749192-1 - Tyco Electronics

Instruction Sheet

Cover Lacing Fixture 91293-1 for

AMPLIMITE* .050 Series Connectors and 408-9750

LOC B

of 4

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

24 JUL 08 Rev C

AMPMODU* 50/50 Grid Connectors

Figure 1

Upper Tooling

Assembly Slide

Stop

Slide Body

Stationary

Locator

Slots for

Termination Covers

Lacing Fixture

Subassembly

Combs

Adjustable

Locator

1. INTRODUCTION

Cover Lacing Fixture 91293–1 is used with Manual

Arbor Frame Assembly 58024–1 to apply discrete

wires to AMPLIMITE .050 Series connectors and wire

lacing termination covers for AMPMODU 50/50 grid

connectors.

Refer to Instruction Sheet 408–6923 for the operating

procedure for the arbor frame.

Dimensions in this instruction sheet are in metric

units [with U.S. customary units in brackets].

Figures are not drawn to scale.

Reasons for reissue of this instruction sheet are

provided in Section 6, REVISION SUMMARY.

2. DESCRIPTION

(Figure 1)

The fixture consists of a slide assembly, a lacing

fixture subassembly, and an upper tooling assembly

containing two 50–position and two 100–position

seating bars. Additional seating bars, purchased

separately, are available for applying 26– and

68–position connectors.

The slide assembly consists of a slide body and a

slide stop. The slide body mounts to the base of the

manual arbor frame assembly and allows the lacing

fixture subassembly to slide back into position under

the upper tooling assembly. The slide stop, which is

used to position the lacing fixture subassembly under

the upper tooling assembly, is a thin bar of steel that

is fastened to the back of the slide at one of two

positions.

The lacing fixture subassembly consists of a

U–shaped base with slots to hold the termination

covers. Each slot has a stationary locator and an

adjustable locator that permit proper positioning of the

termination covers. Mounted onto the base are four

combs (two inner combs and two outer combs), which

are used to guide and hold the wires as they are

pressed into the termination covers during the

termination procedure.

On the underside of the base is a cable clamp which

holds the jacketed cable while the wires from the

cable are being laced into the combs.

The upper tooling assembly features a tool mount, a

top plate, four seating bars, and two cutting blades.

The inner seating bars push the wires at the inside

edge of the termination cover. The center seating

bars, which push the wires down inside the

termination cover, must be installed to match the

termination cover size being applied.

The cutting blades help push the wires downward at

the outside edge of the connector, and then cut the

wires nearly flush with the connector edge.

NOTE

408-9750

Cover Lacing Fixture 91293-1

Rev

of 4 Tyco Electronics Corporation

3. TOOLING ASSEMBLY SETUP

1. Place the slide body onto the base of the arbor

frame, and align the screw holes in the bottom of

the slide body with the holes in the base. Refer to

Figure 2.

2. While holding the slide body in place, tilt the

arbor frame and insert, but do not tighten, the four

mounting screws.

Slide Body

Figure 2

Arbor Frame

Base (Ref)

Mounting

Screws

3. Remove the tool mount from the ram of the

arbor frame assembly, if assembled.

4. Install the proper seating bars for the application

as shown in Figure 3.

Be sure to locate the tabs on the seating bars

toward the BACK of the arbor frame assembly.

5. Place the upper tooling assembly and tool

mount onto the ram, and tighten the flat head

screws. Refer to Figure 4.

6. Align the slide stop with the appropriate pair of

mounting holes in the slide body, and insert and

tighten the two mounting screws. Refer to Figure 5.

The forward-most mounting holes in the slide are

for 26- and 50-position termination covers, and

the rear-most holes are for 68- and 100-position

termination covers.

7. Place the lacing fixture subassembly onto the

slide body as shown in Figure 5.

8. Slide the lacing fixture subassembly back

against the slide stop.

Figure 3

Toward Back of Arbor

Frame Assembly

Orientation of 26-Position

Seating Bars

Orientation of 68-Position

Seating Bars

Cutting

Blade

Socket Head Cap

Screws

Center

Slots

Figure 4

Upper Tooling

Assembly

Tool Mount

Flat Head

Screw

(2 Places)

Arbor Frame

Ram (Ref)

Figure 5

Slide Stop Position for 26- and

50-Position Connectors and

Termination Covers

Slide Stop Position for 68- and

100-Position Connectors and

Termination Covers

Slide Body

Lacing Fixture

Subassembly

NOTE

408-9750

Cover Lacing Fixture 91293-1

of 4Rev

Tyco Electronics Corporation

9. Slowly lower the upper tooling assembly until it

comes in contact with the lacing fixture

subassembly. If the cutting blades strike the

stationary or adjustable locators, then move the

slide assembly until the cutting blades clear the

locators and bottom on the base of the lacing

fixture subassembly.

10. With the upper tooling assembly still lowered

onto the lacing fixture subassembly, tilt the arbor

frame assembly and tighten the slide assembly

mounting screws.

11. Return the arbor frame assembly to the correct

operating position, then carefully raise the ram and

upper tooling assembly until the upper tooling

assembly touches the frame.

12. Carefully lower the ram and upper tooling

assembly to double check that the cutting blades

clear the locators.

13. Secure the arbor frame assembly to the work

surface according to instructions supplied with the

frame assembly, or if using the bend stand

(supplied with lacing fixture), secure the bench

stand to the work surface. Remove the lacing

fixture subassembly from the slide, and place it into

the bench stand. Secure the subassembly by

tightening the thumbscrew. Refer to Figure 6.

4. SEATING PROCEDURE

After tooling is properly installed and secured to the

work surface, proceed as follows:

1. Loosen the adjustable locators in each slot of

the lacing fixture subassembly base, then move

the locators so that the covers will fit into the lacing

fixture subassembly slots.

Due to the keying feature on the stationary

locators, the covers will only fit with the stepped

edge of the cover toward the inside of the lacing

fixture subassembly.

2. Place the termination covers in their respective

slots.

3. Slide the adjustable locators toward the back of

the assembly until the locators touch the covers

and the ball plunger in each adjustable locator

sufficiently secures the covers.

4. Prepare the cable for use as described in the

instructions supplied with the connector or

termination cover.

5. Open the cable clamp by opening the latch.

Refer to Figure 7.

Figure 6

Lacing Fixture

Subassembly

Bench

Stand

Thumbscrew

Work

Surface

Figure 7

Latch

(Closed)

Cable Socket Head

Cap Screws

Cable Clamp

Bracket

Setscrew

(in Back of

Clamp Block)

6. Place a properly prepared cable into the clamp,

with the wires protruding upward through the lacing

fixture, and with the edge of the cable jacket

approximately even with the top edge of the cable

clamp.

7. Close the latch by hooking over the pin on the

clamp.

If the clamp is too tight or too loose, adjust the

clamp by moving the jaw using the setscrew

located in the back of the clamp block. Refer to

Figure 7.

NOTE

408-9750

Cover Lacing Fixture 91293-1

Rev

of 4 Tyco Electronics Corporation

8. Position the cable clamp so that the cable

bundle is centrally located on the termination

cover. To position the clamp, loosen, but do not

remove, the socket head cap screws in the cable

clamp bracket and slide the clamp to the desired

position. Refer to Figure 7.

9. After the cable is secured, untwist the wires (if

twisted) and lace the individual wires into the wire

slots. Pull each wire into the proper slot in the

comb. Continue pulling downward on each wire

until the wire is snug in the slot. When in place, the

wire should not pop out of the slot.

For ease of termination, start at one end of the

covers and work toward the opposite end.

10. After all of the wires are laced, slide the lacing

fixture subassembly back under the upper tooling

assembly until it butts against the stop.

If using the bench stand, remove the lacing

fixture subassembly and place it into the slide of

the arbor frame assembly. Slide the lacing fixture

subassembly back until it butts against the stop.

11. Pull the arbor frame handle downward to seat

and cut the wires. The action of the wires entering

the clips on the termination covers should be felt

through the handles as a slight “snap.”

12. While maintaining pressure on the arbor frame

handle, remove the cut wire ends protruding from

the lacing fixture subassembly.

13. Lift the arbor frame handle to raise the upper

tooling assembly. Slide the lacing fixture

subassembly out, then open the cable clamp.

14. Carefully push upward on the cable, and

remove the covers from the lacing fixture

subassembly.

If necessary, a pointed instrument can be used to

help remove the wires from the inside combs.

Take care to avoid damaging the insulation or

pulling the wires out of the clip in the termination

cover.

15. After the wires are correctly seated into the

termination covers, the covers can be seated onto

the connector. For cover seating procedure, refer

to Instruction Sheet 408–9820.

5. REPLACEABLE PARTS

Customer–replaceable parts are listed in Figure 8.

A complete inventory should be stocked and

controlled to prevent lost time when replacement of

parts is necessary. Parts other than those listed

should be replaced by Tyco Electronics Corporation

to ensure quality and reliability. Order replacement

parts through your 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

PART NUMBER DESCRIPTION

91293-1 Cover Lacing Fixture

(Includes Slide Assembly, Upper Tooling

Assembly, Two 50-position Seating Bars,

Two 100-position Seating Bars, and Lacing

Fixture Subassembly 543481-1)

543481-1 Lacing Fixture Subassembly

(Includes Bench Stand And Clamp)

543494-2 26-Position Seating Bar

543494-1 50-Position Seating Bar

543502-2 68-Position Seating Bar

543502-1 100-Position Seating Bar

Figure 8

6. REVISION SUMMARY

Revisions to this instruction sheet include:

Updated document to corporate requirements

Added paragraph to Section 5

NOTE