Instruction Sheet
Crimping Die Assemblies 1583015-1,
-2, -3, and 1583016-1 for High Speed
Serial Data Connector 2 (HSSDC2)
408-8609
The ferrule, which is ordered separately from the
AMPLIMITE* connector, is sized according to the
insulation diameter of the cable. Each die assembly is
marked with the cable insulation diameter range.
3. DIE ASSEMBLY INSTALLATION
The die assembly is designed to fit securely into the
tool by upper and lower die holder plates; each die is
held in by a single screw. To install the die assembly,
refer to the instructions packaged with the tool:
408-9315
Hand Crimping Tool Frame Assembly
543344-1
408-9245
Hand Crimping Tool Frame Assembly
58235-1
408-9721
Die Holder Assembly 58449-1
409-5822
Pneumatic Power Unit 312522-3
4. CRIMPING PROCEDURE
Assemble the connector. Make sure the ferrule is over
the connector shield cable outlet and butted against
the shield body. Then, proceed as follows:
Figure 1
1. INTRODUCTION
This instruction sheet covers the use and maintenance
of Crimping Die Assemblies 1583015-1, -2, -3, and
1583016-1, which are designed to be used in Hand
Crimping Tool Frame Assembly 543344-1 or 58235-1,
or in Pneumatic Power Unit 312522-3 equipped with
Die Holder Assembly 58449-1. Each die assembly
crimps a ferrule onto round shielded cable used with
HSSDC2 Connectors.
Reason for revision is given in Section 7, REVISON
SUMMARY.
NOTE
i
Dimensions are in millimeters [with inches in
brackets]. Figures and illustrations are for
reference only and are not drawn to scale.
CAUTION The front edge of the ferrule must be against the
stop and the connector body must be clear of the
dies.
!
2. Actuate tool for crimping according to the
instructions packaged with the tool.
3. Remove connector from die assembly and
inspect the crimped ferrule to the requirements
outlined in the applicable application specification:
114-13028
High Speed Serial Data
Connector 2 (HSSDC2)
See Figure 3 for a properly crimped ferrule.
2. DESCRIPTION
Each die assembly consists of an indenter (stationary
die) and an anvil (moving die). When mated, the dies
form two crimping sections: the braid and the
insulation. The braid section crimps the front part of
the ferrule onto the cable shield and the cable outlet of
the connector shield assembly, and simultaneously,
the insulation section crimps the back part of the
ferrule onto the cable insulation. The anvil die is
designed with a stop to ensure proper positioning of
the ferrule for crimping. See Figure 1.
©2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company
All Rights Reserved
*Trademark
1. Place the ferrule on the moving die, with the
cable extending out the back side of the die. Make
sure that the front part of the ferrule is positioned in
the braid section and the back part of the ferrule is
positioned in the insulation section. See Figure 2.
5. MAINTENANCE AND INSPECTION PROCEDURE
The die assembly is inspected prior to shipment,
however, it is recommended that the die assembly be
inspected immediately upon arrival. TE Connectivity
recommends that a maintenance and inspection
program be performed periodically to ensure
continued reliability of the die assembly. The
inspection frequency should be based on the amount
of use, working conditions, operator training and skill,
and established company standards.
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
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners.
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LOC B
ORIGINAL INSTRUCTIONS
19 DEC 11 Rev A
408-8609
Figure 2
3. When die assembly is not in use, mate and store
them in a clean, dry area.
5.2. Periodic Inspection
A. Visual Inspection
1. Remove all lubrication and accumulated film from
the dies by immersing the dies in a suitable
commercial degreaser that will not affect paint or
plastic material.
2. Make sure that all die retention screws and die
components are properly secured.
3. Inspect die assembly for worn, cracked, or
broken surfaces. If damage is evident, the dies must
be replaced. See Section 6, REPLACEMENT
PARTS.
B. Gaging the Crimping Section
Figure 3
5.1. Daily Maintenance
1. Remove accumulated dust, moisture, and other
contaminants with a clean, soft brush or lint-free
cloth. Do NOT use hard or abrasive objects that
could damage the dies.
2. Make sure dies are protected with a THIN coat of
any good SAE 20 motor oil. Do NOT oil excessively.
Rev A
This inspection requires the use of a plug gage
conforming to the dimensions provided in Figure 4.
TE does not manufacture or market these gages. To
gage the crimping section, remove die assembly from
tool and proceed as follows:
1. Remove traces of oil or dirt from the crimping
section and plug gage.
2. Mate the dies until the crimping surfaces have
bottomed; then hold in this position. DO NOT force
the dies beyond initial contact.
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408-8609
GAGE ELEMENT DIMENSIONS
DIE ASSEMBLY
PART NUMBER
GO
NO-GO
WIDTH (Max) “W”
1583015-1
4.293-4.300 [.1690-.1693]
4.544-4.547 [1789-.1790]
2.87 [.113]
1583015-2
5.207-5.215 [.2050-.2053]
5.458-5.461 [.2149-.2150]
2.87 [.113]
1583015-3
5.867-5.875 [.2310-.2313]
6.119-6.121 [.2409-2410]
3.30 [.130]
1583016-1
7.442-7.450 [.2930-.2933]
7.693-7.696 [.3029-.3030]
4.16 [.164]
GAGE ELEMENT DIMENSIONS
DIE ASSEMBLY
PART NUMBER
GO
NO-GO
WIDTH (Max) “W”
RADIUS (Max) “R”
1583015-1, -2, -3
8.572-8.580 [.3375-.3378]
8.773-8.776 [.3454-.3455]
8.51 [.335]
4.27 [.168]
1583016-1
10.223-10.231 [.4025-.4028]
10.424-10.427 [.4104-.4105]
10.16 [.400]
5.08 [.200]
Figure 4
NOTE
Pivot the stop away from the moving die in order to
gage the braid crimping section.
i
3. Carefully insert GO element into the
corresponding crimping section; do not force it. The
GO element must pass completely through the
crimping section.
4. In the same manner, try to insert the NO-GO
element into the same crimping section. The NOGO element may start entry, but must not pass
completely through the crimping section.
If the crimping sections conform to the gage
inspection, they are considered dimensionally correct,
and should be lubricated with a THIN coat of any good
SAE 20 motor oil. If not, the die assembly must be
replaced. Refer to Section 6, REPLACEMENT
PARTS.
Rev A
For additional information concerning the use of a plug
gage, refer to Instruction Sheet 408-7424.
6. REPLACEMENT PARTS
The parts listed in Figure 5 are customer- replaceable.
A complete inventory can be stocked and controlled to
prevent lost time when replacement of parts is
necessary. Parts other than those listed should be
replaced by TE to ensure quality and reliability of the
die assembly.
CUSTOMER SERVICE (038-035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105-3608
7. REVISION SUMMARY
• New logo
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408-8609
ITEM
NO.
DESCRIPTION
CRIMPING DIE ASSEMBLY
1583015-1
1583015-2
1583015-3
1583016-1
QTY PER
DIE ASSY
1
SCREW, Special
543416-1
543416-1
543416-1
543416-1
1
2
INDENTER, Braid
1583013-1
1583013-1
1583013-1
1583023-1
1
3
INSERT, Insulation, Upper
543410-1
543415-1
543408-1
543399-1
1
4
SPACER, Upper
543411-1
543411-1
543411-1
543411-1
1
5
RING, Retaining, External E-Ring
1-21046-3
1-21046-3
1-21046-3
1-21046-3
2
6
SPACER, Lower
543412-1
543412-1
543412-1
543412-1
1
7
INSERT, Insulation, Lower
543409-1
543414-1
543407-1
543400-1
1
8
ANVIL, Braid
1583012-1
1583012-1
1583012-1
1583022-1
1
9
SCREW, Special
543416-2
543416-2
543416-2
543416-2
1
10
STOP, Ferrule
1583014-1
1583014-1
1583014-1
1583014-1
1
Figure 5
Rev A
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