrel such that the tip of the bare wire projects no more than l/32nd to l/16th of an inch beyond the end opposite that into which the wire was inserted, the insulation should be sufficiently contained in the insulation barrel to obtain a good insulation crimp. (2) The bare wire should not be visible at the point at which the wire enters the insulation barrel. 2, When removing insulation from the end of a wire, care must be taken to prevent nicking, scrapping or, in the case of stranded wire, cutting the individual wire strands. In order to prevent damage to the wire, the following should be complied with, based of the type of stripping tool used: A. Multiconductor Stripping Tool (1) Select the wire slot that corresponds with the wire size to be stripped, i.e., #14 slot for #14 AWG wire, #12 slot for #12 AWG wire, etc.. Bl

26 B, Adjustable Stripping Tool (1) Adjust the tool for the wire size to be used, (2) Check the adjustment by performing several strip operations on a sample piece of wire, (3) verify that the insulation is cut cleanly, i,e,, not frayed and the bare wire is not damaged, (4) Repeat the preceeding steps (1) thru (3) as often as necessary to obtain the desired results before proceeding with production work. 3, When using stranded wire, if during the stripping operation the strands unravel, the strands should be trained by twisting to capture all loose strands prior to applying a crimp terminal, B2

27 APPENDIX C SOLDERLESS CRIMP TERMINAL GUIDELINES The guidelines outlined in the paragraphs that follow have been provided in order to ensure a proper crimp is obtained when applying a Solderless Crimp Terminal to the end of a wire. NOTE ONLY CRIMP TOOLS THAT HAVE BEEN QC INSPECTED AND CERTIFIED FOR PRODUCTION ARE TO BE USED TO APPLY SOLDERLESS CRIMP TERMINALS. 1, Initially, verify the following: A. Terminal to be applied is proper for the wire size being used, i.e., the wire size is within the range stamped on the tongue or contact surface of the terminal, B, Correct Crimp Tool is being used to apply the terminal to the wire, This may be verified from the Instruction Sheet supplied with each AMP Crimp Tool. c, Wire has been properly prepared in accordance with guidelines provided in Appendix B, D, Insulation crimp adjustment of the AMP Crimp Tool has been adjusted in accordance with the procedure described in the instruction sheet supplied with the tool. 2. Once the preceeding have been verified, the terminal is applied to the wire as follows: A, Open the crimping dies by squeezing the tool handles until the CERTI-CRIMP ratchet releases. B, With the crimp dies fully open, place terminal in dies so that the wire barrel butts up against the tool locator. c. Squeeze tool handles until terminal is held firmly in place without deforming terminal wire barrel. NOTE WHEN PERFORMING STEP D, DO NOT ALLOW WIRE INSULATION TO ENTER INTO THE TERMINAL. WIRE BARREL, D, Insert stripped wire into terminal wire barrel, hold in place with one hand while squeezing the t0ol handles with the other hand until the ratchet releases. E, Allow tool handles to open and remove termination from tool, Cl

28 3. Upon removal of the crimp termination from the tool, the termination should be mechanically inspected for the following: NOTE REFERENCE SHOULD BE MADE TO QA WORKMANSHIP STANDARDS QC-S-700-4, PAGES 17 THRU 21, WHEN PERFORMING AN INSPECTION OF SOLDERLESS CRIMPED TERMINALS. A. Insulation barrel is in firm contact with wire insulation, insulation is not pierced or distorted due to overcrimping. i.e., B. Insulation sleeve has not been cracked or otherwise damaged over crimping. due to c. Bellmouth and wire strands (1/32 to 1/16 inch) must be visible at the tongue or contact end of the wire barrel. D. Terminal crimped with the crimp exactly parallel to the tongue or contact surface of the terminal. C2