Instruction Sheet Plug-N-Play (PNP) IFE 408-10213 Data Cable Harness Assembly 05 JAN 16 Rev E If the cam handle comes off of the plug housing, Power Plug Connector NOTE re-install it onto the metal band with the upper cam button to the front of the plug housing as shown in Plug Housing Shrink Boot i Figure 1. Dust Cap The contacts accept a wire size of 24 AWG. The quad cable has 4 colored conductors with a maximum outside diameter given in Figure 2. Larger data cable outside diameter are acceptable. Quad Cable Upper Cam Button Metal Band Colored 4.19 .165 Conductors Max Quadrax Socket Contact Kit 2000032-1 (Quadrax Pin Contact Kits 2000031-1 and 2000031-2 Not Shown) and Quad Cable (BMS 13-72T03C04G024) 1835611-3 Ferrule Figure 2 Seal Shell The following Daniels Manufacturing Corporation (DMC) tooling is required to crimp the contacts and ferrule: PIN AND SOCKET CONTACTS HAND TOOL POSITIONER SELECTOR SETTING Dieletric M22520/2-01 K709 5 Quad Cable FERRULE Contacts (Available DIE SET Separately) HAND TOOL Socket Ferrule Pin Ferrule Figure 1 M22520/5-01 (608650-1) Y1996P Y1977 1. INTRODUCTION Quadrax Ferrule Tool 1976593- is also required to hold the ferrule in place for crimping. This instruction sheet covers terminating the PNP IFE Size 8 Quadrax Removal Tool 1738894-1 is available data cable harness assembly. Power plug connector, for contact removal if required for assembly or repair. quadrax pin and socket contacts, and quad cable are required for the termination. TERMINATION 3. Terminate each of the socket and pin contacts onto the Dimensions in this instruction sheet are in metric NOTE quad cable as follows: units with U.S. customary units in brackets . Figures are not drawn to scale. 1. Place the individual seal and ferrule (flange end i first) on the cable between 152 and 304 mm 6 and 12 in. from the end of the cable to avoid Reasons for reissue of this instruction sheet are interference with the termination procedure. provided in Section 6, REVISION SUMMARY. For cables with an outside diameter over 4.19 mm .165 in. , place only the seal onto the cable. Retain 2. DESCRIPTION the ferrule to install after stripping the cable. Components of the power plug connector and quadrax 2. Using an appropriate cable cutter, cut the cable to socket contact kit are shown in Figure 1. the p. roper length. See Figure 3. The cable length must accommodate a minimum of Because of materials, revisions, and physical NOTE NOTE 25.4 mm 1 in. free travel of the plug connector in characteristics, connector and component colors the guide plate required for mating. may vary. i i 2012 Tyco Electronics Corporation, a TE Connectivity Ltd. Company TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change. 1 of 8 All Rights Reserved PRODUCT INFORMATION 1-800-522-6752 For latest revision and Regional Customer Service, Size 8 Quadrax emoval Tool 1738894-1 is *Trademark visit our website at www.te.com LOC B TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners. 408-10213 Detail A Cut Cable to Length Trim Braid (Shield) Detail B Braid (Shield) Fanned Out Figure 3 3. Strip the outer jacket and the braid shielding 10.2 +0.762/-0.254 mm .400 +.030/-.010 in. and Detail C 5.59 +0.51 mm .220 +.020 in. , respectively, from the end of the cable. Do not remove the binder tape Remove Binder Tape at this time. See Figure 4. Strip the Cable Figure 5 Detail A Detail B Remove Center Filler Conductors Fanned Out Outer Jacket Binder Tape Braid (Shield) Figure 4 4. Using tweezers or similar tool, trim the exposed braid (shield) that is over the jacket. See Figure 5, Figure 6 Detail A. Fan out the braid as shown in Figure 5, Detail B. 7. Using a standard stripping tool, strip the outer 5. Trim and remove the exposed binder tape. Refer jacket of each of the 4 colored conductors to to Figure 5, Detail C. 3.43 +1.57 mm .135 +.062 in. as shown in Figure 7. 6. Fan out the 4 colored conductors. The center filler should be exposed. See Figure 6, Detail A. For cables with an outside diameter over 4.19 mm Using tweezers or similar tool, remove the center .165 in. , place the individual ferrule (flange end filler as shown in Figure 6, Detail B. first) on the cable between 152 and 304 mm 6 and 12 in. from the end of the cable to avoid interference with the termination procedure. 2 of 8 Rev E