Glenair AI85112-02S User manual

AI85112-02S Page 1of 4
AI85112-02S
Revision History
Rev
Date
Initiated By
Approved
1
11/06/19
WLL
GH
Tools needed:
•M22520/2-01 AFM8 w/K1906 Crimper & Positioner
•M22520/5-01 Hex Crimp Tool w/Y143
•600-236 Alignment Tool
•600-242 Insert Tool
Twisted Pair Color Orientation of Cable
Figure 1
Cable Layout for Pin Contact 858-032-02
Procedure
Step 1:
Slide grommet follower and crimp bushing over jacket. Cable ends must be cut cleanly and at
right angle to the cable axis with circular cable cutter.
Plastic Bushing
Crimp Bushing
Grommet
Follower
Socket Outer
Body
Outer Insulators
Pin Inner Contacts
Inner Insulator &
Plated Cross Shields

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Step 2:
Remove cable jacket (0.590”) to expose the braid shield.
Step 3:
Flare cable braid to expose the twisted pair wires with aluminum foil shields. Flare wire bundle
with aluminum foil shields and trim the middle filler as close to the jacket as possible.
Step 4:
Identify cable twisted pair color orientation to match Figure 1. Unwrap foil around one pair.
Remove insulation of the conductors to (0.115”). Install inner contacts over conductor until
fully seated. Make sure the conductor is visible through the inspection hole. Crimp the inner
contacts using crimp tool M22520/2-01 and positioner Daniels P/N K1906, Setting #3 for 26
AWG. Re-wrap foil tightly around the wire pair. Use Kapton tape to hold the foil in place. Trim
excess tape and foil to expose wire insulator. No more than 0.100” of insulator should be
exposed. Ensure foil does not cover base of contact.

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Step 5:
Identify the wire colors. Slide the inner insulator (with cross shields) into middle of inner
contacts. Pay attention to the orientation of the wires. Snap the contacts in place of the insulator
slot cavities.
Note: The twisted pairs are essentially parallel to the axis of the bundle with no crossover.
Figure 2
Step 6:
Slide outer insulator over inner insulator. Place the outer insulator such as its key is in
orientation with color code as shown in Figure 2. Push the outer insulator in until outer and
inner tabs nest together.
Step 7:
Slide plastic bushing over outer insulator. Squeeze the plastic bushing down below the 4 tabs of
inner insulator. Push the crimp bushing forward such that the plastic bushing has a very tight
space against the inner insulator and crimp bushing. Trim braid just short of the crimp bushing.
Inspection Step: the gap between the plastic bushing and the adjacent component shall be less
than 0.010”.

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Step 8:
Install outer shell body in tool 600-236. Ensure the male polarization key of the shell is engaged
into the female key locator on the tool. Mate tool into cable assembly. Ensure the polarization
key of the outer insulator is lined up with the polarization key of the shell body per Figure 3.
Use insert tool 600-242 to slide cable assembly into shell body using 600-236 as a guide per
Figure 4. Ensure crimp bushing is fully seated.
Figure 3
Figure 4
Step 9:
Use crimp tool Daniels HX4 M22520/5-01 with die Y143. Load contact assembly into side A.
Locate the step at the back of the contact. Ensure the step is flush with the top face of the die,
crimp contact.
Key