InstructionSheet 408--2786 CrimpingDieAssemblies 220189-[]and58330-1 03MAY11 RevJ PROPERUSEGUIDELINES CumulativeTraumaDisorderscanresultfromtheprolongeduseofmanuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume applications.Awideselectionofpoweredapplicationequipmentforextended--use,productionoperationsisavailable. DieRetainingScrews StationaryJaw IndenterDie PRO--CRIMPER*III FrameAssembly CrimpingDie 354940--1(Ref) Assembly(Ref) Moveable AnvilDie Jaw CenterContact FerruleCrimping CrimpingChamber Chamber DIEASSEMBLYPARTNUMBER CONNECTORBASEPARTNUMBER 220189--1,220189--2 227000,227079,228980,228979 220189--3 225395,225396,225397,225398 58330--1 227079 Figure1 1. INTRODUCTION ReasonsforreissueareprovidedinSection8, REVISIONSUMMARY. NOTE Alldimensionsinthisdocumentareinmillimeters Thisinstructionsheetcoverstheuseand [withinchesinbrackets].FiguresandIllustrations maintenanceofCrimpingDieAssemblieslistedin i areforreferenceonlyandarenotdrawntoscale. Figure1.ThediesareusedinPRO--CRIMPERIII FrameAssembly354940--1tocrimp50-- and 75--OhmBNC,and50--OhmTNCDual--Crimp 2. DESCRIPTION Connectorsontovarioussizecable.RefertoFigure1 Eachdieassemblyconsistsofanindenterdieandan foralistofconnectorsthatarecompatiblewiththe anvildie,whichwhenmatedformtwocrimping dieassemblies.RefertoCatalog82074foradditional chambers.Thelargecrimpingchambercrimpsthe productpartnumberinformation.Forpartnumbers connectorferruleandthesmallcrimpingchamber notlisted,contactTEConnectivityProduct crimpstheconnectorcentercontact.Eachdieisheld Engineeringforrecommendations. inthetoolbyasinglescrew.SeeFigure1. E2011TycoElectronicsCorporation,aTEConnectivityLtd.Company TOOLINGASSISTANCECENTER1--800--722--1111 Thiscontrolleddocumentissubjecttochange. 1of5 AllRightsReserved PRODUCTINFORMATION1--800--522--6752 ForlatestrevisionandRegionalCustomerService, *Trademark visitourwebsiteatwww.te.com TEConnectivity,TEconnectivity(logo),andTE(logo)aretrademarks. Otherlogos,productand/orCompanynamesmaybetrademarksoftheirrespectiveowners. LOCB

408-2786 3. DIEINSTALLATION Crimpingthe CenterContact Tobesurethatthedieassemblyisproperlyaligned duringinstallation,proceedasfollows: 1. Slidethedieassemblyintothepartially--opened tooljaws.Theanvildiemustbeinstalledinthe movablejawofthetoolandtheindenterinthe stationaryjaw.Thecentercontactcrimping chambermustbetowardthefrontofthetoolas CenterContact showninFigure1. FlangeButt 2. Insert,butdonotcompletelytighten,thedie AgainstEdge retainingscrews. ofDie 3. Closethetooljawsandcarefullyalignthedies sothattheanvildieenterstheindenterdie.Once AnvilDie theanvilhasenteredtheindenter,placeacopper busbar(1.57+0.05mm[.062+.002in.]diameter) intothecentercontactcrimpingchamberofthedie StrippedCable assembly. 4. Withbusbarinplace,closethetooljaws completely.Holdthetoolhandlestogetherand FlangeonEndof tightenthedieretainingscrewswiththe Cross--Sectional CenterContact appropriatescrewdriver. View 4. CRIMPINGPROCEDURE EdgeofDie NOTE Fordetailedinformationoncableselection,cable Figure2 striplengths,andproperassemblyofthe i connector,refertotheinstructionsprovidedwith 4.2. Ferrule(Figure3) theconnector. 1. Insertthecrimpedcentercontactintothe connectorbodyuntilthecabledielectricbutts Selecttheappropriatedieassemblythatis againstthedielectricinsidetheconnectorbody. compatiblewiththeconnectorbeingused.Proceed Theflaredbraidmustfitaroundthesupportsleeve asfollows: oftheconnectorbody. 4.1. CenterContact(Figure2) Shoulderon 1. Slidetheferruleontothecable,thenstripthe Connector cabletotheproperdimensions. BodyButts Against 2. Slidecentercontactontocenterconductorof EdgeofDie cable;theninsertcontactassemblyintothecenter contactcrimpingchamberoftheanvildie.See Figure2. NOTE Makesurethattheflangeontheendofthe centercontactbuttsagainsttheedgeofthedie. Ferrulein i Refertothecross--sectionalviewinFigure2. Crimping Chamber onAnvil 3. Crimpthecentercontactbyholdingthecablein Die place;thenclosethetoolhandlesuntiltheratchet releases. 4. Removethecrimpedcentercontactassembly Figure3 fromthecrimpingdies. 2of5 RevJ

408-2786 2. Slidetheferruleforwardoverthebraiduntilthe 4. Whenthediesarenotinuse,mateandstore ferrulebuttsagainsttheshoulderontheconnector theminaclean,dryarea. body. 6.2. PeriodicInspections 3. Placetheferruleintheferrulecrimpingchamber oftheanvildiesothattheshoulderonthe Regularinspectionsshouldbeperformedbyquality connectorbodybuttsagainsttheedgeofthedie. controlpersonnel.Arecordofscheduledinspections SeeFigure3. shouldremainwiththediesand/orbesuppliedto supervisorypersonnelresponsibleforthedies. 4. Holdingtheassemblyinplace,closethetool Thoughrecommendationscallforatleastone handlesuntiltheratchetreleases. inspectionpermonth,theinspectionfrequencyshould bebasedonamountofuse,workingconditions, 5. Removecrimpedassemblyfromthecrimping operatortrainingandskill,andestablishedcompany dies. standards.Theseinspectionsshouldbeperformedin thefollowingsequence: 5. CRIMPHEIGHTADJUSTMENT(Figure4) Screwdriver Thetoolframeassemblyratchetmechanismfeatures anadjustmentwheelwithnumberedsettings.Ifthe crimpheightisnotacceptable,adjusttheratchetas follows: 1. Removethelockscrewfromtheratchet adjustmentwheel. 2. Withascrewdriver,adjusttheratchetwheel Ratchet fromtheoppositesideofthetool. Adjustment Wheel 3. Observetheratchetadjustmentwheel.Ifa tightercrimpisrequired,rotatetheadjustment wheelCOUNTERCLOCKWISEtoa higher--numberedsetting.Ifaloosercrimpis Lockscrew(Typ) required,rotatetheadjustmentwheel CLOCKWISEtoalower--numberedsetting. Figure4 4. Replacethelockscrew. A. VisualInspection 5. Makeasamplecrimpandmeasurethecrimp height.Ifthecrimpheightisacceptable,securethe 1. Removealllubricationandaccumulatedfilmby lockscrew.Ifthedimensionisunacceptable, immersingthediesinasuitablecommercial removelockscrewandcontinuetoadjustthe degreaser. ratchet,andagainmeasureasamplecrimp. 2. Makecertainalldieretainingscrewsanddie componentsareinplaceandsecured.If 6. MAINTENANCEANDINSPECTION replacementsarenecessary,refertoSection7, REPLACEMENT. 6.1. DailyMaintenance 3. Inspectthecrimpareaforflattened,chipped, worn,cracked,orbrokenareas.Ifdamageis Itisrecommendedthateachoperatorofthetoolwith evident,thediesmustbereplaced(seeSection7, thedieassemblybemadeawareof,andresponsible REPLACEMENT). for,thefollowingfourstepsofdailymaintenance: 1. Removedust,moisture,andothercontaminants B. GagingtheCrimpingChamber withaclean,softbrush,oraclean,soft,lint--free cloth.DoNOTuseanyobjectsthatcoulddamage Thisinspectionrequirestheuseofapluggage thediesortool. conformingtothediametersprovidedinFigure5.TE doesnotmanufacture,ormarket,thesegages. 2. Makesurethattheproperdieretainingscrews Proceedasfollows: areinplaceandsecured. 1. Matethediesuntilitisevidentthattheyhave 3. Makecertainthatallsurfacesareprotectedwith bottomed.Holdthediesinthispositionbyholding aTHINcoatofanygoodSAE20motoroil. thetoolhandlesclosedwithmoderatepressure. RevJ 3of5

408-2786 2. AligntheGOelementofthegagewiththe 7. REPLACEMENT crimpingchamber.Pushtheelementstraightinto thechamberwithoutusingforce.TheGOelement PartslistedinFigure6arecustomer--replaceable.A mustpasscompletelythroughthecrimping completeinventorycanbestockedandcontrolledto chamberasshowninFigure5. preventlosttimewhenreplacementofpartsisneces- sary.OrderreplacementsthroughyourlocalTE Representative,orcall1--800--526--5142,orsenda 3. AligntheNO--GOelementwiththecrimping facsimileofyourpurchaseorderto1--717--986--7605, chamberandtrytoinsertitstraightintothe orwriteto: chamber.TheNO--GOelementmaystartentrybut mustnotpasscompletelythrough.SeeFigure5. CUSTOMERSERVICE(38--35) TYCOELECTRONICSCORPORATION P.O.BOX3608 Ifthecrimpingchambersconformtothegage HARRISBURG,PA17105--3608 inspection,thediesareconsidereddimensionally correctandshouldbelubricatedwithathincoatof anygoodSAE20motoroil.Ifnot,thediesmustbe replacedbeforereturningthemtoservice. 8. REVISIONSUMMARY S Updateddocumenttocorporaterequirements. Foradditionalinformationconcerningtheuseofthe pluggage,refertoInstructionSheet408--7424. SuggestedPlugGageDesignfor SuggestedPlugGageDesign GO CenterContactCrimpingChamber NO--GO GO forFerruleCrimpingChamber W Dia Dia Dia NO--GO Dia R Crimping “GO”elementmust Chamber passcompletelythrough thedieclosure. “NO--GO”elementmayenter partially,butmustnotpass GOElement NO--GOElement completelythroughthedieclosure. GAGEELEMENTDIAMETER(mm[in.]) CRIMPINGCHAMBER DDIIEEAASSSSEEMMBBLLYY PARTNO. CENTERCONTACT FERRULE RADIUS WIDTH GO NO--GO GO NO--GO ‘‘R”(Max) ‘‘W”(Max) 1.207--1.214 1.359--1.367 5.156--5.164 5.408--5.410 2.51 5.03 220189--1 [.0475--.0478] [.0535--.0538] [.2030--.2033] [.2129--.2130] [.099] [.198] 1.054--1.062 1.181--1.189 5.969--5.977 6.220--6.223 2.92 5.84 220189--2 [.0415--.0418] [.0465--.0468] [.2350--.2353 [.2449--.2450] [.115] [.230] 1.925--1.928 1.984--1.986 5.405--5.408 5.667--5.669 2.64 5.28 220189--3 [.0758--.0759] [.0781--.0782] [.2128--.2129] [.2231--.2232] [.104] [.208] 1.029--1.036 1.181--1.189 4.191--4.199 4.442--4.445 2.03 4.06 58330--1 [.0405--.0408] [.0465--.0468] [.1650--.1653] [.1749--.1750] [.080] [.160] Figure5 4of5 RevJ

408-2786 30.48mm 11.89mm [1.20in.] [.468in.] 2 34.80mm [1.37in.] 1 WEIGHT:227g[8oz] CUSTOMER--REPLACEABLEPARTS DIEASSEMBLY ANVIL INDENTER PARTNO. (Item1) (Item2) 220189--1 310498--2 310497--2 220189--2 310498--4 310497--4 220189--3 310567--1 310568--1 58330--1 313764--1 313763--1 Figure6 RevJ 5of5