2-327140~2 [MACOM]
Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools.;型号: | 2-327140~2 |
厂家: | Tyco Electronics |
描述: | Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools. |
文件: | 总8页 (文件大小:1712K) |
中文: | 中文翻译 | 下载: | 下载PDF数据表文档文件 |
TERMASHIELD* Ferrule
Crimping Dies
for Tools 59500 and 69270-1
408-1662
26 MAY 10 Rev A
PROPER USE GUIDELINES
Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools. Hand tools are intended for occasional use and
low volume applications. A wide selection of powered application equipment for extended-use, production operations is available.
1. Determine the outside (insulation) diameter of
the primary conductor.
1. INTRODUCTION
This instruction sheet is intended to provide you with
instructions” on product application and a
maintenance and for: TERMASHIELD Ferrule
Crimping Dies (Used in Tools 59500 and 69270-1
(Mod. 2):
2. Locate this dimension in the appropriate
primary conductor insulation range in column 2
of Figure 1. Opposite the insulation range you will
find the catalog numbers of the crimping die.
ferrule and insulating cap to use.
Tools
Crimping Dies
45065-3
Crimping dies, ferrules and insulating caps are
color coded. For example: Use dies color coded
45061-3
45062-3
45063-3
45064-3
45240-2
NOTE
green to crimp a green fermle. Place a green insu-
lating cap on the green ferrule after ferrule is
crimped.
45066-3
45241-2
59500
69270-1
i
45238-2
--
--
B. Multiple Conductor Shielded Wire
45239-2
To determine which dies, ferrule and insulating cap to
use with shielded wire having two or more conductors,
use the following formula: Multiply the outside
(insulation) diameter of one primary conductor by the
“factor”, see Figure 2, listed opposite the total number
of conductors in the wire. For example:
TERMASHIELD ferrules on single and multiple
conductor shielded wires with a primary conductor
insulation range of .033" to .270",
Basic instructions on the use of these tools, dies, die
insertion and removal, etc., are provided in Section 2,
1. If you had a 3-conductor shielded wire, you
would first find the outside (insulation) diameter
of one conductor. In this case, we will use an
outer diameter of .082 inches.
'For further instructions relative to the pneumatic tool
and hand tool, refer to the instructions packaged with
these tools.
2. Opposite the number “3” (the number of
primary conductors in the wire) in column one of
Figure 2, you will find a multiplying factor of 2.17.
Section 3 contains a “Maintenance and Inspection
Procedure” which will enable you to establish and
maintain a die certification program.
3. Multiply the outer diameter of the one
conductor (.082 inches) by this factor (2.17). The
result is.177. This figure (.177) is the primary
conductor insulation range of the three-conductor
shielded wire.
These instructions may be used for dies not listed in
Figure 1 but accompanied by this 408 series
document. For unlisted dies, strip wire and crimp in
the same manner as for identical size dies.
2. INSTRUCTIONS
4. Next, refer to column 2 of Figure 1. Opposite
the insulation range of.145 to .184, you will find
the numbers of the crimping die, ferrule and
insulating cap to use.
2.1. Selection Data for Dies, Ferrules, and Insulating
Caps
A. Single Conductor Shielded Wire
2.2. Die Insertion Hand Tool No 59500
To determine which dies, ferrule and insulating cap to
use with single conductor shielded wire, refer to -
Figure 1.
Dies are coated with oil to prevent rust and corrosion.
Wipe this oil from dies, particularly from crimping area.
The package numbers shown in Figure 1 are sup-
plied with equal quantities of ferrules and insulating
caps, but include only zinc plated ferrules.
1. (To open tool handles, close handles until
CERTI-CRIMP* tool ratchet releases. See Figure
3. Note that once ratchet is engaged, handles
cannot be opened until they are fully closed.
NOTE
i
©2010 Tyco Electronics Corporation, Berwyn, PA
All Rights Reserved
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.tycoelectronics.com
TOOLING ASSISTANCE CENTER 1-800-722-1111
PRODUCT INFORMATION 1-800-522-6752
1 of 8
TE logo and Tyco Electronics are trademarks
*Trademark. Other products, logos, and company names might be trademarks of their respective owners.
LOC B
408-1662
Primary
Conductor
Insulation
Range
Ferrule Number
Die, Ferrule
and Cap
Color Code
Crimping Die
Number
Insulation
Cap
Zinc-Plated
w/Inspctn
Hole
Tin-Plated
w/Out Inspctn
Hole
Tin-Plated w/
Inspctn
Tool
Hole
(Inches)
.033 Max.
.033 -.059
.059 -.085
085 -.095
.095 -.115
.115 -.130
.130 -.145
.145 -.184
.184 -.220
.220 -.245
.245 -.270
. 45061-3
45062-3
45063-3
45064-3
45065-3
45066-3
45238-2
45239-2
45240-2
45241-2
45158-2
327192
323930
323931
323932
323933
323934
327137
327138
327139
327140
327141
2-327192- 1
2-323930-1
2-323931-1
2-323932-1
2-323933-1
2-323934-1
2-327137-1
2-327138-1
2-327139-1
2-327140-1
2-327141-1
Figure 1
--
327768
325009
325010
325011
325012
325013
328224
328225
328226
328227
328228
GREEN
VIOLET
WHITE ‡
BROWN
ORANGE
GREEN
VIOLET
WHITE ‡
BROWN
ORANGE
GREEN
2-32930-2
2-323931-2
2-323932-2
2-323933-2
2·323934-2
2·327137·2
2-327138-2
2-327139-2
2-327140~2
2-327141-2
59500
and
69270-1
59500
2. Each set of dies consists of a male die and a
female die. See Figure 4.
up with the hole in the insert. Insert the female
die holding pin. See Figure 5.
3. Pull female die holding pin out of tool. Close
handles until male die holding screw is visible.
See Figure 4.
Conductors
in Wire
Multiply
Factor
Conductors
in Wire
Multiply
Factor
2
3
2.00
2.17
2.42
2.57
14
15
16
17
18
19
20
21
22
23
24
25
4.30
4.45
4.60
4.75
4.88
5.01
5.14
5.27
5.39
5.52
5.63
5.75
4. Turn die holding screw slot in a vertical
position. See Figure 4.
5. Insert male die into head of tool with the color
coded groove facing operator.
4
5
NOTE
Do not attempt to insert dies into the tool while
holding dies together. Dies are inserted into the
tool separately.
6
2.82
3.04
3.25
3.45
3.64
3.81
3.98
4.15
i
7
6. Insert female die into bead of tool. Both color
coded grooves should now be facing operator.
8
9
7. Turn male die holding screw slot 1/4 sum to left
or right.
10
11
12
13
8. Open the handles slightly and push the female
die down so that the hole in the female die lines
Figure 2
2 of 8
Rev A
LOC B
408-1662
Figure 3
2.3. Die Insertion Pneumatic Tool No. 69270-1 Mod.2
Dies are coated with oil to prevent rust and corrosion.
Wipe this oil from dies, particularly from Crimping
area.
Pneumatic tool No. 69270-1, Model 2 is equipped with
a pneumatic die take-up lever. See Figure 3. This
take-up lever is used to hold the ferrule in a proper position
prior to crimping.
1. Each set of dies consists of a male die and a
female die. See Figure 4.
2. Connect air supply. (85 to 100 P.S.!.)
3. Pull female die holding pin out of tool. Depress
take-up lever until male die holding screw is
visible, See Figure
4. With take-up lever depressed, turn die holding
screw slot in a vertical position. See Figure 4,
5. Insert male die into head of tool with the color
coded groove facing operator.
NOTE
Do not attempt to insert dies into the tool while
holding the dies together. Dies are inserted into the
tool separately.
Figure 4
i
7. Turn male die holding screw slot 1/4 turn to left
or right. (horizontal position) See Figure 5.
6. Insert female die into head of tool. Both color
coded groves should now be facing operator.
8. Release take-up lever, then push female die
down so that hole in female die lines up with hole
3 of 8
Rev A
LOC B
408-1662
in tool. Insert female die holding pin. See
Figure 5.
4. Push die set up with a small screwdriver or
drift pin just enough to permit female die to be
pulled out of tool.
5. Remove male die and insert die holding pin
back into tool.
2.6. Wire Stripping And Crimping Procedures
A. Wire Stripping
1. Strip shielded wire as shown in Figure 7.
Figure 5
2.4. Die Removal Hand Tool No. 59500
1. Remove female die holding pin.
2. Close handles until male die holding screw is
visible. See Figure 6.
3. Turn male die holding screw slot in a vertical
position. See Figure 6.
Figure 7
2. Strip ground wire to dimensions given in Figure
8.
4. Push die set up with a small screwdriver or
drift pin just enough to permit female die to be
pulled out of tool.
Recommended Ground
Ferrule
Strip
5. Remove male die and insert die holding pin
back into tool.
No. of
Wires
Max. Ins
Dia
Number
Length
One # 24
Two # 24
One # 22
One # 20
One # 22
Two # 22
One # 18
One # 20
Two # 20
One # 22
Two # 22
.063
.065
.068
.078
.078
.068
327192
1/4 Inch
Min.
323930
thru
323934
327137
thru
327141
No Limit
on Insul
Diameter
7/16 Inch
Min
Figure 6
2.5. Die Removal Pneumatic Tool No. 69270·1 Mod. 2
1. Remove female die holding pin.
Figure 8
2. Depress take-up lever until male die holding
screw is visible. See Figure 6.
B. Crimping Procedures
3. With take-up lever depressed, turn male die
holding screw slot in a vertical position. See
Figure 6.
1. Place ferrule on shielded wire as shown in
Figure 9. Flare the braid so that it will pass over
and around support sleeve of ferrule.
4 of 8
Rev A
LOC B
408-1662
Pneumatic Tool
a.Place ferrule, with shielded wire and ground
wire attached, in lower crimp area of dies.
Push ferrule all the way into tool. See Figure 1
b.Hold ground wire and shielded wire in
position and depress take-up lever to hold
ferrule in place.
c.Simultaneously release take-up lever and
depress trigger to complete crimp. Release
trigger and remove crimped ferrule.
Figure 9
2. Insert ground wire into ferrule. See Figure 10.
NOTE
On six smaller ferrules (Part No. 327192 and
323930 through 323934) slide the ground wire
insulation under ferrule skirt approximately /16
inch. On five larger ferrules (Part No. 327137
through 327141. DO NOT slide the ground wire
insulation under ferrule skirt.
i
Figure 11
C. Ferrule Insulating Caps
1. Place insulating cap on ferrule as shown in
Figure 12.
2. Insulating caps are color coded for easy
matching with ferrule. To select correct insulating
cap, refer to Figure 1.
Figure 10
Hand Tool
a.Open tool handles all the way.
b.Place ferrule with shielded wire and ground
wire attached in lower crimp area of dies. Push
ferrule all the way into tool. See Figure 11.
c.Hold ground wire and shielded wire in
position and close handles until CERTI-CRIMP
tool ratchet releases. Open handles and
remove crimped ferrule.Pneumatic Tool
Figure 12
5 of 8
Rev A
LOC B
408-1662
3. MAINTENANCE/INSPECTION PROCEDURE
Tyco Electronics recommends that a maintenance-
inspection program be performed periodically. This is
necessary to assure that continued use of the dies will
result in the same dependable and uniform
terminations for which the dies were designed.
We recommend an initial frequency of inspection of
once a month. This frequency may be adjusted to suit
your requirements through experience. The frequency
of an inspection is dependent upon:
• The care, amount of use, and handling of the dies.
• The type and size of the products crimped.
• The degree of operator skill.
• The presence of abnormal amounts of dust and
dirt.; and
• Your own established standards.
Figure 13
With proper maintenance and inspection, these dies
will give years -of satisfactory service.
The die closure inspection is accomplished using GO
NO-GO plug gages. Tyco Electronics neither
manufactures nor sells plug gages, however, a
suggested plug gage design and the GO NO-GO
dimensions of the plug gage members are listed in
Figure 14. The following procedure is recommended
for measuring the die closures.
All Tyco Electronics dies are thoroughly inspected
before being shipped from the factory, however, since
there is a possibility of die damage in shipment, it is
recommended that new dies be inspected in
accordance with Section 3 when received in your
plant.
NOTE
Refer to 408 -7424 for ordering information and for
information concerning the GO NO-GO gages.
3.1. Cleaning
Do not allow deposits of dirt, grease and foreign
matter to accumulate in the die closure area and on
the bottoming surfaces of the dies. These deposits
may prevent the dies from bottoming fully and may
also cause excessive wear in the die closure surfaces,
thereby affecting the quality of the crimp. The dies
should be wiped clean frequently with a clean cloth.
i
1. Remove traces of oil or dirt from die crimping
area and plug gage members.
2. Insert dies in tool.
3. When using hand tool, close handles of tool
until dies bottom. Do not apply additional
pressure to tool handles.
3.2. Visual Inspection
Visually inspect the die closure surfaces for broken or
chipped conditions. Although dies may gage within
permissible limits, worn or damaged die closure
surfaces are objectionable and can affect the quality
of the crimp. Examples of possible damaged die
surfaces are shown in Figure 13.
4. When using pneumatic tool, reduce air supply
pressure to a range between 15-20 p.s.i.
Depress trigger to bottom dies.
5. With crimping dies bottomed, check the die
closure using the proper plug gage. Hold gage in
straight alignment with the die closure and
carefully try to insert without forcing, the GO
member, and then the NO-GO member. See
Figure14. The GO member must pass
3.3. Die Closure Inspection
Every Tyco Electronics die set is inspected and tested
for proper die closure before being shipped from the
factory. An inspection should, however, be performed
periodically to measure the die closure.
completely through the die closure.
Rev A
6 of 8
LOC B
408-1662
Die Set Die Closure Dimensions “A” ‡
Gage Member ‡‡ Dimensions “B”
“C”
Max
“R”
Max
Die Set
GO
NO-GO
.3830
.2910
.3130
.3370
.3610
.1280
.1550
.1800
.1980
.2250
.2400
GO
NO-GO
45158-2
45238-2
.45239-2
.45240-2
.45241-2
.45061-3
.45062-3
.45063-3
.45064-3
.45065-3
45066-3
.3770
.2850
.3070
.3310
.3550
.1220
.1490
.1740
.1920
.2190
.2340
.3770-.3773
.2850-.2853
.3070-.3073
.3310-.3313
.3550-.3553
.1220-.1223
.1490-.1493
.1740-.1743
.1920-.1923
.2190-.2193
.2340-.2343
.3829-.3830
.2909-.2910
.3129-.3130
.3369-.3370
.3609-.3610
.1279-.1280
.1549-.1550
.1799-.1800
.1979-.1980
.2249-.2250
.2399-.2400
.374
.170
.180
.220
.280
.100
.090
.090
.160
.110
.090
.187
.085
.090
.110
.140
.050
.045
.045
.060
.055
.045
‡ Plug gag.e dimensions apply when dies are bottomed, but not under pressure.
‡‡ Material -- Tool Steel
Figure 14
6. The NO-GO member may enter partially, but
must not pass completely through the die
closure.
1. Make a test crimp using ferrule, shielded wire
and ground wire as outlined in Paragraph 2.6,B.
When this crimp is made, close handles until the
ratchet is free, however, DO NOT RELAX
PRESSURE ON TOOL HANDLES.
7. If the die closures meet the GO NO-GO gage
conditions, the dies may be considered
dimensionally correct. If you find that the die
closures do not conform with the GO NO-GO
gage conditions, contact your local Tyco
Electronics field service representative.
2. If a .001 or smaller shim can be inserted
between the bottoming surfaces of the dies. or if
there is no opening whatever, the ratchet is
considered satisfactory.
3. If the clearance between the bottoming
surfaces of the dies is greater than .001, the dies
are considered as not bottoming. Contact your
local Tyco Electronics field service
representative.
3.4. CERTI-CRIMP Tool Ratchet Inspection
The CERTI-Crimp tool ratchet feature on Tyco
Electronics hand tools should be checked to make
certain that the ratchet does not release prematurely
allowing dies to open before they have fully bottomed.
To check ratchet feature:
Rev A
7 of 8
LOC B
408-1662
replacement die inserts that can be purchased from
Tyco Electronics Corporation.
3.5. Replacement Parts
It may be advantageous to stock replacement dies to
prevent loss of production time. Figure 16 lists the
Figure 15
For customer spares, refer to:
4. REVISION SUMMARY
•
•
Applied the TE logo
Changed values in Figure 14
CUSTOMER SERVICE (038-035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105-3608
Die Set Numbers
Item
Description
45158-2
2-2306144-6
304803-6
45238-2
2-306144-2
45250-2
45239-2
2-306144-3
45251-2
45240-2
2-306144-5
45252-2
45241-2
2-306144-4
45252-2
45061-3
4-306144-1
304803-7
1
2
Male Die
Female Die
Die Set Numbers
45064-3
Item
Description
45062-3
2-306144-5
45253-2
45063-3
4-306144-1
304803-7
45065-3
45066-3
1
2
Male Die
45902-8
45902-9
596
1-45902-0
59656-2
Female Die
59656
Figure 16
Rev A
8 of 8
LOC B
相关型号:
2-327141-1
Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools.
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2-327141-2
Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools.
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2-327192-1
Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools.
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