JBX2OUTLS13 - SOURIAU - Product.Network

JBX PLUG ASSEMBLY INSTRUCTIONS

Optional Boot

1. Determine what size cable you will be using. Then select the proper collet number for that

cable.

REV 4 – April 14, 2004

2. Strip the cable and each wire to the required strip length.

REV 4 – April 14, 2004

3. When assembling a plug with a protective boot (#3), prep the cable by taking the protective

boot and sliding it with the small inside diameter first onto the cable. Then slide the end of the

back nut (#2) that has the smaller diameter onto the cable. Next, take the collet (#1) and slide

the end with the gripping teeth first onto the cable until the opposite end of the collet is flush

with the cut end of the jacket. If the cable has shielding, fold back the braid so that it is

covering the outside diameter of the collet. Do not place braid into any area of the alignment

slots. Then insure that the braid does not interfere with the alignment slots of the collet.

Gripping Teeth

4. Attach removable contacts to wires:

a. If using crimped contacts, crimp the contacts onto the ends of the exposed wires using

the proper crimping tool set on the correct AWG wire. (see FIGURE 4.A). After the

contact has been crimped to the wire, check each contact to insure that the contact is

securely crimped to the wire.

Locator for pin and socket 0.7 - 0.9 mm and 1.3 mm contacts

FIGURE 4.A

Male contact Female contact

Shell

size Ø

contacts AWG SOURIAU P/N DANIELS P/

ASTRO P/N SOURIAU P/N DANIELS P/N ASTRO P/N

0.7 22 - 24 – 26 JBX 0 OUT LP07 86 – 223 / JBX 0 OUT LS07 86 – 224 /

0 0.9 20 - 22 – 24 JBX 0 OUT LP09 86 – 225 / JBX 0 OUT LS09 86 – 226 /

0.7 22 - 24 – 26 JBX 1 OUT LP07 86 – 196 642 – 001 JBX 1 OUT LS07 86 – 197 642 – 004

0.9 20 - 22 – 24 JBX 1 OUT LP09 86 – 198 642 – 002 JBX 1 OUT LS09 86 – 199 642 – 005

1.3 18 - 20 – 22 JBX 1 OUT LP13 86 – 200 642 – 003 JBX 1 OUT LS13 86 – 201 642 – 006

0.7 22 - 24 – 26 JBX 2 OUT LP07 86 – 202 642 – 007 JBX 2 OUT LS07 86 – 203 642 – 010

0.9 20 - 22 – 24 JBX 2 OUT LP09 86 – 204 642 – 008 JBX 2 OUT LS09 86 - 205 642 – 011

1.3 18 - 20 – 22 JBX 2 OUT LP13 86 – 206 642 – 009 JBX 2 OUT LS13 86 – 207 642 – 012

0.7 22 - 24 – 26 JBX 3 OUT LP07 86 – 217 642 – 014 JBX 3 OUT LS07 86 – 214 642 – 017

0.9 20 - 22 – 24 JBX 3 OUT LP09 86 – 218 642 – 015 JBX 3 OUT LS09 86 – 215 642 – 018

1.3 18 - 20 – 22 JBX 3 OUT LP13 86 – 219 642 – 016 JBX 3 OUT LS13 86 – 216 642 - 019

Turret with locator for pin and socket 1.6 mm and 2 mm contacts

Male and female contacts

Shell size Ø contacts AWG SOURIAU P/N DANIELS P/N ASTRO P/N

1.6 14 - 16 – 18 JBX 2 OUT LT16 TH 564 650 – 030

2 2 12 - 14 – 16 JBX 2 OUT LT20 TH 565 650 – 031

1.6 14 - 16 – 18 JBX 3 OUT LT16 TH 566 650 – 038

3 2 12 - 14 – 16 JBX 3 OUT LT20 TH 567 650 - 035

REV 4 – April 14, 2004

Crimping Tool

Specifications MIL-C-22520 / 7.01 MIL P/N – SOURIAU P/N Supplier P/N

Contacts 0.7 mm – 0.9 mm

and 1.3mm

MIL-22520/7-01

Daniels: MH860

Specifications MIL-C-22520 / 1.01 MIL P/N – SOURIAU P/N Supplier P/N

Contacts 1.6 mm and 2 mm

MIL-22520/1-01

Daniels: AF8

Buchanan: 61570 8

b. If using soldered contacts, prep each wire with flux and then tin dip each exposed wire

end. Next pre-load a piece of heat shrink onto the wire (Individual heat shrink tubes are

optional). Solder each wire to the solder cup end of the contact. To avoid shorts, make

sure that no solder comes in contact with any other contact or wire on the connector.

After the contact has been soldered to the wire, check each contact to ins ure that the

contact is securely soldered to the wire. Slide the pre-loaded heat shrink over the solder

joint and shrink into place. Do not over-heat the solder joint area as it c an cause the

solder to re-flow or it could burn the wire insulation.

5. If inserting removable contacts:

REV 4 – April 14, 2004

a. Starting with the interface end of the contact, carefully insert each contact into the

backside of the insulator that has the position loading path indicator (worm) on it. Start

with the end of the position loading path indicator (worm) that has the half circle on it

(Position #1). Then follow the position loading path indicator (worm) around the

insulator. You will go counter clockwise if using a male contact and clockwise if using

a female contact (see diagram below for the position loading path indicator (worm)

layout). If the connector has center contacts, it is sometimes easier to start at the end of

the position loading path indicator (worm) (last position) and work backwards. This is

up to the assembler and the process they are using to insert the contacts. Make sure not

to bend the contact when inserting it into the ins u lator. It is extremely important that the

contact is completely seated in to the insulator. For the connector to function properly,

the contact should click/snap into place when seated. To confirm the seating of the

contact, check each contact for proper seating.

6. Removal of contacts:

a. Using the proper extraction tool insert the tool over the front of the contact and push

contact out. Failure to use the proper extraction tool can result in damage to the contact.

TOOLINGS – JBX – JKX

Manual Extraction Tools

Contacts automatically extracted without pulling on the cable.

The extraction tool is the same for both male and female contacts.

7. Take the keyed half bushing (#6) and place it over the insulator so th at the window is lined up

with the key on the insulator and the key on the half bushing is pointing to the back of the

insulator (position loading path indicator (worm end)). Then take the half bushing without the

window (#6) and place on the opposite side of the insulator so that both half bushings are

aligned with each other.

8. Take the collet that is pre-loaded on the cable and align the slots in the collet with the keys on

the end of the half bushings (you may need to move the braid away from the slots and spin the

collet slightly). Once they are aligned, compress the assemb ly so that it is in line and there are

no gaps between the collet & the half bushings. The braid should still be in place once the

assembly is inserted.

9. Take a connector housing (#7) and slide it over the insulator so that the red dot on the

connector housing lines up with the key on the half bushing with window. Push the whole

assembly into the connector housing until it bottoms out. Insure that the keys are seated

properly by turning the collet that is already aligned with the half bushings. If the collet does

not turn, then the keys are correctly aligned. If the collet does turn, then you must withdraw the

assembly & realign the keys.

REV 4 – April 14, 2004

10. Once the assembly is installed into the connector housing and is aligned properly, apply thread

lock to thread area. Then slide the back nut up until you can m anually start the back nut threads

onto the threaded end of the connector housing. Tighten the back nut up as far as you can by

hand, then take the appropriate wrenches and place the wrenches onto the flats located on the

connector housing. Do not over torque back nut as it can cause connector failure.

REV 4 – April 14, 2004

11. If the connector requires a protective boot, slide the boot over the lip on the back nut.

12. Potting of backend of plug with clipped contacts:

Clipped contacts are designed to float in the connector so that they self align when mated. It is

sometimes necessary to pot the back end of the connector so that the contacts are sealed off from the

environment. When this application is needed, it is recomm ended that the assembler engage a mating

connector/alignment tool to the assembly being potted. Once the mating connector/alignment tool is

engaged, it must be left engaged until the potting compound has hardened. This will insure that the

true position requirements are met. If the application is for low volume, a mating connector can be

used. If the application is for high volume, it is recommended that an alignment tool be purchased

from the supplier. Trouble Shooting

Problem: Cause: Correction:

Contact will not seat in

connector, contact bac ki ng out. Wrong wire or insulation size, wrong strip

length, poor crimping, broken clips,

damaged insulator, removed contact without

proper removal tool, bad crimp.

Use correct wire, adjust strip length, strip and

re-crimp with new contact, replace insulator,

using wrong crimp tool, replace contact.

Bent in handling, bent in soldering

operation, connector assembled incorrectly.

Bent solder contact

Pins and insulator were inserted into

electrical test while unprotected by

shell

Replace insert with contacts.

Connector will not release

from mating part or operate

correctly

Not using flats on latching sleeve and back

nut to torque connector, improper assembly

of the connector, over mold material inside

connector.

Release back nut and re-torque, disassemble

and reassemble, replace connector.

Over tightened the back nut. Connector will not release from mating part

or operate correctly, damage connector. Loosen back nut and retighten.

Collet will not grip cable. Loose cable in connect or. Check correct collet size is being used.

Connector will not assemble. Incorrect alignment of key in connector,

half bushings, connector housing, insulator,

collet, braid in key slots in collet.

Disassemble connector and reassemble

connector-aligning keys, relocate braid in

collet.

Contact stubbing after mating. Bent contact and damaged contact,

connector-assembled inc orrectly. Re-align contact, replace insert with contacts.

Electrical failure. Improper crimping, wrong wire strip length,

wire loadin g incorrect location, poor solder

joint.

Remove contact with correct removal tool,

reinstall new contact, and verify strip length.