TE Connectivity 220189 Series User manual

Instruction Sheet

Crimping Die Assemblies 408--2786

LOC B

1of 5

E2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company

*Trademark

TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners.

TOOLING ASSISTANCE CENTER 1--800--722 -- 1111

PRODUCT INFORMATION 1--800--522--6752

This controlled document is subject to change.

For latest revision and Regional Customer Service,

visit our website at www.te.com

03 MAY 11 Rev J220189- [ ] and 58330- 1

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.

PRO--CRIMPER* III

Frame Assembly

354940--1 (Ref)

Stationary Jaw

Die Retaining Screws

Indenter Die

Crimping Die

Assembly (Ref)

Anvil Die

Center Contact

Crimping Chamber Ferrule Crimping

Chamber

Moveable

Jaw

DIE ASSEMBLY PART NUMBER CONNECTOR BASE PART NUMBER

220189--1, 220189--2 227000, 227079, 228980, 228979

220189--3 225395, 225396, 225397, 225398

58330--1 227079

Figure 1

1. INTRODUCTION

This instruction sheet covers the use and

maintenance of Crimping Die Assemblies listed in

Figure 1. The dies are used in PRO--CRIMPER III

Frame Assembly 354940--1 to crimp 50-- and

75--Ohm BNC, and 50--Ohm TNC Dual--Crimp

Connectors onto various size cable. Refer to Figure 1

for a list of connectors that are compatible with the

die assemblies. Refer to Catalog 82074 for additional

product part number information. For part numbers

not listed, contact TE Connectivity Product

Engineering for recommendations.

Reasons for reissue are provided in Section 8,

REVISION SUMMARY.

All dimensions in this document are in millimeters

[with inches in brackets]. Figures and Illustrations

are for reference only and are not drawn to scale.

2. DESCRIPTION

Each die assembly consists of an indenter die and an

anvil die, which when mated form two crimping

chambers. The large crimping chamber crimps the

connector ferrule and the small crimping chamber

crimps the connector center contact. Each die is held

in the tool by a single screw. See Figure 1.

NOTE

408- 2786

Rev J2 of 5

3. DIE INSTALLATION

To be sure that the die assembly is properly aligned

during installation, proceed as follows:

1. Slide the die assembly into the partially--opened

tool jaws. The anvil die must be installed in the

movable jaw of the tool and the indenter in the

stationary jaw. The center contact crimping

chamber must be toward the front of the tool as

shown in Figure 1.

2. Insert, but do not completely tighten, the die

retaining screws.

3. Close the tool jaws and carefully align the dies

so that the anvil die enters the indenter die. Once

the anvil has entered the indenter, place a copper

bus bar (1.57+0.05 mm [.062+.002 in.] diameter)

into the center contact crimping chamber of the die

assembly.

4. With bus bar in place, close the tool jaws

completely. Hold the tool handles together and

tighten the die retaining screws with the

appropriate screwdriver.

4. CRIMPING PROCEDURE

For detailed information on cable selection, cable

strip lengths, and proper assembly of the

connector, refer to the instructions provided with

the connector.

Select the appropriate die assembly that is

compatible with the connector being used. Proceed

as follows:

4.1. Center Contact (Figure 2)

1. Slide the ferrule onto the cable, then strip the

cable to the proper dimensions.

2. Slide center contact onto center conductor of

cable; then insert contact assembly into the center

contact crimping chamber of the anvil die. See

Figure 2.

Make sure that the flange on the end of the

center contact butts against the edge of the die.

Refer to the cross--sectional view in Figure 2.

3. Crimp the center contact by holding the cable in

place; then close the tool handles until the ratchet

releases.

4. Remove the crimped center contact assembly

from the crimping dies.

Figure 2

Center Contact

Flange Butt

Against Edge

of Die

Anvil Die

Stripped Cable

Crimping the

Center Contact

Flange on End of

Center Contact

Edge of Die

Cross--Sectional

View

4.2. Ferrule (Figure 3)

1. Insert the crimped center contact into the

connector body until the cable dielectric butts

against the dielectric inside the connector body.

The flared braid must fit around the support sleeve

of the connector body.

Figure 3

Shoulder on

Connector

Body Butts

Against

Edge of Die

Ferrule in

Crimping

Chamber

on Anvil

Die

NOTE

408- 2786

3of 5Rev J

2. Slide the ferrule forward over the braid until the

ferrule butts against the shoulder on the connector

body.

3. Place the ferrule in the ferrule crimping chamber

of the anvil die so that the shoulder on the

connector body butts against the edge of the die.

SeeFigure3.

4. Holding the assembly in place, close the tool

handles until the ratchet releases.

5. Remove crimped assembly from the crimping

dies.

5. CRIMP HEIGHT ADJUSTMENT (Figure 4)

The tool frame assembly ratchet mechanism features

an adjustment wheel with numbered settings. If the

crimp height is not acceptable, adjust the ratchet as

follows:

1. Remove the lockscrew from the ratchet

adjustment wheel.

2. With a screwdriver, adjust the ratchet wheel

from the opposite side of the tool.

3. Observe the ratchet adjustment wheel. If a

tighter crimp is required, rotate the adjustment

wheel COUNTERCLOCKWISE to a

higher--numbered setting. If a looser crimp is

required, rotate the adjustment wheel

CLOCKWISE to a lower--numbered setting.

4. Replace the lockscrew.

5. Make a sample crimp and measure the crimp

height. If the crimp height is acceptable, secure the

lockscrew. If the dimension is unacceptable,

remove lockscrew and continue to adjust the

ratchet, and again measure a sample crimp.

6. MAINTENANCE AND INSPECTION

6.1. Daily Maintenance

It is recommended that each operator of the tool with

the die assembly be made aware of, and responsible

for, the following four steps of daily maintenance:

1. Remove dust, moisture, and other contaminants

with a clean, soft brush, or a clean, soft, lint--free

cloth. Do NOT use any objects that could damage

the dies or tool.

2. Make sure that the proper die retaining screws

are in place and secured.

3. Make certain that all surfaces are protected with

a THIN coat of any good SAE 20 motor oil.

4. When the dies are not in use, mate and store

them in a clean, dry area.

6.2. Periodic Inspections

Regular inspections should be performed by quality

control personnel. A record of scheduled inspections

should remain with the dies and/or be supplied to

supervisory personnel responsible for the dies.

Though recommendations call for at least one

inspection per month, the inspection frequency should

be based on amount of use, working conditions,

operator training and skill, and established company

standards. These inspections should be performed in

the following sequence:

Figure 4

Screwdriver

Ratchet

Adjustment

Wheel

Lockscrew (Typ)

A. Visual Inspection

1. Remove all lubrication and accumulated film by

immersing the dies in a suitable commercial

degreaser.

2. Make certain all die retaining screws and die

components are in place and secured. If

replacements are necessary, refer to Section 7,

REPLACEMENT.

3. Inspect the crimp area for flattened, chipped,

worn, cracked, or broken areas. If damage is

evident, the dies must be replaced (see Section 7,

REPLACEMENT).

B. Gaging the Crimping Chamber

This inspection requires the use of a plug gage

conforming to the diameters provided in Figure 5. TE

does not manufacture, or market, these gages.

Proceed as follows:

1. Mate the dies until it is evident that they have

bottomed. Hold the dies in this position by holding

the tool handles closed with moderate pressure.

408- 2786

Rev J4 of 5

2. Align the GO element of the gage with the

crimping chamber. Push the element straight into

the chamber without using force. The GO element

must pass completely through the crimping

chamber as shown in Figure 5.

3. Align the NO--GO element with the crimping

chamber and try to insert it straight into the

chamber. The NO--GO element may start entry but

must not pass completely through. See Figure 5.

If the crimping chambers conform to the gage

inspection, the dies are considered dimensionally

correct and should be lubricated with a thin coat of

any good SAE 20 motor oil. If not, the dies must be

replaced before returning them to service.

For additional information concerning the use of the

plug gage, refer to Instruction Sheet 408--7424.

7. REPLACEMENT

Parts listed in Figure 6 are customer--replaceable. A

complete inventory can be stocked and controlled to

prevent lost time when replacement of parts is neces-

sary. Order replacements through your local TE

Representative, or call 1--800--526--5142, or send a

facsimile of your purchase order to 1--717--986--7605,

or write to:

CUSTOMER SERVICE (38--35)

TYCO ELECTRONICS CORPORATION

P.O. BOX 3608

HARRISBURG, PA 17105--3608

8. REVISION SUMMARY

SUpdated document to corporate requirements.

Crimping

Chamber

GO Element NO--GO Element

Dia NO--GO

Dia

NO--GO

Dia

“GO” element must

pass completely through

the die closure.

“NO--GO” element may enter

partially, but must not pass

completely through the die closure.

Suggested Plug Gage Design for

Center Contact Crimping Chamber

Suggested Plug Gage Design

for Ferrule Crimping Chamber

GAGE ELEMENT DIAMETER (mm [in.])

CRIMPING CHAMBER

PART NO. CENTER CONTACT FERRULE

GO NO--GO GO NO--GO RADIUS

‘‘R” (Max)

WIDTH

‘‘W” (Max)

220189--1 1.207--1.214

[.0475--.0478]

1.359--1.367

[.0535--.0538]

5.156--5.164

[.2030--.2033]

5.408--5.410

[.2129--.2130]

2.51

[.099]

5.03

[.198]

220189--2 1.054--1.062

[.0415--.0418]

1.181--1.189

[.0465--.0468]

5.969--5.977

[.2350--.2353

6.220--6.223

[.2449--.2450]

2.92

[.115]

5.84

[.230]

220189--3 1.925--1.928

[.0758--.0759]

1.984--1.986

[.0781--.0782]

5.405--5.408

[.2128--.2129]

5.667--5.669

[.2231--.2232]

2.64

[.104]

5.28

[.208]

58330--1 1.029--1.036

[.0405--.0408]

1.181--1.189

[.0465--.0468]

4.191--4.199

[.1650--.1653]

4.442--4.445

[.1749--.1750]

2.03

[.080]

4.06

[.160]

Figure 5

408- 2786

5of 5Rev J

30.48 mm

[1.20 in.]

11.89 mm

[.468 in.]

WEIGHT: 227g[8oz]

34.80 mm

[1.37 in.]

CUSTOMER--REPLACEABLE PARTS

DIE ASSEMBLY

PART NO.

ANVIL

(Item 1)

INDENTER

(Item 2)

220189--1 310498--2 310497--2

220189--2 310498--4 310497--4

220189--3 310567--1 310568--1

58330--1 313764--1 313763--1

Figure 6

Mouser Electronics

Authorized Distributor

Click to View Pricing, Inventory, Delivery & Lifecycle Information:

TE Connectivity:

58330-1 220189-1 220189-2 220189-3

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