Instruction Sheet
408-2055
Twin BNC Series
COAXICON* Connectors
Body
Plug
Male Center
Contact
Dielectric
Ferrule
Female Center
Contact
Jam Nut
CONNECTOR
Ferrule
Dielectric
Body
Gasket
Lock Washer
Jam Nut
Male Center
Contact
Crimp End
Bulkhead Jack Adapter
Seal
Crimp End
Female Center
Contact
Seal
Collar
Bulkhead Jack
19 NOV 14 Rev C
Lock Washer
Gasket
CABLE
Adapter Assembly
CRIMP TOOLING (Instruction Sheet)
0332225-0
Plug
5332225-5
Bulkhead Jack
Bulkhead Jack Adapter
RG-108 and 108A
SDE-SA Hand Crimping Tool
Frame Assembly
9-1478240-0
(408-8851)
SDE Crimping Die Assembly
91909-1
(408-8580)
—
—
—
5332225-0
3323425332342-0
3322155332215-0
Figure 1
This instruction sheet covers selection and assembly of twin BNC series COAXICON connectors. The
connectors consist of plugs, bulkhead jacks, and bulkhead jack adapters. See Figure 1. These connectors are
designed for field service applications.
NOTE
Dimensions in this instruction sheet are in metric units [with U.S. customary units in brackets]. Figures are not drawn to scale.
Reasons for re-issue of this instruction sheet are provided in Section 3, REVISION SUMMARY.
1. ASSEMBLY PROCEDURE
1.1. Plug and Bulkhead Jack
1. Refer to Figure 1 for applicable cable size and crimp tooling.
2. Slide the ferrule, small diameter end first, onto the cable. See Figure 2.
3. Strip the cable using the dimensions given in Figure 2.
4. Flare the cable braid, but do not comb the braid.
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All Rights Reserved
*Trademark
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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.te.com.
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and/or company names may be trademarks of their respective owners.
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408-2055
15.875 mm [.625 in.]
12.7 mm [.50 in.]
Ferrule
9.525 mm [.325 in.]
Cable
Note: Not to Scale
Center Contacts
Flared Cable Braid
Figure 2
5. Hold the ferrule in place, and from the crimp end, insert the stripped cable conductors into each center
contact. See Figure 3, Detail A. Ensure that the braid passes over and around the support sleeve as
shown in Figure 3, Detail B.
6. Push the crimp end under the cable braid. Apply sufficient pressure to cause the cable dielectric to
bottom against the dielectric inside of the crimp end. Twist the crimp end slightly to ensure bottoming.
7. Slide the ferrule over the cable braid until it bottoms against the connector shoulder. See Figure 3,
Detail C.
Detail A
Connector
Center Contacts
Detail B
Detail C
Stripped Cable Conductors
Support Sleeve
Flared Cable Braid Over and Around Support Sleeve
Ferrule Over Braid and Bottomed Against Connector Shoulder
Figure 3
8. Crimp the ferrule according to instruction sheets included with the tooling (referenced in Figure 1).
9. Crimp the center contacts according to instruction sheets included with the tooling (referenced in
Figure 1). Measure each center contact across the flats of the crimp to ensure that the crimp height is
within 1.181 and 1.316 mm [.0465 and .0518 in.].
NOTE
Refer to the instruction sheet included with the hand crimping tool frame assembly for information on operating the tool. Refer
to the instruction sheet included with the die assembly for instructions on crimping the ferrule and center contacts.
10. Slide the seal over the center contacts. Refer to Figure 4.
Rev C
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408-2055
11. Insert the center contacts into the dielectric, making sure that the male contact protrudes.
12. Using a wrench on the flats of the crimp end, thread the crimp end onto the body. See Figure 4.
13. Using a wrench on the flats of the connector, tighten the components to a torque of 1.7 to 2.26 Nm
[15 to 20 in.-lb]. See Figure 4.
Plug
Body
Dielectric
Seal
Bulkhead Jack
Crimp End
Body
Crimped
Ferrule
Crimped
Center Contacts
Male Contact Protruding
from Dielectric
Dielectric
Seal
Crimped
Ferrule
Crimped
Center Contacts
Male Contact Protruding
from Dielectric
Use 3/8-in. Wrench on
Flats of Crimp End
Crimp End
Use 3/8-in. Wrench on
Flats of Crimp End
Seal
Seal
Use 11/16-in. Wrench on Flats of Connector
Use 7/16-in. Wrench on Flats of Connector
Figure 4
1.2. Mounting Bulkhead Jack and Bulkhead Jack Adapter
1. Cut the panel to the dimensions given in Figure 5.
Recommended Panel Cutout
Panel Thickness: 4.762 [.187]
12.83+0.13/-0.00 mm
[.505+.005/-.000 in.]
11.05+0.13/-0.00 mm
[.435+.005/-.000 in.]
Figure 5
2. Slide the gasket over the body and into the groove. See Figure 6.
3. Insert the connector through the hole in the panel.
Rev C
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408-2055
4. Assemble the lock washer and jam nut onto the connector. Tighten the jam nut using a 9/16-inch wrench.
Bulkhead Jack
Bulkhead Jack Adapter
Gasket
Adapter Assembly
Panel
Lock Washer
Lock Washer
Panel
Jam Nut
Jam Nut
Figure 6
1.3. Connector Coupling
This procedure is required for proper alignment of the connector dielectrics during coupling.
1. Align the slots in the plug body collar with the lugs on the bulkhead jack. See Figure 7, Detail A.
2. Push the plug over the bulkhead jack until the ends of the dielectrics butt.
3. As the dielectrics come into alignment, slide the plug collar over the bulkhead jack lugs and into the
locked position. For some connectors, the dielectrics will properly align and permit the collar to slide
over the lugs. For connectors with misaligned dielectrics, grasp the rear of the plug over the flats and
twist the plug while applying slight pressure. See Figure 7, Detail B. As the dielectric aligns, the collar
will be allowed to slide over the lugs and into the locked position.
Detail A—Aligned Dielectrics
Detail B—Misaligned Dielectrics
Slots of Plug Body Collar Aligned with Lugs on Bulkhead Jack
Twist Plug to Align Dielectric
Figure 7
2. REPLACEMENT AND REPAIR
Components of the connectors are not repairable. Damaged or defective components must not be used.
Connectors cannot be re-used by removing the cable.
3. REVISION SUMMARY
Revisions to this instruction sheet include:
Replaced hand crimping tool, replaced obsolete connector part numbers, and added bulkhead jack
adapter part numbers to Figure 1
Added step 9 to Paragraph 1.1, and corrected wrench sizes in Figure 4
Removed bulkhead jack adapter panel cutout, and added Section 2
Rev C
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