Tyco Electronics AMP 91907 User manual

Instruction Sheet
SDE Crimping Die Assemblies 91902–1,
91907–[ ], 91908–1, 91909–1, 91910–[ ], 408–8580
E 2004 Tyco Electronics Corporation, Harrisburg, PA
AllInternationalRightsReserved
AMP and Tyco are trademarks. *Trademark
Other products, logos, and company names used are the property of their respective owners. LOC B
1 of 4
TOOLINGASSISTANCECENTER1–800–722–1111
FAX/PRODUCT INFO1–800–522–6752
For Regional Customer Service, visit our website at
www.tycoelectronics.com
This controlled document is subject to change.
For latest revision, call the FAX/PRODUCT INFO number.
06 APR 04 Rev A
and 1424050–1
PROPER USE GUIDELINES
CumulativeTraumaDisorderscanresultfromtheprolongeduseofmanuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume
applications. A wide selection of powered application equipment for extended–use, production operations is available.
Figure 1
Indenter
Die
Anvil
Die
Ferrule
Crimping
Chambers
CenterContact
Crimping
Chamber
Typical
CrimpingDie
Assembly
1. INTRODUCTION
SDE (Four–Piece) Crimping Die Assemblies are
designed to crimp a variety of connectors when used
in PRO–CRIMPER* II Frame Assembly 354940–1.
Refer to Figure 5 for a list of connectors and their
associated dies.
Catalog 1307191 provides a guide for cable–
to–connector selection. For connectors not
referenced in the catalog, contact Tyco Electronics
Product Engineering for recommendations.
Refer to instruction sheet 408–9930 for information
concerning PRO–CRIMPER II Hand Tool Frame
354940–1.
Dimensions in this document are in metric units
[with U.S. customary units in brackets]. Figures
are for reference only and are not drawn to scale.
Reasons for revision are provided in Section 9,
REVISION SUMMARY.
2. DESCRIPTION
Each four–piece crimping die assembly consists of
two indenter dies and two anvil dies, which when
closed form two or three crimping chambers. The
larger crimping chambers crimp the ferrule of the
connector onto the coaxial cable. The smaller
crimping chamber crimps the center contact onto the
center conductor of the coaxial cable. Each die is held
in the PRO–CRIMPER II hand tool jaws by a single
screw.
3. DIE INSTALLATION (Figure 1)
1. Close the tool handles until the ratchet releases,
(hand tool only) 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.
3. Install indenter die in the stationary jaw of the
tool frame. Slowly close the tool handles, allowing
the dies to align themselves.
Once the anvil has entered the indenter, place
a copper bus bar (1.57 + 0.05 [.062 + .002]
diameter) into the center contact crimping
chamber of the die assembly.
4. Close the tool handles completely.
5. Securely tighten both screws with the
appropriate screwdriver.
4. CRIMPING PROCEDURE
Select the appropriate cable size and connector. The
wire size and insulation diameter must be within the
specified range for the connector.
This tool is provided with a crimp height
adjustment feature.Initially, the crimp height
should be verified. Refer to Section 5, CRIMP
HEIGHTADJUSTMENT, to verify crimp height
before using the tool.
For detailed information on cable strip lengths and
proper assembly of the connector, refer to the
instructions packaged with the connector. Make sure
that the connector’s ferrule has been placed onto the
cable, and that the cable’s braided shield is flared
away from the cable. Then proceed as follows:
4.1. Crimping the Center Contact (Figure 2)
1. Close the tool handles until the dies are partially
closed.
2. Assemble the center contact onto the cable
center conductor and place the center contact in
the smallest crimping chamber of the anvil die.
Make sure the flange on the end of the center
contact butts against the die.
NOTE
NOTE
NOTE

408–8580
SDE Crimping Die Assemblies
Rev A2 of 4
Figure 2
Anvil Die
Flange on End of
CenterContact
Butts Against Die
Stripped
Cable
Crimping the
Center Contact Plug
Contact
Crimping
Die
Flangeon
End of Contact
Flangeon
End of Contact
Crimping
Die
Jack
Contact
Cross–SectionalView
3. Holding the cable in place, close the tool
handles until the ratchet releases.
4. Allow the tool handles to open fully and remove
the crimped center contact from the dies.
4.2. Crimping the 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 or
until the center contact is securely positioned
within the connector. Make sure that the braided
shield is over the support sleeve of the connector
body and 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
connectorto determine theappropriate crimping
chamber for the ferrule.
4. While holding the assembly together, begin to
close the tool handles. Keep holding the assembly
until the dies have closed enough to clamp the
assembly in place.
Make sure that both sides of the ferrule are
started evenly into the crimping chamber. Do
NOT attempt to crimp an improperly positioned
ferrule.
5. Carefully close the tool handles until the ratchet
releases.
6. Allow the tool handles to open fully and remove
the crimped connector from the dies.
Figure 3
Ferrule in
Crimping
Chamber on
Anvil Die
Shoulder on
ConnectorBody
ButtsAgainst
Edge of Die
Crimping the Ferrule
Note: Typical Crimping Dies Shown.
NOTE
CAUTION

408–8580
SDE Crimping Die Assemblies
3of 4Rev A
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.
Damaged product should not be used. If
damaged product is evident, it should be cut from
the wire and replaced with new product.
6. MAINTENANCE AND INSPECTION
6.1. 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 properly secured.
3. When the dies are not in use, store them in a
clean, dry area.
4. Store the tool with the tool handles closed to
prevent objects from becoming lodged within the
jaws.
6.2. Inspection
1. Remove all lubrication and accumulated film
from 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.
Figure 4
ScrewDriver
Ratchet
Adjustment
Wheel
Lockscrew
(Typ)
6.3. Measuring the Die Opening
The die assembly will perform correctly as long as:
(1) the product specified is correct for the application,
(2) the specific die assembly is used, (3) the die
assembly has been measured to ensure that the
openings are correct, and (4) the tool has been
adjusted correctly. Figure 5 provides information on
die opening sizes.
7. REPLACEMENT
These crimping die assemblies are inspected before
shipment. It is recommended that the dies be
inspected immediately upon arrival at your facility to
ensure that the dies have not been damaged during
shipment.
Order replacements through your local Tyco
Electronics 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
Per EC 0990–0400–04:
S Update document to corporate requirements
S Added new part number 91907–2 to document
S Added new lockscrew to artwork in Figures 2,
3, and 4
CAUTION

408–8580
SDE Crimping Die Assemblies
Rev A4 of 4
58 59 RG174–188
COMM BNC
1424050–1
A " 0.05 [.002]
B " 0.05 [.002]
C " 0.10
[.004]
D " 0.10
[.004] RG–141
RG–58
N PLUG
91902–1
A " 0.03
[.001] B
" 0.10
[.004]
C " 0.08
[.003]
TRIAXIAL CONN
ARINC 8
91907–[ ]
B " 0.05 [.002]
A " 0.03
[.001]
C " 0.05
[.002]
50–Ohm INSULCRIMP BRAID CRIMP
91910–[]
A Typ.
B " 0.05
[.002]
C " 0.05
[.002]
SMACONN
91908–1
B " 0.10
[.004]
A "
0.03
[.001]
C " 0.10
[.004]
D " 0.08
[.003]
E " 0.08[.003]
1.29 5.69
RG 108
TWIN
BNC
91909–1
A Typ.
A Typ.
B " 0.10
[.004]
C " 0.10
[.004]
P
A
RT
MB R
PRO T R PT O
DIE CLOSURE DIMENSIONS
PRT
NU
MB
E
R
PRO
DUC
T
DESC
R
I
PT
I
O
NA B C D E
1424050–1 50–Ohm BNC Connectors 1.12 [.044] 1.27 [.050] 2.64 [.104] 4.32 [.170] ––
91907–[ ] ARINC Size 8 Triaxial Contact 1.24 [.049] 3.78 [.149] 6.07 [.239] –– ––
91908–1 SMA Series 50–Ohm RF Connectors 1.27 [.050] 2.44 [.096] 4.72 [.186] 5.54 [.218] 2.82 [.111]
91902–1 50–Ohm C, HN, N, and TNC
COAXICON Connectors 1.93 [.076] 4.98 [.196] 5.56 [.219] –– ––
91910–[ ] 50–Ohm BNC COAXICON Connectors 1.219 / 1.283
[.048 / .051] 2.90 [.114] 3.61 [.142] –– ––
91910–2 50–Ohm BNC COAXICON Connectors 1.219 / 1.283
[.048 / .051] 2.34 [.092] 2.77 [.109] –– ––
91909–1 50–Ohm C, HN, N, and TNC
COAXICON Connectors 1.321 / 1.257 [.052 / .050] 5.69 [.224] 7.16 [.282] –– ––
Figure 5