loc b 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 occas ional 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 us e 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 cert ification program. these instructions may be us ed 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 zi nc plated ferrules. 1. determine the outside (i nsulation) diameter of the primary conductor. 2. locate this dimension in the appropriate primary conductor i nsulation range in column 2 of figure 1. opposite th e 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 on e 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 th is case, we will use an outer diameter of .082 inches. 2. opposite the number ?3? (the number of primary conductors in the wire) in colu mn one of figure 2, you will find a mult iplying factor of 2.17. 3. multiply the outer diameter of the one conductor (.082 inches) by this factor (2.17). the result is.177. th is figure (.177) is the primary conductor insulation ran ge 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 regi onal customer service, visit our website at www.tycoelectronics.com
loc b figure 1 2. each set of dies consists of a male die and a female die. see figure 4. 3. pull female die holding pin out of tool. close handles until male die hold ing screw is visible. see figure 4. 4. turn die holding screw slot in a vertical position. see figure 4. 5. insert male die into he ad of tool with the color coded groove facing operator. do not attempt to insert dies into the tool while holding dies together. dies are inserted into the tool separately. 6. insert female die into bead of tool. both color coded grooves should now be facing operator. 7. turn male die holding screw slot 1/4 sum to left or right. 8. open the handles slightly and push the female die down so that the hole in the female die lines up with the hole in the insert. insert the female die holding pin. see figure 5. figure 2 tool primary conductor insulation range (inches) crimping die number ferrule number insulation cap die, ferrule and cap color code zinc-plated w/inspctn hole tin-plated w/out inspctn hole tin-plated w/ inspctn hole 59500 and 69270-1 . 033 max. . 45061-3 327192 2-327192- 1 -- 327768 green .033 -.059 45062-3 323930 2-323930-1 2-32930-2 325009 violet .059 -.085 45063-3 323931 2-323931-1 2-323931-2 325010 white ? 085 -.095 45064-3 323932 2-323932-1 2-323932-2 325011 brown .095 -.115 45065-3 323933 2-323933-1 2-323933-2 325012 orange .115 -.130 45066-3 323934 2-323934-1 2323934-2 325013 green 59500 .130 -.145 45238-2 327137 2-327137-1 23271372 328224 violet .145 -.184 45239-2 327138 2-327138-1 2-327138-2 328225 white ? .184 -.220 45240-2 327139 2-327139-1 2-327139-2 328226 brown .220 -.245 45241-2 327140 2-327140-1 2-327140~2 328227 orange .245 -.270 45158-2 327141 2-327141-1 2-327141-2 328228 green note i conductors in wire multiply factor conductors in wire multiply factor 2 2.00144.30 3 2.17154.45 4 2.42 16 4.60 5 2.57174.75 6 2.82 18 4.88 7 3.04195.01 8 3.25 20 5.14 9 3.45215.27 10 3.64 22 5.39 11 3.81 23 5.52 12 3.98 24 5.63 13 4.15 25 5.75 2 of 8 408-1662 rev a
loc b 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 he ad of tool with the color coded groove facing operator. do not attempt to insert dies into the tool while holding the dies together. dies are inserted into the tool separately. 6. insert female die into head of tool. both color coded groves should now be facing operator . figure 4 7. turn male die holding screw slot 1/4 turn to left or right. (horizontal position) see figure 5. 8. release take-up lever, then push female die down so that hole in female die lines up with hole note i 3 of 8 408-1662 rev a
loc b in tool. insert female die holding pin. see figure 5. 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. 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. figure 6 2.5. die removal pneumatic tool no. 692701 mod. 2 1. remove female die holding pin. 2. depress take-up lever until male die holding screw is visible. see figure 6. 3. with take-up lever depressed, turn male die holding screw slot in a vertical position. see figure 6. 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 7 2. strip ground wire to dimensions given in figure 8. figure 8 b. crimping procedures 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. ferrule number recommended ground strip length no. of wires max. ins dia 327192 one # 24 .063 1/4 inch min. two # 24 .065 one # 22 .068 323930 thru 323934 one # 20 .078 one # 22 .078 two # 22 .068 327137 thru 327141 one # 18 no limit on insul diameter 7/16 inch min one # 20 two # 20 one # 22 two # 22 4 of 8 408-1662 rev a
loc b figure 9 2. insert ground wire into ferrule. see figure 10. 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. figure 10 hand tool a.open tool handles all the way. b.place ferrule with shielded wire and ground wire attached i n 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 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 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 12 note i 5 of 8 408-1662 rev a
loc b 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 fr equency 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. with proper maintenance and inspection, these dies will give years -of satisfactory service. 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. 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. 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. 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. figure 13 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 desi gn 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. refer to 408 -7424 for ordering information and for information concerning the go no-go gages. 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. 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 completely through the die closure. note i 6 of 8 408-1662 rev a
loc b figure 14 6. 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? max go no-go go no-go 45158-2 .3770 .3830 .3770-.3773 .3829-.3830 .374 .187 45238-2 .2850 .2910 .2850-.2853 .2909-.2910 .170 .085 .45239-2 .3070 .3130 .3070-.3073 .3129-.3130 .180 .090 .45240-2 .3310 .3370 .3310-.3313 .3369-.3370 .220 .110 .45241-2 .3550 .3610 .3550-.3553 .3609-.3610 .280 .140 .45061-3 .1220 .1280 .1220-.1223 .1279-.1280 .100 .050 .45062-3 .1490 .1550 .1490-.1493 .1549-.1550 .090 .045 .45063-3 .1740 .1800 .1740-.1743 .1799-.1800 .090 .045 .45064-3 .1920 .1980 .1920-.1923 .1979-.1980 .160 .060 .45065-3 .2190 .2250 .2190-.2193 .2249-.2250 .110 .055 45066-3 .2340 .2400 .2340-.2343 .2399-.2400 .090 .045 ? plug gag.e dimensions apply when dies are bottomed, but not under pressure. ?? material -- tool steel 7 of 8 408-1662 rev a
loc b 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 item description die set numbers 45062- 3 45063-3 45064-3 45065-3 45066-3 1 male die 2-306144-5 4-306144-1 45902-8 45902-9 1-45902-0 2 female die 45253-2 304803-7 59656 596 59656-2 8 of 8 408-1662 rev a
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