TE Connectivity IDC Hand tool RAST 2.5 User manual

Operation Manual
IDC Hand tool RAST 2.5 and 5
Customer Manual Nr.: 412-94126-1 Rev. A
Customer Manual PN: 744015-5
Language: en (Translation of the original German version)

IDC Hand tool RAST 2.5 and 5
©2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
1/ 55 Operation Manual
744015-5
*Trademark. Other products, logos, and company names used are the property of their respective owners.
The data specified above only serve to describe the product. No statements concerning a
certain condition or suitability for a certain application can be derived from our information.
The information given does not release the user from the obligation of own judgment and
verification. It must be remembered that our products are subject to a natural process of wear and aging
© This document, as well as the data, specifications and other information set forth in it, are the exclu-
sive property of TE Connectivity Ltd.
It may not be reproduced or given to third parties without its consent.
The cover page shows a sample configuration. The delivered product may thus differ from the figure.
The original operation manual is written in German.

IDC Hand tool RAST 2.5 and 5
©2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
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1General information...................................................................................................4
1.1 Copyrights, industrial property rights......................................................................................................4
2Using the operation manual.......................................................................................5
2.1 Abbreviations used.................................................................................................................................5
3General safety instructions........................................................................................6
3.1 Intended use...........................................................................................................................................6
3.2 Improper use..........................................................................................................................................6
3.3 Reasonably foreseeable misuse............................................................................................................6
3.4 Qualification of personnel.......................................................................................................................7
3.5 Safety instructions in this document.......................................................................................................7
3.6 Adhere to the following instructions .......................................................................................................8
3.6.1 General instructions..............................................................................................................8
3.6.2 During operation ...................................................................................................................8
3.6.3 During disposal.....................................................................................................................8
3.7 Obligations of the operator.....................................................................................................................8
4Scope of delivery.......................................................................................................9
5Product description..................................................................................................10
5.1 Handled connectors .............................................................................................................................10
6Content of case.......................................................................................................11
6.1 Components overview..........................................................................................................................11
6.2 Construction of the hand tool...............................................................................................................12
6.3 Construction of the tool heads .............................................................................................................13
6.3.1 AMP DUOPLUG 2.5 Mark II...............................................................................................13
6.3.2 AMP DUOPLUG 2.5 Power................................................................................................14
6.3.3 AMP multifitting Mark II.......................................................................................................15
6.3.4 AMP MONO-SHAPE Mark II ..............................................................................................16
6.3.5 AMP MONO-SHAPE Mark I ...............................................................................................17

IDC Hand tool RAST 2.5 and 5
©2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
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7Using the table mounting.........................................................................................18
8Preparation of the connector...................................................................................20
9Making a connection................................................................................................23
9.1 AMP DUOPLUG 2.5 Mark II.................................................................................................................23
9.2 AMP DUOPLUG 2.5 Power .................................................................................................................29
9.3 AMP multifitting Mark II........................................................................................................................34
9.4 AMP MONO-SHAPE Mark II................................................................................................................40
9.5 AMP MONO-SHAPE Mark I.................................................................................................................46
10 Maintenance and Repair .........................................................................................52
10.1 Daily Maintenance................................................................................................................................52
10.2 Periodically Maintenance.....................................................................................................................52
11 Disposal...................................................................................................................53
12 Troubleshooting.......................................................................................................54
13 Appendix .................................................................................................................55
13.1 Contact information..............................................................................................................................55

IDC Hand tool RAST 2.5 and 5
©2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
4/ 55 Operation Manual
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1 General information
1.1 Copyrights, industrial property rights
© This document, as well as the data, specifications and other information set forth in it,
are the exclusive property of TE Connectivity Ltd.
It may not be reproduced or given to third parties without its consent.
This manual is exclusively meant for the carrier of the „IDC Hand tool RAST 2.5 and 5“
(in further course called “IDC Hand tool”) and its personnel for internal use only.
The additional device-specific manual includes descriptions, engineering drawings, instructions and
references, that you may not copy, reproduce or distribute without written consent neither completely
nor in parts.
If the competition try for discover and inspect this manual, we do expect the same fairness, that you
may expect from your customers in that case.
All rights, including rights created by patent grant or registration of a utility model or
design, are reserved.
Subject to change without notice. Errors and omissions excepted.

IDC Hand tool RAST 2.5 and 5
©2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
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2 Using the operation manual
These instructions contain important information on the safe and appropriate operation and simple
troubleshooting of the hand tool.
Read these instructions completely, especially section 3 “General safety instructions”, before working
with the IDC Hand tool.
Each person entrusted with the job of operating the IDC Hand tool, must be familiar with the opera-
tion manual and strictly observe the instructions therein.
TE Connectivity Ltd. decline to accept any liability for damages that are incurred due to the fact that
the instructions in the operation manual have been disregarded.
The user is responsible for supplementing the operation manual with any instructions resulting from
current national regulations for accident prevention and protection of the environment.
Also observe the generally applicable, legal or otherwise binding regulations of the European or na-
tional legislation and the rules for the prevention of accidents and for environmental protection appli-
cable in your country.
2.1 Abbreviations used
Abbreviation
Meaning
IDC
Isolation Displacement Connection
RAST
grid connection plug technology Rastera
n
schlussstec
k-
PN
Part
-
No.
RoHS Restriction of (the use of certain) hazardous substances

IDC Hand tool RAST 2.5 and 5
©2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
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3 General safety instructions
The IDC Hand tool has been manufactured according to the accepted rules of current technology. There is,
however, still a risk of personal injury or damage to equipment if the following general safety instructions and
the warnings before the steps contained in these instructions are not complied with.
Read these instructions completely and thoroughly before working with the IDC hand tool.
Keep these instructions in a location where they are accessible to all users at all times.
Always include the operating instructions when you pass the IDC hand tool to third parties.
RoHS Information
Information on the presence and location of any substances subject to
RoHS (Restriction on Hazardous Substances) can be found at the following website:
http://www.tycoelectronics.com/customersupport/rohssupportcenter/
Click on “Find Compliance Status” and enter equipment part number.
3.1 Intended use
The „IDC RAST Hand tool 2.5 and 5“ has been designed to apply connectors according to the AMP specifi-
cation (section 5 „Product description“) with wires following the grid connection plug technology using Insula-
tion Displacement Technique.
It is only permitted to use the „IDC hand tool 2.5 and 5“ exclusively for repair proposes or preparation of
samples. Do not use it for serial production.
The IDC hand tool is not a product in terms of the EU-Machinery Directive 2006/42/EG.
Intended use includes having read and understood these instructions, especially
section 3 “General safety instructions”.
Application Notes:
Cumulative Trauma Disorders can result from a prolonged use of manually powered hand tools.
TE Connectivity Ltd. hand tools are intended for occasional use and low volume applications.
For extended use or production operations TE Connectivity Ltd. offers a wide selection of
powered application equipment.
3.2 Improper use
Any use of the IDC RAST hand tool other than described in section 3.1“Intended use” is considered as
improper.
3.3 Reasonably foreseeable misuse
Any attempt to use the IDC hand tool with other than the specified connectors, described in
section 3.1 “Intended use” is considered as a reasonable foreseeable misuse.
Moreover, the IDC hand tool may used exclusively within the limits of its intended use
(section 3.1 “Intended use”).

IDC Hand tool RAST 2.5 and 5
©2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
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3.4 Qualification of personnel
In order to ensure operating safety, these activities may therefore only be carried out by qualified
technical personnel or an instructed person under the direction and supervision of qualified personnel.
Qualified personnel are those who can recognize possible hazards and institute the appropriate safety
measures due to their professional training, knowledge, and experience, as well as their understanding of
the relevant conditions pertaining to the work to be done. Qualified personnel must observe the rules
relevant to the subject area.
3.5 Safety instructions in this document
Type of risk!
Consequences
Precautions
Safety sign (warning triangle): Draws attention to the hazard
Signal word: Identifies the degree of hazard
Type of danger: Identifies the type or source of the hazard
Consequences: Describes the consequences of non-compliance
Precautions: States how the hazard can be prevented
The signal words have the following meaning:
Signal word Application
Indicates an imminently hazardous situation which, if not avoided,
will certainly result in serious injury or even death.
Indicates a potentially hazardous situation, which, if not avoided,
could result in serious injury or even death.
Indicates a potentially hazardous situation which, if not avoided,
could result in minor or moderate injury or damage to equipment.
If this information is disregarded, it may result in machine malfunc-
tion or breakdown.

IDC Hand tool RAST 2.5 and 5
©2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
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3.6 Adhere to the following instructions
3.6.1 General instructions
Observe the regulations for accident prevention and environmental protection for the country where
the product is used and at the workplace.
Exclusively use the IDC hand tool in good technical order and condition.
Check the IDC hand tool for visible defects, for example missing parts in set case or
broken parts.
You must generally not modify or retrofit the product.
Only use the product appropriate to the intended use described in this manual.
Person who assemble, operate, disassemble or maintain the machine must not
consume any alcohol, drugs or pharmaceuticals that may affect their ability to
respond.
Before putting the IDC Hand tool into operation, it is always important to check whether all devices
are at hand and functioning correctly.
The warranty only applies to the delivered configuration. The warranty will not apply if the product
is incorrectly assembled, not used as intended and/or handled improperly.
If the IDC hand tool is apparently damaged or do not work proper, you must send it in for repairs
(section 13.1 „Contact Information”).
3.6.2 During operation
Only persons who have been authorized by the operator may be granted access to the direct
operating range.
3.6.3 During disposal
For environmentally friendly disposal please observe the notes in section 11 ”Disposal”.
3.7 Obligations of the operator
The operator of the TE Connectivity Ltd. products is bound to provide for personnel training on a regular
basis regarding the following subjects:
Observation and use of the operating instructions and the legal regulations
Intended use and operation of the IDC hand tool.

IDC Hand tool RAST 2.5 and 5
©2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
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4 Scope of delivery
The scope of delivery includes following parts:
1 transport case containing
misc. tools (section 6.1 ”Components overview”)
1 operating manual

IDC Hand tool RAST 2.5 and 5
©2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
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5 Product description
Depending on the application the IDC Hand tool has been designed to apply connectors
(according to the TE specification) (section 5 „Product description“) with wires using Insulation Displacement
Technique (RAST 2.5 and 5).
It is only permitted to use the „IDC hand tool 2.5 and 5“ only for repair proposes or preparation of samples.
Do not use it for serial production.
5.1 Handled connectors
Following connectors of the type „RAST 2.5“ and „RAST 5“ are used:
Connector TE -
specification PN tool case
( ref. Fig. 1)
AMP DUOPLUG 2.5 Mark II 114-18467-0 1-1579012-1
RAST 2.5
AMP DUOPLUG 2.5 Power 114-18458-0 1-1579012-2
AMP multifitting Mark II 114-18288 1-1579012-6
AMP MONO-SHAPE Mark II 114-20104 1-1579012-5
114-20016 (TAB)
RAST 5
AMP MONO-SHAPE Mark I 114-20018 (PC) 1-1579012-4

IDC Hand tool RAST 2.5 and 5
©2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
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6 Content of case
6.1 Components overview
Fig. 1: Components overview
1 Set of socket head wrenches 5 Side cutter (latching rib)
2 IDC- RAST Hand tool with
tool head and adapter 6 End cutter (Keying rib)
3 Table clamp piece 7 Bracket
4 Transport case 8 Cutter knife
This operating manual is stored in the inner shed of the transport case.
Pull the foam piece by using the clip (arrow).
The operating manual will find behind the foam piece.

IDC Hand tool RAST 2.5 and 5
©2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
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6.2 Construction of the hand tool
The Hand tool consists of the movable handle with the guidance and the stuffer (4), the adapter (5), the
table mounting consists of the table clamp piece (2) and the bracket (3) as well as the tool head consists of
the holding fixture with connector clamping (1).
Fig. 2: Hand Tool Design (similarly)
1 Holding fixture incl. Connector clamping
2 Table clamp piece
3 Bracket
4 Guidance incl. Stuffer unit
5 Adapter
CAUTION!
Damage to property! Stuffer damage hazard!
Strictly observe to exchange the complete tool head.
The fixture including the connector clamping may only use in combination with the
appropriate provided gripper.
A combination of a holding fixture with a guidance of another type will probably crash and will
cause a damage of the stuffer!

IDC Hand tool RAST 2.5 and 5
©2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
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6.3 Construction of the tool heads
6.3.1 AMP DUOPLUG 2.5 Mark II
Fig. 3: Tool Head Design AMP DUOPLUG 2.5 Mark II
1 Chamber’s exterior fixation, static 4 Stuffer
2 Press bar for connector’s fixation 5 Tool head /
guidance incl. stuffer unit
3 Chamber fixation 6 Forked sleeve for
Chamber fixation

IDC Hand tool RAST 2.5 and 5
©2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
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6.3.2 AMP DUOPLUG 2.5 Power
Fig. 4: Head Design AMP DUOPLUG 2.5 Power
1 Tool head /
guidance incl. stuffer unit 4 Tool head / holding fixture incl. connector clamping
2 Stuffer 5 Press bar for connector’s fixation
3 Chamber’s exterior fixation,
static

IDC Hand tool RAST 2.5 and 5
©2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
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6.3.3 AMP multifitting Mark II
Fig. 5: Tool Head Design AMP multifitting Mark II
1 Locking screw 6 Chamber fixation
2 Tool head / holding fixture incl.
connector clamping 7 Forked sleeve for Chamber fixation
3 Chamber’s exterior fixation,
static foldaway 8 Stuffer
4 Chamber’s exterior fixation,
adjustable 9 Tool head / guidance incl. stuffer unit
5 Gauge piece resp. snap-fitting
of the connector’s width

IDC Hand tool RAST 2.5 and 5
©2009 Tyco Electronics Corporation, Harrisburg, PA
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TE logo and Tyco Electronics are trademarks.
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6.3.4 AMP MONO-SHAPE Mark II
Fig. 6: Tool Head Design AMP MONO-SHAPE Mark II
1 Locking screw 6 Chamber fixation
2 Tool head / holding fixture incl.
connector clamping 7 Forked sleeve for Chamber fixation
3 Chamber’s exterior fixation,
static, foldaway 8 Stuffer
4 Chamber’s exterior fixation,
adjustable 9 Tool head / guidance incl. stuffer unit
5 Gauge piece resp. snap-fitting
of the connector’s width

IDC Hand tool RAST 2.5 and 5
©2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
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6.3.5 AMP MONO-SHAPE Mark I
Fig. 7: Tool Head Design AMP MONO-SHAPE Mark I
1 Locking screw 6 Gauge piece resp. snap-fitting of
the connector’s width
2 Tool head / holding fixture incl.
connector clamping 7 Chamber fixation
3 Compensation bar for type
“PC”
( 9.5 „AMP MONO-SHAPE
Mark I“)
8 Stuffer
4 Chamber’s exterior fixation,
static, foldaway 9 Tool head / guidance incl. stuffer unit
5 Chamber’s exterior fixation,
adjustable 10
Forked sleeve for
Chamber fixation

IDC Hand tool RAST 2.5 and 5
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TE logo and Tyco Electronics are trademarks.
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7 Using the table mounting
For assistance the hand tool can be fixed on a work table, so you can use both the hands to work.
Attach the table mounting (1 / see page 11) to an appropriate place.
Insert the bracket into the mounting bore (arrow) of the bracket (2) and fix it by the locking screw
placed on the face of the table mounting.
Fig. 8: Fastening the fixture
Place the hand tool with its mounting hole onto the free end of the bracket (arrow) and fix it by us-
ing the two locking screws placed in the adapter plate.
Fig. 9: Fastening the hand tool

IDC Hand tool RAST 2.5 and 5
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Fix the bracket in the requested position by using the two clamp screw of the adapter(arrow).
Fig. 10: Fixation of the bracket
The complete hand tool is exemplary displayed in Fig. 11.
Fig. 11: Complete hand tool with table mounting