P/N167-9504
5 pin plug (non-shielded) |
| Note: These instructions apply only to assemblies using .090 Dia. silicone
coated FEP cable P/N 178-8315. Reynolds does
not recommend customer assembly of the shielded version of the Series
1205 plug due to the complexity of the shielded version. |
 Step
1
Cut cable to length, clean and square. Strip cable to dimension
shown. Make sure there are no severed strands and not more than two strands
nicked. Hot tin dip the exposed conductor. Remove all flux using isopropyl
alcohol. |
 Step
2
Flux conductor and solder contact to conductor through the
feed hole in contact using SN60 solder. Completed solder joint must have
a continuous fillet of solder between the cable conductor and the contact.
Solder in the feedhole must be free of pin holes and flush or below flush.
Rear of contact shoulder must be as flush as possible with insulation
of cable as shown. Make sure the clamp nut, washer and cable retainer
are in place as shown. Mask contact in area shown. Lightly abrade the
contact area as shown using either clean abrasive cloth or air blast with
clean sand. Do not abrade the cable. Brush a thin film of General Electric
SS4004 primer over contact in area shown. Do not allow primer to get inside
the contact and do not prime the cable. Allow primer to dry for 1 hour
at room temperature. |
 Step
3
Brush a light film of General Electric RTV 162 adhesive over
the primed surface of the contact and about 1 inch of the cable. Immediately
insert the contact into the connector insulator. Rotation of the contact
is okay during insertion. Apply enough forward pressure to displace residual
air at the interface. Make sure the contact shoulder butts against the
internal flange of the insulator and that the ‘control dimension’
is maintained. Repeat steps 1 through 3 for each cable that is to be installed
into the connector. Place assembly in a humidity oven with a relative
humidity of at least 60% for 24 hours @ 100°F. Do not disturb the
assembly during the curing cycle.
|
 Step
4
Slide cable retainer into back of connector. Make sure retainer
is properly aligned according to identification numbers (1-5)
Slide washer and clamp nut up in place. Tighten clamp nut firmly. Before
mating the connector for the first time, verify that the *Control Dimension
has been maintained for each cable installed. |
