Products     PDF Catalogs 
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EMI/RFI Band Application System For M85049/128 Shield Termination Bands
DMC has worked closely with the world's leading connector accessory manufacturers to develop the necessary tooling and accessories to meet the stringent demands of aerospace and defense system contractors. The resulting products afford the user many benefits which include:
Models are available for .250 in. (6.350 mm) and .125 in. (3.175 mm) wide bands from all current suppliers to M85049/128. THE HAND OPERATED BAND APPLICATION TOOL (REFERENCE AS81306/2) The lightweight construction and small “nose” profile enable the user to apply termination bands in even the tightest of working areas. THE PNEUMATIC BAND APPLICATION TOOL The calibration system of the pneumatic band tool is adjustable, and can be checked by use of the calibration devices available from DMC. The cutter blade and other components of the DMC Pneumatic Band tools are interchangeable with the DBS-1100 and DBS-1200 series hand tools. The rugged design and field replaceable blades make the PBT/PMBT series the best choice for production applications where EMI/RFI bands are used to terminate wire harness shielding. ONE-STEP BANDING TOOL SYSTEM
Contact DMC for One-Step Tool information and part numbers. TWO-STEP BANDING TOOL SYSTEM
The hand tools meet the requirements of AS81306/2-01 and AS81306/2-02. DBS-1100 & DBS-1200 HAND OPERATED BAND APPLICATION TOOLSThe DBS series Hand Actuate Tools (AS81306/2) are designed to apply all currently available AS85049/128 bands. These tools are constructed to survive the demands of production and maintenance use, and remain precisely adjusted to provide a quality band termination. The tension-lock system gives the operator a positive indication when the precise tension has been reached.
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The termination of EMI/RFI shielding materials is a specialized science
in today’s aerospace wiring systems. Application tooling is a critical factor in the overall performance of the wiring system components.
the hand opeerated band application tool is an excellent choice for many production and maintenance operations. Like the power driven models, they
too can be calibrated by the user to provide reliable terminations throughout the service life.
The pneumatic band application tool is a cost effective system that speeds production and improves ergonomic conditions which are present when manual tools are used. Band tension
is precisely applied by a dependable pneumatic system which is consistent and repeatable.
DMC’s One-Step Banding Tools are compatible with M85049/128-03, M85049/128-04, M85049/128-07 and M85049/128-08 bands. These tools tension, fold, and 
DMC’s Two-Step Banding Tools are compatible with all currently available bands. These tools tension and cut the band and leave an extended cut off tab. The second step provides an extra level of security by utilizing a roll-over tool to bend the cut off tab over a full 180 degrees.
DBS-1100 - .250 Wide Band Application Tool:
PBT1100 - .250 Wide Band Application Tool:
The DMC Roll-Over Tool (P/N: DBS-RO3) is used to fold the extended band tab securely over the buckle. Experts agree that the “folded tab” method assures maximum strength and reliability. Like other DMC Band Application Tools, the Roll-Over
Tool is compatible with all currently available bands. 
All the DMC Hand and Pneumatic Band Application Tools may be calibrated to insure correct band tension.
This calibration fixture will allow the operator to gage the exact tension produced by the tool.
Field calibration fixtures and Go/No-Go gauges were developed to allow the user a quick means of checking calibration of band application tools in the field. A band is placed into the calibration fixture. The band is drawn through the tool until the nose of the banding tool is firmly against the calibration fixture. Once the full banding pressure has been applied, insert the “GO” side of the Gage into the verification slot of the calibration fixture. If it does not insert freely, the tool
is exerting excessive force. Likewise, if the NO-GO probe freely enters the verification slot, the tool is below the minimum force, thus alerting the user that the tool is out of calibration.
TWO-STEP APPLICATION TOOLS, ACCESSORIES AND COMPONENTS |
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.250 Width Band Tools |
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| DBS-1100 | AS8103/2-xx Hand Operated Band Application Tool | |
| DBS-1101 | Hand Operated Band Application Tool Set (includes DBS-1100, DBS-R03) | |
| DBS-1102 | Hand Operated Band Application Tool Set (includes DBS-1100, DBS-R03, DBS-CG2 & G691) | |
| DBS-1100-32 | Calibration Adjustment Key | |
| DBS-1100-7 | AS8103/2-xx Replacement Blade for .250 Band Tools | |
| DBS-RO3 | Roll-Over Tool for .250 Band Tab | |
.125 Width Mini-Band Tools |
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| DBS-1200 | AS8103/2-xx Hand Operated Mini Band Tool | |
| DBS-1201 | Hand Operated Mini Band Application Tool Set (includes DBS-1200, DBS-R04) | |
| DBS-1202 | Hand Operated Mini Band Application Tool Set (includes DBS-1200, DBS-R04, DBS-CG3 & G752) | |
| DBS-1100-7 | AS8103/2-xx Replacement Blade for .125 Band Tools | |
| DBS-RO4 | Roll-Over Tool for .125 Band Tab | |
Pneumatic Band Tools for .250 width Bands |
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| PBT1100 | Pneumatic Band Application Tool | |
Pneumatic Band Tools for .125 width Bands |
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| PMBT1200 | Pneumatic Band Application Tool | |
Tool Calibration Instrumentation |
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| DBS-CG1 | Laboratory Verification Instrument (all tools) | |
| DBS-CG1-F | DBS-CG1 Holding Fixture (Banding tool & DBS-CG1 NOT included) | |
| DBS-CG2 | Field Verificatiion Fixture for DBS-1100 | |
| G691 | Go/No-Go Gage for DBS-CG2 Fixture | |
| DBS-CG2A | AS8103/2-xx Field Verification Set which includes DBS-CG2 & G691 | |
| DBS-CG3 | Field Verification Fixture for DBS-1200 | |
| G752 | Go/No-Go Gage for DBS-CG3 Fixture | |
| DBS-CG3A | AS8103/2-xx Field Verification Set which includes DBS-CG3 & G752 | |
Banding Application KitS |
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| DMC1379 | AS8103/2-xx .250 Banding Tool Kit | |
| DMC60A | Complete EMI/RFI Shielding Maintenance/Repair System (AS8103/2-xx .250 bands and tools) | |
Bands & Rings |
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| 4-1380 | M85049/128-01 .250 wide x 14.0 long EMI/RFI Band (Flat)* | |
| 4-1553 | M85049/128-08 .125 wide x 14.0 long EMI/RFI Band (Flat)* | |
| 4-1376 | .500 Dia. Split Ring Set |  |
| 4-1377 | .750 Dia. Split Ring Set | |
| 4-1378 | 1.00 Dia. Split Ring Set | |
| 4-1379 | 1.50 Dia. Split Ring Set | |
| * Band can also be supplied curled (contact factory) | ||
AS85049/128 BAND IDENTIFICATION CHART |
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BAND P/N |
CONFIGURATION |
WIDTH |
TERMINATE WITH |
| M85049/128-01 | Folded Buckle, Flat | .250 | 2 Step Only |
| M85049/128-02 | Folder Buckle, Curled | .250 | 2 Step Only |
| M85049/128-03 | Stamped Buckle, Flat | .250 | 1 or 2 Step Tools |
| M85049/128-04 | Stamped Buckle, Curled | .250 | 1 or 2 Step Tools |
| M85049/128-05 | Folded Buckle, Flat | .125 | 2 Step Only |
| M85049/128-06 | Folder Buckle, Curled | .125 | 2 Step Only |
| M85049/128-07 | Stamped Buckle, Flat | .125 | 1 or 2 Step Tools |
| M85049/128-08 | Stamped Buckle, Curled | .125 | 1 or 2 Step Tools |
AS85049/128 TOOL IDENTIFICATION CHART |
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TOOL P/N |
DESCRIPTION |
WIDTH |
DMC P/N** |
| M81036/1-01 | 1 Step Band Tool | .250 | Consult DMC |
| M81036/1-02 | 1 Step Band Tool | .125 | Consult DMC |
| M81036/1-01A | Verification Inspection Gage | .250 | Consult DMC |
| M81036/1-02B | Verification Inspection Gage | .125 | Consult DMC |
| M81036/2-01 | 2 Step Band Tool | .250 | DBS-1100** |
| M81036/2-02 | 2 Step Band Tool | .125 | DBS-1200** |
| M81036/2-03 | Roll Over Tool | .250 | DBS-R03 |
| M81036/2-04 | Roll Over Tool | .125 | DBS-R05 |
| M81036/2-01A | Set: Verification Gage & Compression Fixture | .250 | DBS-CG1 |
| M81036/2-02B | Set: Verification Gage & Compression Fixture | .125 | DBS-CG2 |
| **The DMC Two Step Band Tools are recommended for Military stystems use where multi-source band procurement limits the use of the One Step Tools. Consult DMC for details. | |||
PROCEDURES FOR BANDING
Careful measurement should be made prior to installing the backshell. The outer jacket is then uniformly removed at a distance which would allow the braid to make a comfortable transition onto the backshell termination area. This dimension will vary depending upon the differences between cable and backshell diameters or other application dependent factors.
The braid is then trimmed to a length which will allow it to extend 1 inch past the backshell termination platform. Then the braid is carefully folded rearward to expose the wires which will be inside the backshell.
A sufficient number of wraps of self-vulcanizing tape (normally red in color) are applied over the wires to buildup a diameter slightly less than the inside diameter of the backshell. Care should be taken not to apply tension to the contacts located in the outer perimeter of
the connector.
These layers of tape are followed by a minimum of one layer of Teflon tape which will prevent adhesion with the backshell and other components.
The backshell is then installed onto the connector, using a nonabrasive tool such as a strap wrench. The braid is then carefully moved from under the backshell. It is important to retain the woven characteristics of the braid during this step.
Use self vulcanizing tape or a preformed component to build up the area behind the backshell. It is important that the braid is supported in the transition from the backshell rear diameter to the natural diameter of the wire bundle. Leave approximately 1/8 inch spacing between the tape wrap and the backshell.
The braid is pushed into position over the backshell termination platform. Care must be taken to make sure the weave is uniform and no large “windows” are present. A shield termination band is then loaded into the tool. The band is then slid over the connector/backshell assembly into a position of alignment with the termination platform. Apply an adequate amount of pressure in line with the cable as it enters the backshell to allow the 1/8 inch space to be reduced to zero. The tool is then activated to the preset tension. The band is then bent sharply at the buckle approximately 90° then cut-off using the cut-off lever on the tool. If band is uncurled for any reason, it must be double looped thru the buckle, before termination.
The 90° tab is then curled and folded back over the buckle using the rollover tool.
For braided a non-jacket cable use fine point shears
to trim the excess braid as close to the connector side of the bands as possible. 
Do not leave any unsecured braid wires longer than
1/8 inch. Do not allow the trimmed wires to fall into
any areas where they may present a foreign object damage hazard.
PROCEDURE FOR SPLICING
The jacket is present, and shield are cut and separated to expose the wires requiring service. Care must be taken to avoid damaging the insulation on internal wires. The required service
is then completed.
The wire bundle is then protected by a few wraps of self-vulcanizing tape followed by 2–3 layers of teflon tape. An appropriate size split ring set is then selected and installed. One layer of teflon tape is applied over the split ring set to hold the halves in position while the next steps are being performed.
The braid is then overlapped across the split ring set.
Be sure the braid ends protrude completely under the
band in both directions.
Heat shrinkable tape is then applied over the splice. Where a jacketed cable is used, be sure the tape extends onto the jacket in both directions.