Instruction Sheet
408-- 4116
Crimping Die Assembly
58559- 1
11 MAR 10 Rev A
Spring
Retainer
Adjustment
Screw
Nut
Stationary Jaw
(Ref)
Locator
PRO-- CRIMPER III Frame
Assembly 354940-- 1 (Ref)
Straightener
Spring
Indenter Die
Die Retaining
Screws (Ref)
Anvil Die
Movable Jaw
(Ref)
Figure 1
1. INTRODUCTION
Crimping Die Assembly 58559--1 is designed to crimp
Consumer RF Series BNC plug connectors when
used in PRO--CRIMPER III Frame Assembly
354940--1. Read these instructions thoroughly before
using the die assembly.
NOTE
i
Dimensions in this instruction sheet are in
millimeters [with inches in brackets]. Figures are
not drawn to scale.
Reasons for reissue of this instruction sheet are
provided in Section 8, REVISION SUMMARY.
2. DESCRIPTION (See Figure 1)
The die assembly consists of an indenter die and an
anvil die. The die assembly features a locator and
straightener assembly (straightener, adjustment
screw, nut, spring retainer, and spring). Each die is
held in the tool jaws by a single screw.
When mated, the dies form two crimping chambers.
The small crimping chamber crimps the center
contact onto the center conductor of the coaxial cable
and the large crimping chamber crimps the ferrule of
the connector onto the coaxial cable. The ferrule
crimping chamber actually places two different size
crimps on the ferrule; one crimp in the connector
support sleeve area, and another crimp in the cable
insulation area directly behind the cable braid.
The locator and straightener assembly properly
positions and holds the center contact of the
connector during the crimping procedure.
3. INSTALLATION AND REMOVAL OF DIE ASSEMBLY
(See Figure 1)
1. Close the tool handles until the ratchet releases,
then allow the handles to open fully.
2. Remove the two die retaining screws from the
tool jaws.
3. Install the anvil die in the movable jaw of the
tool. Insert the short die retaining screw through
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LOC B
408- 4116
Crimping Die Assembly 58559- 1
the retaining hole in the jaw and through the anvil
die. Tighten the screw just enough to hold the die
in place. Do not tighten the screw completely at
this time.
4. Install the indenter die in the stationary jaw of
the tool frame. Insert the long die retaining screw
through the retaining hole in the jaw and through
the indenter die. Tighten the screw just enough to
hold the die in place. Do not tighten the screw
completely at this time.
5. Carefully close the tool handles, making sure
that the dies align properly. Continue closing the
tool handles until the tool ratchet has engaged
sufficiently to hold the dies in place, then tighten
both die retaining screws.
NOTE
i
4. CRIMPING PROCEDURE
Initially, the connector retention force should be
verified as specified in Paragraph 5.2., Retention
Force Adjustment, before using the tool.
NOTE
i
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 ferrule has been placed onto the
cable, and that the cable braided shield is flared away
from the cable. Then proceed as follows:
4.1. Crimping the Center Contact (See Figure 2)
The ratchet has detents that create audible clicks
as the tool handles are closed.
6. Attach the straightener onto the spring retainer
with the adjustment screw. Insert the spring into
the spring retainer and place the locator over the
spring.
7. While holding the locator against the spring
retainer, place the screw hole in the spring retainer
over the end of the long die retaining screw. The
locator should be against the side of the tool jaw.
8. Place the nut onto the end of the long die
retaining screw and tighten the nut enough to hold
the locator and straightener assembly in place, but
still allowing the locator to slide up and down.
9. To remove the die assembly, close the tool
handles until the ratchet releases. Remove the nut,
the locator and straightener assembly, and the two
die retaining screws. Slide the anvil and indenter
out of the tool jaws.
1. Holding the center contact by the mating end,
insert the contact through the front of the tool and
into the crimping chamber and onto the anvil die.
2. Close the tool handles so that the dies partially
close. Position the contact so that the locator drops
into the contact wire stop slot and the end of the
contact is inside the groove in the straightener. See
cross--section of Figure 2.
3. Hold the contact in place and squeeze the tool
handles together until the ratchet engages just
enough to hold the contact in place. Do not deform
the contact wire barrel.
4. Insert stripped cable into contact wire barrel
until it is butted against the locator. See
cross--section of Figure 2.
5. Holding the cable in position, close the tool
handles until the ratchet releases. Allow the tool
handles to open fully and remove the crimped
center contact.
Crimping Center Contact
Top of Locator
Cross--Section
Locator Positioned
in Contact Wire
Stop Slot
Stripped
Wire
End of Contact
Positioned in
Straightener
2 of 4
Anvil
Die
Locator
Center
Contact
Straightener
Contact Wire Stop
Slot
Anvil
Die
Figure 2
Tyco Electronics Corporation
Rev A
408- 4116
Crimping Die Assembly 58559- 1
NOTE
i
The crimped center contact may stick in the
crimping area, but the contact can be easily
removed by pushing downward on the top of the
locator (see Figure 2).
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 of the cable is over the support sleeve of the
connector body and that no strands from the shield
enter the connector body.
5. TOOL ADJUSTMENTS
5.1. Contact Support Adjustment
Make a sample crimp and determine if the center
contact is bending upward, bending downward, or
bending from side to side. If the contact is bent,
adjustment is required.
1. Loosen the adjustment screw.
2. Place a contact with cable into the proper
crimping chamber and close the tool handles until
the locator and straightener assembly is holding
the contact in position.
3. Move the straightener up or down, as required,
to eliminate the bending of the center contact.
2. Slide the ferrule up over the braided shield and
onto the connector until the ferrule butts against
the shoulder on the connector body.
4. Tighten the adjustment screw and close the
handles until the ratchet releases.
3. Place the ferrule in its crimping chamber of the
anvil die so that the shoulder on the connector
body butts against the edge of the die.
4. While holding the assembly together, begin to
close the tool handles. Keep holding the assembly
until the dies have closed enough to hold the
assembly in place.
CAUTION
!
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. Remove and inspect the center contact.
6. Make another sample crimp. If the contact is still
being bent during crimping, repeat the adjustment
procedure.
5.2. Retention Force Adjustment (Figure 4)
The tool ratchet mechanism features an adjustment
wheel with numbered settings. If the retention force is
not acceptable, adjust the ratchet as follows:
Refer to the appropriate Application Specification
(114--Series) for the required retention force of
the connector.
NOTE
5. Carefully close the tool handles until the ratchet
releases.
6. Allow the tool handles to open fully, and remove
the crimped connector.
i
1. Remove the lockscrew from the ratchet
adjustment wheel.
Crimping Ferrule
Shoulder of
Connector Body
Against Edge of Die
Ferrule in Crimping
Chamber on Anvil Die
Cross--Section
Ferrule
Anvil Die
Figure 3
Rev A
Tyco Electronics Corporation
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408- 4116
Crimping Die Assembly 58559- 1
Screwdriver
Lockscrew
(Typ)
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 AND REPAIR.
6.3. Measuring 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 dimensions of
the die openings.
Ratchet
Adjustment
Wheel
Figure 4
2. With a screwdriver, adjust the ratchet wheel
from the opposite side of the tool.
B
A
C
3. Observe the ratchet adjustment wheel.
If a tighter retention is required, rotate the
adjustment wheel COUNTERCLOCKWISE to a
higher--numbered setting. If a looser retention is
allowed, rotate the adjustment wheel CLOCKWISE
to a lower--numbered setting.
Note: Not to Scale
4. Re--install the lockscrew.
5. Make a sample crimp and measure the retention
force with a pull force tester. If the retention force
is acceptable, secure the lockscrew. If the retention
force is unacceptable, remove lockscrew and
continue to adjust the ratchet, and again measure
a sample crimp.
6. MAINTENANCE AND INSPECTION
DIMENSION (mm [in.])
A +0.05 [+.002]
B +0.10 [+.004]
C +0.10 [+.004]
0.66 [.026]
2.64 [.104]
4.32 [.170]
Figure 5
7. REPLACEMENT AND REPAIR
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 die assembly or tool.
2. Make sure that the die retaining screws are
properly secured.
3. When the die assembly is not in use, mate and
store it in a clean, dry area.
4. Clean the die assembly with a soft, lint--free
cloth.
It is recommended that the die assembly be inspected
when you receive it and at regularly scheduled
intervals. The die assembly is not repairable, and it
should be replaced when it is worn or damaged.
Order die assemblies through your 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
PO BOX 3608
HARRISBURG PA 17105--3608
6.2. Inspection
1. Remove all lubrication and accumulated film
from the dies by immersing them in a suitable
commercial degreaser.
2. Make certain that all die retaining screws and
die components are properly secured.
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8. REVISION SUMMARY
Revisions to this instruction sheet include:
S Updated instruction sheet to corporate
requirements
Tyco Electronics Corporation
Rev A
