TE Connectivity 220189 Series User manual

Instruction Sheet
Crimping Die Assemblies 408--2786
LOC B
1of 5
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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
i

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
i
NOTE
i

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
GO
Dia NO--GO
Dia
GO
Dia
NO--GO
Dia
R
W
“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.])
D
I
E
A
S
S
E
M
B
L
Y
CRIMPING CHAMBER
D
I
E
A
S
S
E
M
B
L
Y
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.]
2
1
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

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