1918932-5 - Tyco Electronics

Instruction Sheet

PRO BEAM* Jr. Expanded Beam (EB)

Sealed D-Hole 408-10249

LOC B

of 11

2008 Tyco Electronics Corporation, Harrisburg, PA

All International Rights Reserved

TE logo and Tyco Electronics are trademarks.

*Trademark. Other products, logos, and company names used are the property of their respective owners.

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.tycoelectronics.com

30 OCT 08 Rev A

Bulkhead Connectors

Protective

Cap

Figure 1

Housing

Collet Nut

Seal

O-Ring

Jam Nut

Collet

Sleeve

D-Hole

Housing

Bulkhead Connector Shell Kit

(1918940-1 Shown)

Cable Adapter Kit

(1918932-2 Shown)

Panel

Nut

126-

Ferrule Assembly

O-Ring

Ferrule Assembly Kit

(1588700-1 Shown)

Spring

Dust

Cover

Ferrule Plate

Screw

EB Insert Assembly Kit

(1515743-1 Shown)

Guide

EB Insert

Wave

Spring

Extension

Washer

Crimp

Sleeve

Boot

Cable

Seal

Crimp

Support

1. INTRODUCTION

PRO BEAM Jr. EB sealed D–hole bulkhead

connectors are designed to be installed onto military

tactical type fiber optic cable with aramid fiber

strength members.

Dimensions in this instruction sheet are in metric

units. Figures are not drawn to scale.

The connector must be assembled using a bulkhead

connector shell kit, an EB insert assembly kit, ferrule

assembly kit (one for each fiber or channel), and a

cable adapter kit. Sample part numbers are given in

Figure 1. The combination of the kits selected is

based on the diameter of the cable, the mode and

quantity of fibers, and the operating wavelength of the

system.

To avoid poor optical performance or permanent

damage to the lens of the EB insert, use ONLY

Tyco Electronics ferrule assembly kits. Other

manufacturers' ferrule assemblies ARE NOT

compatible with the EB insert assembly kit.

These connectors are designed to be rear panel

mounted.

2. DESCRIPTION

Each kit contains the components shown in Figure 1.

The EB insert assembly kit is shipped with a white

protective label on the back (end opposite the lens) of

the EB insert which is installed immediately after final

testing to keep the channel cavities clean. The EB

insert is ready for assembly as shipped.

3. HANDLING

To avoid personal injury, NEVER look into the

end of terminated or unterminated optical fibers.

Laser radiation is invisible but can damage eye

tissue.

Do not touch the lens of the EB insert with your

fingers or with any tools

If the lens is touched or otherwise contaminated,

clean the lens according to Instruction Sheet

408-8828.

Always have the protective cap installed or the

connector mated to prevent contamination to

the EB insert assembly

NOTE

CAUTION

DANGER

NOTE

408-10249

PRO BEAM Jr. EB Sealed D-Hole Bulkhead Connectors

Rev

of 11 Tyco Electronics Corporation

Apply Thin Film of the Grease Here

Outside Surface at Front of Extension

Figure 2

Collet

Nut Washer

Cable

Seal

Cable

ExtensionJam NutSeal

O-Ring

Collet

Sleeve

Wave

Spring

Boot

Assemble These Components Before Installing onto Cable

4. TOOLS AND MATERIALS

The following tools and materials are necessary for

preparation, assembly, inspection, and maintenance

of the connector and cable assembly. Follow the

operating instructions packaged with the tools and

safety guidelines packaged with the materials.

Items without a part number or supplier are

customer supplied.

4.1. Tools

— cable jacket strip tool

— Aramid Fiber Shears 1278637–1

— SDE PEW 12 Hand Tool 91382–1 with Die Set

1673667–1 (408–8795)

— micrometer or vernier, dial, or digital caliper

— Fiber Stripping Tool 504024–1 (125–

m, red

handle) (408–9485)

— Heat Cure Oven Assembly 502134–1 (120 Vac)

or –2 (240 Vac) includes universal heat cure block

(408–9460)

— Curing Fixture 1693797–1 (408–8857)

— Sapphire Scribe Tool 504064–1 (408–4293)

— polishing machine (recommended) or Polishing

Bushing 504862–1 (for hand polishing)

— 200



Microscope 1754767–1

— Ferrule Insertion Tool 1693820–1

— 2.5–mm hex wrench

— EB Insert Assembly Fixture 1515844–1

— Bench–Mount Assembly Fixture 1918503–2 or

1918503–3

— 15–mm U–wrench

— 17–mm U–wrench

— 23–mm U–wrench

Loctite, 480, Prism, and 243 are trademarks of Henkel Corporation.

Dow Corning and Molykote are trademarks of Dow Corning Corporation.

4.2. Materials

— DOW CORNING MOLYKOTE 55M grease

— LOCTITE PRISM 480 instant adhesive

— lint–free tissues or cloths

— isopropyl alcohol (99%) or acetone

— Epoxy 504035–1 (4 grams)

— Epoxy Mixer 501202–1

— Epoxy Applicator Kit 501473–3

For hand polishing only:

—5–

m Aluminum Oxide Polishing Film

228433–8

— 1mm Rubber Polishing Pad 501858–1

(green)

— Polishing Plate 501197–1 (216



280 mm)

— 0.3–

m Diamond Polishing Film 228433–5

— Final Polishing Film 502748–2

— lint–free applicator swabs

— LOCTITE 243 threadlocker

5. ASSEMBLY PROCEDURE

IMPORTANT:

Assemble the connector using a laminar

flow table in a clean environment meeting the

requirements of International Organization for

Standardization (ISO) 14644–1 (Class 5),

“Cleanrooms and Associated Controlled

Environments, Part 1.” Make sure that all components

are free from contamination.

Proceed as follows:

If using a 4-fiber breakout cable (which requires

a 7.5-mm cable adapter kit), refer to 408-10010

for the assembly procedure (which must be used

in conjunction with these instructions).

5.1. Prepare the Cable

1. Thread the jam nut onto the front of the

extension until it stops. DO NOT force the jam nut

past this point. Refer to Figure 2.

NOTE

408-10249

PRO BEAM Jr. EB Sealed D-Hole Bulkhead Connectors

of 11Rev

Tyco Electronics Corporation

2. Slide the seal O–ring onto the front of the

extension and into the groove in the jam nut. Apply

thin film

of the grease around the outside edge at

the front of the extension. Refer to Figure 2.

3. Slide the components shown in Figure 2 onto

the cable allowing 1 m at the end of the cable for

stripping the cable. Make sure to orient each

component as shown.

4. Using the cable jacket strip tool, strip the jacket

to the dimension given in Figure 3, exposing the

strength members and fiber.

5. Using the shears, trim the strength members to

the length given in Figure 3.

These instructions are for single-channel

connectors. For multi-channel connectors,

perform the same assembly procedure for each

channel.

5.2. Terminate the Fiber

1. Apply 1 or 2 small drops of the instant adhesive

onto the cable jacket between 4 and 5 mm from

the stripped end of the jacket. See Figure 4,

Detail A.

2. Slide the crimp support (large diameter end first)

over the fibers and strength members and onto the

jacket until it bottoms. See Figure 4, Detail B.

3. Apply a thin band of the instant adhesive around

the knurled portion of the crimp support. Make sure

that the band is continuous around the entire

circumference. See Figure 4, Detail C.

4. Flare the strength members away from the fiber.

See Figure 4, Detail C.

Then

quickly

, before the instant adhesive

begins

harden, slide the crimp sleeve over the fiber,

pushing the strength members back over the crimp

support until it bottoms on the rear flange of the

crimp support. See Figure 4, Detail D.

LOCTITE 480 PRISM Instant Adhesive is a

cyanoacrylate which hardens extremely quick. If

longer working time is needed, use EPO-TEK

353ND Epoxy instead (for this step only).

5. Place the crimp sleeve in the 8.6–mm hex nest

of the hand tool, and crimp the crimp sleeve onto

the crimp support. Make sure to position the crimp

sleeve in the hex nest so that the crimp will locate

from the back of the crimp sleeve to within the

dimension shown in Figure 4, Detail E.

Loctite, 480, and Prism are trademarks of Henkel Corporation.

EPO-TEK is a trademark of Epoxy Technology Inc. Corporation.

Figure 3

Jacket

Fiber Strength

Members

65+5mm

Cable Strip Length

Note:

Not to Scale

11+1mm

Figure 4

Detail A

Detail C

Jacket

End of Jacket

Apply Thin Band of Instant Adhesive Here

Detail B

Crimp Support

Bottomed on Jacket

Strength

Members

Fiber

Apply Instant Adhesive Here

4-5 mm

Strength Members

Flared

Detail D

Detail E

Crimp

Sleeve

2+1mm

Crimp Location

Rear Flange of

Crimp Support

Back of Crimp Sleeve

NOTE

408-10249

PRO BEAM Jr. EB Sealed D-Hole Bulkhead Connectors

Rev

of 11 Tyco Electronics Corporation

6. Using the micrometer or caliper, measure the

crimp sleeve across the flats of the hex crimp to

make sure that it conforms to the crimp height and

crimp width shown in Figure 5, Detail A.

If necessary, crimp again, and re–measure the

crimp.

7. At the back of the crimp support, apply the

instant adhesive around the circumference of the

crimp support at the junction of the cable and the

crimp support. Then at the front of the crimp

sleeve, apply the adhesive over the opening of the

crimp sleeve to encapsulate the strength members.

See Figure 5, Detail B. Remove any excess

adhesive.

8. Mark the fiber at the dimension shown in

Figure 5, Detail C, and using the fiber stripping

tool, strip the buffer to the mark, exposing the bare

fiber. Using a lint–free tissue or cloth dampened

with the isopropyl alcohol or acetone, clean the

bare fiber.

Take care not to break the bare fiber. If any part

of the fiber breaks, the crimp support and crimp

sleeve must be replaced, and the cable must be

re-stripped.

9. Slide the spring over the fiber. See Figure 5,

Detail D.

10. Pre–heat the heat cure oven to 100

11. Prepare the epoxy according to the following:

a. Remove the separating clip from the epoxy

package. Using the epoxy mixer, mix the two

components together thoroughly for 20 to 30

seconds.

b. Install the needle tip on the applicator from

the epoxy applicator kit. Make sure it is secure.

Remove the plunger.

c. Cut the epoxy packet open, and squeeze

the epoxy into the back of the applicator.

Re–assemble the plunger. Hold the applicator

vertically, and slowly push on the plunger until

the entrapped air escapes and a bead of epoxy

appears at the needle tip.

d. Using a lint–free tissue or cloth dampened

with the isopropyl alcohol or acetone, clean the

tip of the applicator.

Figure 5

Mark and Strip Fiber Buffer

Detail C

Detail D

Spring

55+1/-0 mm

Bare Fiber Fiber Buffer

Detail B

8.7+0.1 mm

Crimp Height

5+0.1 mm

Crimp Width

Detail A

Back of

Crimp Support

Junction of Cable and Crimp Support

Apply Instant Adhesive Here

Opening of Crimp Sleeve

CAUTION

408-10249

PRO BEAM Jr. EB Sealed D-Hole Bulkhead Connectors

of 11Rev

Tyco Electronics Corporation

12. Hold the ferrule assembly vertically, and insert

the needle tip into the base of the ferrule assembly

until it is against the back (end closest to the base)

of the ferrule assembly. Refer to Figure 6.

13. While holding the ferrule assembly

firmly

against the needle tip,

slowly

inject the epoxy until

a small bead of epoxy (approximately 0.75 mm in

diameter) forms at the end face of the ferrule

assembly. DO NOT allow the bead to get too large

or smear.

14. Withdraw the needle slightly, and inject an

additional small amount of epoxy so that the cavity

at the base of the ferrule assembly is

approximately one–third to one–half full.

To avoid personal injury, remember that epoxy is

a hazardous material, and pay particular attention

to the following:

ĊALWAYS follow manufacturer's safety guidelines.

ĊALWAYS wear protective gloves when using epoxy.

ĊALWAYS use epoxy in a well ventilated area.

ĊAVOID prolonged and frequent contact with skin.

ĊAVOID inhaling fumes from epoxy.

15. Place the crimp sleeve and fiber into the curing

fixture according to the instructions included with

the curing fixture.

Carefully insert the fiber into the back of the ferrule

assembly (previously prepared with epoxy).

Simultaneously slide and rotate the ferrule

assembly on the fiber (to prevent any air pockets

from being trapped in the epoxy) until it bottoms.

Make sure that the bare fiber is protruding from the

end face of the ferrule assembly. If it is not, re–strip

and re–terminate the fiber.

Place the ferrule assembly in the curing fixture

according to 408–8857 (instructions included with

the curing fixture).

16. Cure the assembly in the heat cure oven for 20

minutes. Remove the assembly from the oven, and

allow the assembly to cool to room temperature.

17. Remove the assembly from the curing fixture

according to 408–8857. Measure the assembly to

make sure that it conforms to the dimension given

in Figure 7. If it does not, re–strip and re–terminate

the fiber.

Although the curing fixture is designed to ensure

that the required functional length is obtained, it

is still important to measure the assembly for this

length after curing.

Figure 6

Figure 7

0.75-mm Diameter (Approx)

Bead of Epoxy

Applicator Needle

End Face of

Ferrule Assembly Base of

Ferrule Assembly

Base and O-Ring

of Ferrule Assembly

Crimp

Sleeve

Curing Fixture

Spring

Cable

Fiber

65.5+1/-0 mm

Required Functional Length

Assembly After Curing

DANGER

NOTE

408-10249

PRO BEAM Jr. EB Sealed D-Hole Bulkhead Connectors

Rev

of 11 Tyco Electronics Corporation

5.3. Cleave the Fiber

Firmly support the ferrule assembly, and draw the

beveled edge of the scribe tool across the fiber as

shown in Figure 8. After scoring the fiber, pull the

fiber straight away from the ferrule assembly.

Safely dispose of excess fiber.

To avoid damage to the tip of the scribe tool,

DO NOT allow the scribe tool to contact the

epoxy.

5.4. Polish the Fiber

It is recommended polishing the fiber using a

polishing machine. The polish must produce a

super–physical contact (PC) end finish for singlemode

connectors and a flat end finish for multimode

connectors.

Machine polishing produces the best

results.

Polish the fiber according to the machine

manufacturer’s instructions.

If machine polishing is not possible, hand polish the

fiber according to the following:

1. Using a small piece of the 5–

m polishing film,

remove the fiber stub to the level of the epoxy.

2. Install the ferrule assembly onto the polishing

bushing.

3. For singlemode connectors, place the green

polishing pad on the polishing plate. Place the

5–

m polishing film on the green polishing pad.

For multimode connectors, place the polishing

plate on a hard flat surface. Place the 5–

polishing film on the polishing plate.

4. Hold the ferrule assembly and rest the tips of

your index finger, middle finger, and thumb on the

top of the polishing bushing. Starting with very light

pressure, polish the tip of the fiber in a figure–8

pattern. Refer to Figure 9. Polish the fiber until the

epoxy turns a very light yellow.

DO NOT remove all the epoxy. As the epoxy gets

lighter, check the tip of the fiber frequently.

5. Clean the end face of the ferrule assembly and

polishing bushing with isopropyl alcohol or acetone

and a lint–free tissue.

Figure 8

After Scoring, Pull Fiber Straight Away

Fiber

Scribe Tool

Epoxy

End Face of

Ferrule Assembly

Figure 9

Figure-8

Pattern

Polishing

Bushing

6. Place the 0.3–

m polishing film on the polishing

pad (singlemode) or polishing plate (multimode).

Polish in a figure–8 pattern. Stop polishing

as soon

all the epoxy is removed.

7. Clean the end face of the ferrule assembly and

polishing bushing with isopropyl alcohol or acetone

and a lint–free tissue.

8. Place the final polishing film on the polishing

pad (singlemode) or polishing plate (multimode).

Apply several drops of water to an unused area of

the film. Move the ferrule assembly in 20–mm

circles on the water for 25 seconds.

One sheet of final polishing film will be sufficient

for 10 to 20 ferrule assemblies.

DANGER

CAUTION

NOTE

408-10249

PRO BEAM Jr. EB Sealed D-Hole Bulkhead Connectors

of 11Rev

Tyco Electronics Corporation

9. Remove the ferrule assembly from the polishing

bushing. Clean the end face and sides of the

ferrule assembly with isopropyl alcohol or acetone

and a lint–free tissue.

5.5. Inspect the Ferrule Assembly and Fiber

Never inspect or look into the end of a fiber when

optical power is applied to the fiber. The infrared

light used, although it cannot be seen, can cause

injury to the eyes.

1. Using the microscope, inspect the ferrule

assembly and fiber according to the following

criteria (refer to Figure 10):

— Make sure that any epoxy is removed from the

ferrule assembly

— Dirt may be mistaken for small pits. If dirt is

evident on the ferrule assembly or fiber, clean with

isopropyl alcohol or acetone and a lint–free tissue,

then dry

— Fine polishing lines are acceptable

— Small peripheral chips (at the outer rim) on the

fiber are acceptable

— Large chips in the center of the fiber and dark

scratches are unacceptable, and the fiber must be

re–terminated

2. If necessary, install the dust cover onto ferrule

assembly to prevent contamination to the end face.

5.6. Complete the Assembly

1. Remove the protective label from the back (end

opposite the lens) of the EB insert.

2. Align the end of the ferrule assembly with the

appropriate channel cavity of the EB insert, and

insert the ferrule assembly into the channel cavity

until the O–ring is against the channel cavity. See

Figure 11, Detail A. To avoid damage to the fiber,

DO NOT push the fiber to install the ferrule

assembly.

IMPORTANT:

The channels for each fiber pair are

designated on the EB insert with “A1” and “B1,” and

“A2” and “B2”. For proper end–to–end system

connection, connect A1 to B1, B1 to A1, A2 to B2,

and B2 to A2.

3. Slide the spring over the fiber until it is against

the O–ring of the ferrule assembly. See Figure 11,

Detail B. Using the ferrule insertion tool, push the

spring until the ferrule assembly bottoms in the

channel cavity (the O–ring will be inside of the

cavity, and the spring will protrude slightly from the

cavity). See Figure 11, Detail B.

Figure 10

Acceptable

Fiber

Fine Polishing

Lines

Small Peripheral

Chips

Ferrule

Assembly

Tip

Unacceptable

Dark Scratches

Large Chips

Ferrule

Assembly

Tip

Figure 11

Detail A

Detail B

Ferrule Assembly Bottomed

in Channel Cavity

EB Insert

Spring Against O-Ring

Fiber

Spring

Ferrule Assembly Inserted

into Channel Cavity with

O-Ring Against Cavity

Using the Ferrule Insertion Tool

Place Jaw of Tool Over Spring

2Push Against Spring Until Jaw of Tool

Bottoms on EB Insert

Spring Protrudes Slightly

from Channel Cavity

DANGER

408-10249

PRO BEAM Jr. EB Sealed D-Hole Bulkhead Connectors

Rev

of 11 Tyco Electronics Corporation

If necessary, to remove the ferrule assembly from

the cavity, firmly grasp the end of the ferrule

assembly (but not the spring) with the

needle-nose pliers, and pull it out of the cavity.

To avoid damage to the fiber, DO NOT PULL OR

PUSH THE FIBER to install or remove the ferrule

assembly from the cavity.

4. Align the index pin hole of the ferrule plate with

the index pin at the back of the EB insert, and slip

the fiber into the closest slotted hole in the ferrule

plate. See Figure 12, Detail A.

5. Hold the ferrule plate against the EB insert,

making sure that the index pin enters the index

hole. Thread the screw through the screw hole of

the ferrule plate and into the hole in the EB insert.

See Figure 12, Detail B. Using the 2.5–mm hex

wrench, tighten the screw to a torque between 0.8

and 1.0 N–m. Check to make sure that the ferrule

plate is flush with the EB insert.

6. Align the guide pins with the guide holes, and fit

the EB insert assembly fixture onto the EB insert

assembly. Refer to Figure 12, Detail C.

Using the fixture will help guide the EB insert

assembly into the housing and minimize the

possibility of grease contaminating the face of the

EB insert.

7. Using an applicator swab, apply a

thin film

of the

grease around the O–ring of the EB insert, the

inside of the front seal on the inside of the housing,

and the internal O–ring of the D–hole housing.

Remove any excess grease. Refer to Figure 13,

Detail A.

To avoid contaminating optical components,

DO NOT use heavy deposits of the grease.

8. Align the D–hole housing with the back (end

opposite the front seal) of the housing so that the

desired rotational orientation is established (use

the flat on the D–hole housing as the reference

point). See Figure 13, Detail B. Then slide the

D–hole housing onto the housing until it stops (it

will “snap” into place). The interference fit of the

internal O–ring of the D–hole housing with the

housing should prevent the D–hole housing and

housing from separating during assembly.

There are 4 rotational orientations for mounting

the connector to the panel: top, bottom, left, or

right. Aligning one of the keyways located inside

the D-hole housing with one of the external keys

of the housing will establish the rotational

orientation (one keyway is parallel to the flat).

Refer to Figure 13, Detail B.

Figure 12

Detail A

Index

Ferrule

Plate Index Pin

Hole

Fiber in

Slotted Hole

Detail B

Screw

Screw Hole of

Ferrule Plate

Detail C

EB Insert Assembly

Fixture EB Insert Assembly

Apply Thin Film of Grease Here

O-Ring of EB Insert

Housing

Front Seal (Inside Housing)

Apply Thin Film of Grease Here

D-Hole Housing

Apply Thin Film of Grease Here

Internal O-Ring

(Visible Inside D-Hole Housing)

Detail B

External Key

(2 Places) of Housing

Keyway (4 Places)

of D-Hole Housing Flat

Detail A

Figure 13

NOTE

CAUTION

NOTE

CAUTION

NOTE

408-10249

PRO BEAM Jr. EB Sealed D-Hole Bulkhead Connectors

of 11Rev

Tyco Electronics Corporation

9. Align the internal key (small bar inside) of the

housing with the keyway (slot along the outside) of

the EB insert, and slide the fixture along with the

EB insert assembly into the housing. See Figure

14, Detail A.

10. Using the 2.5–mm hex wrench, push the EB

insert assembly into the housing until it bottoms. To

avoid damage to the fiber, DO NOT push the fiber

or cable to install the EB insert assembly.

11. Remove the fixture from the front of the

housing.

12. Slide the wave spring over the crimp sleeve

and into the housing. See Figure 14, Detail B.

13. Apply 2 to 3 drops of the threadlocker to the

threads at the front of the collet sleeve. See

Figure 14, Detail C.

14. Slide the collet sleeve over the crimp sleeve

and into the housing. Thread the collet sleeve onto

the housing, BEING VERY CAREFUL NOT to

pinch the back end of the collet sleeve which would

cause the cable to twist. See Figure 14, Detail D.

15. Secure the bench–mount assembly fixture to a

stable work surface. Fit the end of the housing

onto the captive housing of the bench–mount

assembly fixture. See Figure 14, Detail E.

16. Using 15–mm U–wrench, tighten the collet

sleeve to a torque between 4 and 5 N–m.

17. Using an applicator swab, apply a

thin

film

the grease to the housing O–ring, threads of the

collet sleeve, and the ramp of the collet sleeve.

Refer to Figure 14, Detail F.

Figure 14

Detail A

Internal Key of Housing

(Visible Inside Housing) Keyway of

EB Insert

Detail C

Wave

Spring

Detail B

Crimp Sleeve

Detail F

Detail D

Detail E

Apply Threadlocker Here

Threads at Front of Collet Sleeve

Collet Sleeve

Crimp Sleeve

Bench-Mount

Assembly Fixture

Housing

Collet Sleeve

Housing O-Ring

Threads of Collet Sleeve

Ramp of Collet Sleeve

Apply Thin Film of Grease Here

Housing

End of Housing

408-10249

PRO BEAM Jr. EB Sealed D-Hole Bulkhead Connectors

Rev

A10

of 11 Tyco Electronics Corporation

18. Slide the collet nut onto the collet sleeve.

Using the 15–mm U–wrench, tighten the collet nut

to a torque between 3.6 and 4 N–m. See Figure

15, Detail A.

19. Apply 2 to 3 drops of the threadlocker to the

threads of the housing. See Figure 15, Detail A.

20. Slide the washer against the collet sleeve. See

Figure 15, Detail B. Slide the cable seal over the

cable until it is approximately 10 mm from the

washer. See Figure 15, Detail C.

21. Apply the grease to the front and back and to

the outside diameter of the cable seal. Also, apply

the grease around the cable jacket between the

cable seal and the washer. See Figure 15,

Detail D.

22. Apply a

thin film

of the grease to the inside

edge of the extension (this is necessary to prevent

damage to the O–ring of the housing). See Figure

15, Detail E.

23. Thread the extension (with the jam nut) onto

the D–hole housing. See Figure 15, Detail E. Using

the 17–mm U–wrench, tighten the extension to a

torque between 6 and 7 N–m.

Check to make sure that the seal O–ring is still in

the groove at the front of the jam nut (described in

Paragraph 5.1, Step 2). Then thread the jam nut

until it is against the D–hole housing (the seal

O–ring should be compressed). See Figure 15,

Detail F. Using the 23–mm U–wrench, tighten the

jam nut to a torque between 10 and 12 N–m.

If the seal O-ring is not in the groove, apply a

thin film of the grease to the seal O-ring, and

re-position it.

24. Apply the instant adhesive completely around

the cone of the extension. See Figure 15, Detail F.

Detail A

Apply Threadlocker Here

Threads of Housing

Figure 15

Collet Nut

Washer

Detail B

Collet

Sleeve

Detail C

Cable

Seal

10 mm

Detail D

Apply Grease Here

Cable Seal

Apply Grease Here

Cable Jacket

Apply Instant Adhesive Here

Cone of Extension

Detail F

Detail E

Assembled Extension

and Jam Nut

D-Hole Housing

Jam Nut

Apply Grease Here

Inside Edge of Extension

Housing O-Ring

NOTE

408-10249

PRO BEAM Jr. EB Sealed D-Hole Bulkhead Connectors

of 11Rev

Tyco Electronics Corporation

25. Slide the boot over the cone of the extension

until it is tight against the shoulder of the extension.

Immediately rotate the boot so that the orientation

tab is aligned with a desired reference point (using

the guide pin of the EB insert is recommended;

facing the bench–mount fixture assembly, the

guide pin is positioned at 12 o’clock). See

Figure 16.

Make sure to use the same reference point to

align the boot for subsequent connectors.

26. Unscrew the housing, and remove the

connector from the bench–mount assembly fixture.

5.7. Mount the Connector onto the Panel and

Install the Protective Cap

1. Cut the panel using the dimensions provided in

Figure 17.

Make sure that the flat edge is located in position

to match the established rotational orientation.

2. Install the connector through the back of the

panel so that the O–ring attached to the shoulder

of the D–hole housing is flat against the panel. See

Figure 18, Detail A.

3. Thread the panel nut onto the D–hole housing.

See Figure 18, Detail A. Tighten the panel nut to a

torque of approximately 40 N–m. The O–ring

should be compressed.

4. Thread the protective cap onto the housing,

then hand–tighten the protective cap as shown in

Figure 18, Detail B.

6. REPLACEMENT AND REPAIR

Components are not repairable. DO NOT use any

damaged or defective components. DO NOT re–use

the crimp support, crimp sleeve, or ferrule assembly

by removing the fiber.

Order replacement parts through your Tyco

Electronics representative, or call 1–800–526–5142,

or send a facsimile of your purchase order to

717–986–7605, or write to:

CUSTOMER SER VICE (038–035)

TYCO ELECTRONICS CORPORATION

PO BOX 3608

HARRISBURG PA 17105–3608

7. REVISION SUMMARY

Initial release of instruction sheet

Boot

Shoulder of

Extension

Orientation Tab

Guide Pin of EB Insert

at 12 O'Clock

Figure 16

Figure 17

Recommended Panel Cutout

Panel Thickness Range of 1-4 mm

30+0.2/-0.0 mm

28+0.2/-0.0 mm

Note:

Not to Scale

Flat Edge

Figure 18

Detail A

Detail B

Protective

Cap

O-Ring on Shoulder of

D-Hole Housing

Panel

Nut

Back of Panel

Housing

D-Hole

Housing

NOTE