Tyco Electronics 91904 Series User manual

Instruction Sheet
SDE Crimping Die Assemblies
91900–1, 91901–1, 91903–1, 408–8579
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.
10 FEB 04 Rev B
91904–[ ], and 91905–1
PROPER USE GUIDELINES
CumulativeTraumaDisorderscanresultfromtheprolongeduseofmanuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume
applications. A wide selection of powered application equipment for extended–use, production operations is available.
Figure 1
Indenter
Die Typical
CrimpingDie
Assembly
Ferrule
Crimping
Chambers
CenterContact
CrimpingChamber
Anvil Die
1. INTRODUCTION
SDE (Two–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 instruction sheet are in
millimeters [with inches in brackets]. Figures are
for reference only, and are not drawn to scale.
Reasons for reissue of this instruction sheet are
provided in Section 8, REVISION SUMMARY.
2. DESCRIPTION
Each two–piece crimping die assembly consists of an
indenter die and an anvil die, which when closed
forms 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.
See Figure 1.
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.
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.
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.
NOTENOTE
NOTENOTE
NOTE
NOTENOTE

408–8579
SDE Crimping Die Assemblies
Rev B2 of 4
Figure 2
Anvil Die
Stripped
Cable
Crimpingthe
CenterContact
NOTE: Typical Crimping Dies Shown
Cross–SectionalView
Typical Plug
Contact
Typical Jack
Contact
Flange on End
ofContact
Flange on End
ofContact
Crimping
Die
Crimping
Die
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 the appropriate crimping
chamber for the ferrule.
4. With a screwdriver, adjust the ratchet wheel
from the opposite side of the tool.
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.
Damaged product should not be used. If a
damaged contact or ferrule is evident, it should
be replaced with a new one.
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.
Figure 3
Crimping the Ferrule
Ferrule in
Crimping
Chamberon
Anvil Die
Shoulderon
ConnectorBody
ButtsAgainst
Edge of Die
NOTE: Typical Crimping Dies Shown
NOTE
CAUTION
CAUTION

408–8579
SDE Crimping Die Assemblies
3of 4Rev B
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. 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.
Die assembly 91901–1 will require a center contact
crimp height inspection using a micrometer with a
with a modified anvil as shown in Figure 6. Tyco
Electronics recommends use of the modified
micrometer (Crimp Height Comparator
RS–1019–5LP) which can be purchased from:
ShearerIndustrialSupplyCo.
717–767–7575 or VALCO 610–691–3205
Proceed with center contact crimp height inspection
as follows:
1. Select an appropriate center contact and cable.
2. Crimp a test center contact.
3. Using crimp height comparator, measure wire
barrel crimp height as shown in Figure 6. If the
crimp height conforms to that shown in the chart,
the tool is considered dimensionally correct. If not,
return the tool to Tyco Electronics for evaluation
and repair (refer to Section 7, REPLACEMENT).
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 (or send for evaluation and
repair) 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 (038–035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105–3608
8. REVISION SUMMARY
Per EC: 0990–0121–04
S Updated document to corporate requirements
S Changed artwork and dimensions in table for
91901–1 in Figure 5

408–8579
SDE Crimping Die Assemblies
Rev B4 of 4
91900–1
B (Typ) A +0.03[.001]
B +0.05[.002]
91904–[]
91903–1
91901–1
91905–1
A +0.05[.002]
B+0.05/–0.08
[+.002/–.003]
B +0.08[.003]
C+0.05/–0.08
[+.002/–.003]
A +0.08[.003]
A+0.05/–0.08
[+.002/–.003]
A+0.05/–0.08
[+.002/–.003] B +0.03[.001]
T
RPTO
DIE CLOSURE DIMENSIONS
DIE SE
T
DESC
R
I
PT
I
O
NA B C
91904–1 BNC COAXICON Connectors 4.32 [.170] 1.321–1.257 [.0520–.0500] –––
91904–2 BNC COAXICON Connectors 6.20 [.244] 1.321–1.257 [.0520–.0500] –––
91904–3 BNC COAXICON Connectors 5.54 [.218] 1.283–1.219 [.0510–.0480] –––
91904–4 BNC COAXICON Connectors 5.05 [.199] 1.321–1.257 [.0520–.0500] –––
91901–1 BNC COAXICON Connectors 1.89 [.074] 5.54 [.218] –––
91905–1 ARINC COAXICON Connectors 6.50 [.256] 5.56 [.219] 4.32 [.170]
91903–1 50–Ohm C, HN, N, and TNC COAXICON Connectors 6.50 [.256] 1.93 [.076] –––
91900–1 LFR Fiber Optic Connectors 4.98 [.196] 2.77 [.109] –––
Figure 5
Figure 6
Anvil Spindle
Blade
1.93–2.00
[.076–.079]