Instruction Sheet SDE Crimping Die Assemblies 91900-1, 91901-1, 91903-1, 408-8579 91904-[ ], and 91905-1 10 MAR 11 Rev C PROPER USE GUIDELINES Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools. Hand tools are intended for occasional use and low volume applications. A wide selection of powered application equipment for extended-use, production operations is available. coaxial cable. Each die is held in the PRO-CRIMPER Indenter III hand tool jaws by a single screw. See Figure 1. Typical Die Crimpiing Die Assembly 3. DIE INSTALLATION (Figure 1) 1. Close the tool handles until the ratchet releases, then allow the tool handles to open fully. 2. Install anvil die in the movable jaw of the tool frame. Align the die with the retaining screw hole, then secure die with the die-retaining screw. Do NOT fully tighten. Ferrule Crimping 3. Install indenter die in the stationary jaw of the tool Chamber frame. Slowly close the tool handles, allowing the dies to align themselves. Once the anvil has entered the indenter, place a NOTE copper bus bar (1.57 ± 0.05 [.062 ± .002] diameter) Anvil Die Center Contact into the center contact crimping chamber of the die i Crimping Chamber assembly. Figure 1 4. Close the tool handles completely. 5. Securely tighten both screws with the appropriate 1. INTRODUCTION screwdriver. SDE (Two-Piece) Crimping Die Assemblies are designed to crimp a variety of connectors when used 4. CRIMPING PROCEDURE in PRO-CRIMPER* III Frame Assembly 354940-1. Select the appropriate cable size and connector. The Refer to Figure 5 for a list of connectors and their wire size and insulation diameter must be within the associated dies. specified range for the connector. Catalog 1307191 provides a guide for cable-to- This tool is provided with a crimp height adjustment NOTE connector selection. For connectors not referenced in feature. Initially, the crimp height should be verified. the catalog, contact Tyco Electronics Product Refer to Section 5, Crimp height Adjustment, to Engineering for recommendations. i verify crimp height before using the tool. Refer to instruction sheet 408-9930 for information For detailed information on cable strip lengths and concerning PRO-CRIMPER II Hand Tool Frame proper assembly of the connector, refer to the 354940-1. instructions packaged with the connector. Make sure Dimensions in this instruction sheet are in that the connector's ferrule has been placed onto the NOTE cable, and that the cable's braided shield is flared millimeters [with inches in brackets]. Figures are for reference only, and are not drawn to scale. away from the cable. Then proceed as follows: i 4.1. Crimping the Center Contact (Figure 2) Reasons for reissue of this instruction sheet are 1. Close the tool handles until the dies are partially provided in Section 8, REVISION SUMMARY. closed. 2. DESCRIPTION 2. Assemble the center contact onto the cable center conductor and place the center contact in the Each two-piece crimping die assembly consists of an smallest crimping chamber of the anvil die. indenter die and an anvil die, which when closed forms two or three crimping chambers. The larger crimping Make sure the flange on the end of the center NOTE chambers crimp the ferrule of the connector onto the contact butts against the die. coaxial cable. The smaller crimping chamber crimps i the center contact onto the center conductor of the ©2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change. 1 of 5 All Rights Reserved PRODUCT INFORMATION 1-800-522-6752 For latest revision and Regional Customer Service, TE logo is a trademark. visit our website at www.te.com *Trademark. Other products, logos, and company names might be trademarks of their respective owners. LOC B 408-8579 Crimping the Center Contact Flange on End of Typical Plug Contact Contact Crimping Die Typical Jack Flange on End of Contact Stripped Contact Cable Anvil Die Crimping Die NOTE: Typical Crimping Dies Shown Figure 2 3. Holding the cable in place, close the tool handles Make sure that both sides of the ferrule are started CAUTION until the ratchet releases. evenly into the crimping chamber. Do not attempt to crimp an improperly positioned ferrule. ! 4. Allow the tool handles to open fully and remove the crimped center contact from the dies. 5. Carefully close the tool handles until the ratchet 4.2. Crimping the Ferrule (Figure 3) releases. 1. Insert the crimped center contact into the Crimping the Ferrule connector body until the cable dielectric butts against the dielectric inside the connector body or Shoulder on until the center contact is securely positioned within Connector Body the connector. Make sure that the braided shield is Butts Against over the support sleeve of the connector body and Edge of Die that no strands from the shield enter the connector body. 2. Slide the ferrule up over the braided shield and onto the connector until the ferrule butts against the shoulder on the connector body. 3. Place the ferrule in the appropriate crimping chamber of the anvil die so that the shoulder on the connector body butts against the edge of the die. Refer to the instruction sheet packaged with the NOTE connector to determine the appropriate crimping chamber for the ferrule. i Ferrule in Crimping Chamber on Anvil Die 4. With a screwdriver, adjust the ratchet wheel from the opposite side of the tool. NOTE: Typical Crimping Dies Shown Figure 3 Rev C 2 of 5 408-8579 6. Allow the tool handles to open fully and remove 6. MAINTENANCE AND INSPECTION the crimped connector from the dies. 6.1. Maintenance Damaged product should not be used. If a CAUTION 1. Remove dust, moisture, and other contaminants damaged contact or ferrule is evident, it should be with a clean, soft brush, or a clean, soft, lint-free replaced with a new one. ! cloth. Do NOT use any objects that could damage the dies or tool. 5. CRIMP HEIGHT ADJUSTMENT (Figure 4) 2. Make sure that the proper die-retaining screws are properly secured. The tool frame assembly ratchet mechanism features an adjustment wheel with numbered settings. If the 3. When the dies are not in use, store them in a crimp height is not acceptable, adjust the ratchet as clean, dry area. follows: 4. Store the tool with the tool handles closed to 1. Remove the lockscrew from the ratchet prevent objects from becoming lodged within the adjustment wheel. jaws. 2. With a screwdriver, adjust the ratchet wheel from 6.2. Inspection the opposite side of the tool. 1. Remove all lubrication and accumulated film from Screwdriver the dies by immersing the dies in a suitable commercial degreaser. 2. Make certain that all die-retaining screws and die components are properly secured. 3. Inspect the crimping surfaces for flattened, chipped, worn, or cracked areas. If damage is evident, the dies must be replaced. Refer to Section 7, REPLACEMENT. 6.3. Measuring the Die Opening The die assembly will perform correctly as long as: • the product specified is correct for the application, • the specific die assembly is used, Ratchet Adjustment Wheel • the die assembly has been measured to ensure that the openings are correct, and Lockscrew (Typ) • the tool has been adjusted correctly. Figure 5 provides information on die opening sizes. Die assembly 91901-1 will require a center contact Figure 4 crimp height inspection using a micrometer with a with a modified anvil as shown in Figure 6. Tyco 3. Observe the ratchet adjustment wheel. If a tighter Electronics does not manufacture or market these crimp is required, rotate the adjustment wheel gages. However TE recommends use of the modified COUNTERCLOCKWISE to a higher-numbered micrometer (Crimp Height Comparator) found in setting. If a looser crimp is required, rotate the 408-7424. Refer to 408-7424 for instructions and adjustment wheel CLOCKWISE to a lower- ordering information of the crimp height comparators. numbered setting. Proceed with center contact crimp height inspection as 4. Replace the lockscrew. follows: 5. Make a sample crimp and measure the crimp 1. Select an appropriate center contact and cable. height. If the crimp height is acceptable, secure the lockscrew. If the dimension is unacceptable, remove 2. Crimp a test center contact. lockscrew and continue to adjust the ratchet, and 3. Using crimp height comparator, measure wire again measure a sample crimp. barrel crimp height as shown in Figure 6. If the crimp height conforms to that shown in the table, the tool is considered dimensionally correct. If not, return the tool to Tyco Electronics for evaluation and repair (refer to Section 7, REPLACEMENT). Rev C 3 of 5 408-8579 DIE CLOSURE DIMENSIONS DIE SET DESCRIPTION AB C 1.321-1.257 91904-1 BNC COAXICON Connectors 4.32 [.170] --- [.0520-.05000] 1.321-1.257 91904-2 BNC COAXICON Connectors 6.20 [.244] --- [.0520-.05000] 1.283-1.219 91904-3 BNC COAXICON Connectors 5.54 [.218] --- [.0510-.0480] 1.321-1.257 91904-4 BNC COAXICON Connectors 5.05 [.199] ---- [.0520-.05000] 5.54 91901-1 BNC COAXICON Connectors 1.89 [.074] ---- [.218] 5.56 91905-1 ARINC COAXICON Connectors 6.50 [.256] 4.32 [.170] [.219] 1.93 91903-1 50-Ohm C HN, N, and TNC COAXICON Connectors 6.50 [.256] ---- [.076] 2.77 91900-1 LFR Fiber Optic Connectors 4.98 [.196] ---- [.109] Figure 5 Rev C 4 of 5 408-8579 7. REPLACEMENT CUSTOMER SERVICE (038-035) TYCO ELECTRONICS CORPORATION These crimping die assemblies are inspected before PO BOX 3608 shipment. It is recommended that the dies be HARRISBURG PA 17105-3608 inspected immediately upon arrival at your facility to ensure that the dies have not been damaged during shipment. 8. REVISION SUMMARY Order replacements (or send for evaluation and repair) through your local Tyco Electronics Representative, or Since the previous release of these instructions, the call 1-800-526-5142, or send a facsimile of your TE Connectivity logo has been applied. purchase order to 1-717-986-7605, or write to: Blade Spindle Anvil Figure 6 Rev C 5 of 5