Series 521 (Sea Level version P/N 167-3516 and 167-3561-1)
Series 521 (Reduced Pressure version P/N 167-4534 and 167-4534-1)

Step 1
Cut cable to length, clean and square. Strip outer jacket to dimension shown. Trim exposed braid to dimension. Strip inner insulation to dimension and hot tin dip core. No nicked or severed strands allowed during stripping.

Step 2
Slip cable seal over center conductor. Slide contact over inner conductor. Place in fixture to apply compression to the cable seal and maintain pressure until completion of the soldering process. Solder contact into place through hole using SN60 solder in accordance with J-STD- 006. Completed solder joint must have a continuous fillet of solder between the inner conductor and the contact. The solder in the feed hole must be flush or below flush and free of pinholes.

Step 3
Slip boot and crimp sleeve over cable. Flair braid slightly by moving inner insulation in a circular motion. Coat inner insulation and cable seal liberally with fluorsilicone grease.

Step 4
Insert prepared cable into the connector carefully. Do not pinch or otherwise damage the cable seal. Guide braid smoothly over the crimp area of the connector until the contact shoulder butts against the insulator (see “X”). Slide the crimp sleeve into position, trim excess braid, and crimp using Thomas & Betts crimp tool No. WT-540 with Die No. 5456. (NOTE: this Die Number supercedes the one called out in our printed catalogs). Measure contact depth before and after crimping. Make sure braid does not extend beyond the end of the crimp sleeve. Install interface seal with fluorosilicone grease applied on the back face of the seal. A 521 series receptacle can be used to guide and push the interface seal in place by mating the connectors.