323933_技术文档

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

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

.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

.160

.110

.090

.187

.085

.090

.110

.140

.050

.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


型号：	323933
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

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