Cover Lacing Fixture 91293-1 for
AMPLIMITE* .050 Series Connectors and
AMPMODU* 50/50 Grid Connectors
Instruction Sheet
408-9750
24 JUL 08
Rev C
Upper Tooling
Assembly
Slide
Stop
Slots for
Termination Covers
Lacing Fixture
Subassembly
Slide Body
Adjustable
Combs
Locator
Stationary
Locator
Figure 1
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.
NOTE
Dimensions in this instruction sheet are in metric
units [with U.S. customary units in brackets].
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.
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at
www.tycoelectronics.com
LOC B
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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
E
2008 Tyco Electronics Corporation, Harrisburg, PA
TOOLING ASSISTANCE CENTER 1-800-722-1111
PRODUCT INFORMATION 1-800-522-6752
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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.
Cover Lacing Fixture 91293-1
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.
Orientation of 68-Position
Seating Bars
408-9750
Toward Back of Arbor
Frame Assembly
Cutting
Blade
Slide Body
Center
Slots
Socket Head Cap
Screws
Orientation of 26-Position
Seating Bars
Figure 3
Arbor Frame
Mounting
Screws
Arbor Frame
Base (Ref)
Ram (Ref)
Flat Head
Screw
Figure 2
(2 Places)
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.
NOTE
Be sure to locate the tabs on the seating bars
toward the BACK of the arbor frame assembly.
Tool Mount
Upper Tooling
Assembly
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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.
NOTE
The forward-most mounting holes in the slide are
for 26- and 50-position termination covers, and
Figure 4
Slide Stop Position for 68- and
100-Position Connectors and
Termination Covers
Slide Stop Position for 26- and
50-Position Connectors and
Termination Covers
Lacing Fixture
Subassembly
i
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.
Slide Body
Figure 5
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Tyco Electronics Corporation
Rev
C
Cover Lacing Fixture 91293-1
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.
Work
Surface
408-9750
Bench
Lacing Fixture
Subassembly
Stand
Thumbscrew
Figure 6
Setscrew
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.
NOTE
Due to the keying feature on the stationary
locators, the covers will only fit with the stepped
(in Back of
Clamp Block)
Latch
(Closed)
Cable Clamp
Bracket
Cable
Socket Head
Cap Screws
i
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 7
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.
NOTE
If the clamp is too tight or too loose, adjust the
clamp by moving the jaw using the setscrew
i
located in the back of the clamp block. Refer to
Figure 7.
Rev
C
Tyco Electronics Corporation
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Cover Lacing Fixture 91293-1
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.
NOTE
For ease of termination, start at one end of the
covers and work toward the opposite end.
408-9750
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 SERVICE (038–035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105–3608
PART NUMBER
91293-1
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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.
NOTE
If using the bench stand, remove the lacing
fixture subassembly and place it into the slide of
DESCRIPTION
Cover Lacing Fixture
(Includes Slide Assembly, Upper Tooling
Assembly, Two 50-position Seating Bars,
Two 100-position Seating Bars, and Lacing
i
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.
NOTE
If necessary, a pointed instrument can be used to
help remove the wires from the inside combs.
Fixture Subassembly 543481-1)
543481-1
Lacing Fixture Subassembly
(Includes Bench Stand And Clamp)
543494-2
543494-1
543502-2
543502-1
26-Position Seating Bar
50-Position Seating Bar
68-Position Seating Bar
100-Position Seating Bar
Figure 8
6. REVISION SUMMARY
Revisions to this instruction sheet include:
S
Updated document to corporate requirements
S
Added paragraph to Section 5
i
Take care to avoid damaging the insulation or
pulling the wires out of the clip in the termination
cover.
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Tyco Electronics Corporation
Rev
C
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