408-1662 MACOM | Alldatasheet
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TERMASHIELD* Ferrule Crimping Dies for Tools 59500 and 69270-1 408-1662
26 MAY 10 Rev A
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. 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): 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, 'For further instructions relative to the pneumatic tool and hand tool, refer to the instructions packaged with these tools. Section 3 contains a “Maintenance and Inspection Procedure” which will enable you to establish and maintain a die certification program. 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 2.1. Selection Data for Dies, Ferrules, and Insulating Caps A. Single Conductor Shielded Wire To determine which dies, ferrule and insulating cap to use with single conductor shielded wire, refer to - Figure 1 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. Determine the outside (insulation) diameter of the primary conductor. 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. Crimping dies, ferrules and insulating caps are color coded. For example: Use dies color coded green to crimp a green fermle. Place a green insu- lating cap on the green ferrule after ferrule is crimped. B. Multiple Conductor Shielded Wire 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: 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. 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. 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. 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. 2.2. Die Insertion Hand Tool No 59500 Dies are coated with oil to prevent rust and corrosion. Wipe this oil from dies, particularly from crimping area. 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. Tools Crimping Dies 59500 69270-1 45061-3 45065-3 45240-2 45062-3 45066-3 45241-2 45063-3 45238-2 -- 45064-3 45239-2 -- NOTE i NOTE i 1 of 8©2010 Tyco Electronics Corporation, Berwyn, PA All Rights Reserved TE logo and Tyco Electronics are trademarks *Trademark. Other products, logos, and company names might be trademarks of their respective owners. TOOLING ASSISTANCE CENTER 1-800-722-1111 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.tycoelectronics.com
- The NO-GO member may enter partially, but must not pass completely through the die closure. 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. 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: 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. 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. Die Set Die Set Die Closure Dimensions “A” ‡ Gage Member ‡‡ Dimensions “B” “C” Max “R” MaxGO NO-GO GO NO-GO ‡ Plug gag.e dimensions apply when dies are bottomed, but not under pressure. ‡‡ Material -- Tool Steel 7 of 8 408-1662 Rev A
3.5. Replacement Parts It may be advantageous to stock replacement dies to prevent loss of production time. Figure 16 lists the replacement die inserts that can be purchased from Tyco Electronics Corporation. Figure 15 For customer spares, refer to: CUSTOMER SERVICE (038-035) TYCO ELECTRONICS CORPORATION PO BOX 3608 HARRISBURG PA 17105-3608 4. REVISION SUMMARY
- Applied the TE logo
- Changed values in Figure 14 Figure 16 Item Description Die Set Numbers 45158-2 45238-2 45239-2 45240-2 45241-2 45061-3
1 Male Die 2-2306144-6 2-306144-2 2-306144-3 2-306144-5 2-306144-4 4-306144-1
2 Female Die 304803-6 45250-2 45251-2 45252-2 45252-2 304803-7
45062-3 45063-3 45064-3 45065-3 45066-3