Tyco Electronics 69156-1 User manual

Instruction Sheet

Hand Crimping Tools 408--1791

LOC B

1of 6

E2010 Tyco Electronics Corporation, Berwyn, PA

TE logo and Tyco Electronics are trademarks.

*Trademark. Other product names, logos, or 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

24 AUG 10 Rev L69156- 1 and 69241- 1

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.

Figure 1

Crimping

Dies

CERTI--CRIMP*

Tool Ratchet

1. INTRODUCTION

Hand Crimping Tools 69156--1 and 69241--1, see

Figure 1, are designed to crimp TERMASPLICE*

splices on coaxial or shielded cables within a primary

insulation diameter range as listed in Figure 2. Splice

lead and ground wire sizes 24 through 20 AWG are

simultaneously crimped in the splice with the shielded

or coaxial cable. Read these instructions thoroughly

before using the tools.

Reasons for reissue of this document are provided in

Section 6, REVISION SUMMARY.

Dimensions on this sheet are in millimeters [with

inches in brackets].

2. DESCRIPTION

The tool (shown in Figure 1) features two sets of

crimping dies and a CERTI--CRIMP ratchet.

One die set crimps the cable center conductor and

the splice lead conductor in a parallel splice; and the

other set crimps the cable braid and ground wire

conductor together in a parallel braid splice. Both

crimps are simultaneously accomplished with one

operating cycle of the tool.

The CERTI--CRIMP ratchet ensures full crimping of

the splice. Once engaged, the ratchet will not release

until the handles have FULLY closed.

The crimping dies bottom before the

CERTI--CRIMP tool ratchet releases. This design

feature ensures maximum electrical and tensile

performance of the crimp. Do NOT re--adjust the

ratchet.

3. CRIMPING PROCEDURE

Each hand tool is coated with a preservative to

prevent rust or corrosion. Wipe this preservative

from the tool, particularly from the crimping jaws,

before using the tool.

The crimping procedure requires two separate

operations. First, the cable and wires must be

prepared and assembled in the splice; then the entire

assembly is crimped using the hand tool.

3.1. Cable / Wire Preparation and Assembly

Select the proper cable, splice lead, and ground wire

and strip to the dimensions shown in Figure 2. Then

refer to Figure 3, and proceed as follows:

1. Slightly twist the cable center conductor strands.

2. Flare the cable braid so that it will easily slide

over the support sleeve of the splice.

3. Carefully insert cable into splice so that the

center--conductor insulation passes through the

support sleeve and the braid passes over and

around the support sleeve. Continue to insert cable

until the stripped center conductor enters parallel

splice area and insulator bottoms in support

sleeve.

NOTE

CAUTION

NOTE

408- 1791

Hand Crimping Tools 69156- 1 and 69241- 1

Rev L2 of 6 Tyco Electronics Corporation

Figure 2

SPLICE

NUMBER

STRIP LENGTHS

ABC

COLOR

CODE

RECOMMENDED

COAXIAL

CABLE

PRIMARY

INSULATION

DIA. RANGE

HAND

TOOL

14.3

[.56]

4.8 [.19] 6.4 [.25]

4.0 [.16] 7.1 [.28]

329413 VIOLET RG--174--U, RG--187--U 0.84--1.50 [.033--.059] 69241--1

328812 TIN RG--180--U, RG--195--U 2.16--2.41 [.085--.095] 69156--1

Coaxial or Shielded Cable Assembled Splice

Crimped Splice

Outer

Jacket Braid

Conductor Insulation Conductor

6.4

[.25]

7.1

[.28]

Splice Lead (24 -- 20 AWG)

Ground Wire (24 -- 20 AWG)

Ground Wire Splice

Lead

Shielded

Coaxial

Cable

Color Coded Skirt

(Inside Insulation)

Support

Sleeve

Insulation

Skirt

Special 24--20

Parallel Splice

Ground Wire

Conductor Under

Skirt and Over Braid Splice

Lead

Shielded

or Coaxial

Cable

Braid Cable Conductor

and Splice Lead

Conductor in

Parallel Splice

Figure 3

4. Insert ground wire under side of skirt that has

been “stretched” to accommodate the ground wire.

Ground wire will then be positioned between the

skirt and the braid.

5. While holding ground wire and cable securely in

place, insert splice lead into parallel splice area.

Make certain that splice lead does not move or

bend the cable center conductor. Parallel splice

area will accept solid or stranded wire sizes 24

through 20 AWG.

3.2. Crimping the Splice Assembly

To crimp the splice assembly, refer to Figure 4 and

proceed as follows:

1. Open the tool’s crimping dies by squeezing the

handles until the ratchet releases and then allow

the handles to open FULLY.

2. Position the splice assembly in the splice and

braid crimping dies, as shown in Figure 4. Small

shoulder on tapered end of splice should butt

against lower splice crimping die.

Make certain that section of splice containing

ground wire faces upper braid die.

NOTE

408- 1791

Hand Crimping Tools 69156- 1 and 69241- 1

3of 6Rev LTyco Electronics Corporation

Figure 4

Ground Wire

Portion of

Splice Faces

Upper Braid

Crimping Die

Position of

Ground Wire

Shielded or

Coaxial Cable

Position of

Splice Lead

Shoulder on End of

Tapered Portion of

Splice Butts Against

Lower Splice Crimping Die

Braid

Crimping

Dies

Splice

Crimping

Dies

3. Slowly squeeze tool handles until splice body is

heldfirmlyinplace.

4. While holding cable and wires in place, continue

to close tool handles until ratchet releases. Allow

handles to open FULLY and remove crimped

splice.

4. MAINTENANCE AND INSPECTION PROCEDURE

Tyco Electronics recommends that a maintenance

and inspection program be performed periodically to

ensure dependable and uniform terminations.

Frequency of inspection depends on:

1. The care, amount of use, and handling of the

hand tool.

2. The presence of abnormal amounts of dust and

dirt.

3. The degree of operator skill.

4. Your own established standards.

The hand tool is inspected before being shipped;

however, it is recommended that the tool be inspected

immediately upon its arrival at your facility to ensure

that the tool has not been damaged during shipment.

Due to the precision design, it is important that no

parts of these tools be interchanged except those

replacement parts listed in Figure 7.

4.1. Daily Maintenance

1. Remove dust, moisture, and other contaminants

with a clean brush, or a soft, lint--free cloth. Do

NOT use objects that could damage the tool.

2. Make certain that the retaining pins are in place

and that they are secured with retaining rings.

3. All pins, pivot points, and bearing surfaces

should be protected with a thin coat of any good

SAE 20 motor oil. Do not oil excessively.

4. When the tool is not in use, keep handles closed

to prevent objects from becoming lodged in the

crimping dies. Store the tool in a clean, dry area.

4.2. Lubrication

Lubricate all pins, pivot points, and bearing surfaces

with SAE 20 motor oil as follows:

Tools used in daily production -- lubricate daily

Tools used daily (occasional) -- lubricate weekly

Tools used weekly -- lubricate monthly

Wipe excess oil from tool, particularly from crimping

area. Oil transferred from the crimping area onto

certain terminations may affect the electrical

characteristics of an application.

4.3. Periodic Inspection

1. Hand tool should be immersed (handles partially

closed) in a reliable commercial degreasing

compound to remove accumulated dirt, grease,

and foreign matter.

408- 1791

Hand Crimping Tools 69156- 1 and 69241- 1

Rev L4 of 6 Tyco Electronics Corporation

2. Close tool handles until ratchet releases and

then allow them to open freely. If they do not open

quickly and fully, the spring is defective and must

be replaced. See Section 5, REPLACEMENT AND

REPAIR.

3. Inspect head assembly for worn, cracked, or

broken dies. If damage is evident, return the tool

for evaluation and repair. See Section 5,

REPLACEMENT AND REPAIR.

4.4. Crimping Die Closure Inspection

This inspection requires the use of two plug gages

conforming to the dimensions shown in Figure 5. Tyco

Electronics does not manufacture or market these

gages.

To gage die closure, refer to Figure 6 and proceed as

follows:

1. Remove traces of oil or dirt from the crimping

chamber and plug gage.

2. Close the tool handles until it is evident that the

dies have bottomed; then hold in this position. Do

NOT force the dies beyond initial contact.

3. Align the GO element of the proper plug gage

with the braid crimp section. Push element straight

into the crimp section without using force. The GO

element must pass completely through the crimp

section.

4. Check the braid crimp section with the NO--GO

element in the same manner as step 3. The

GO--GO element may start entry, but must not

pass completely through the crimp section.

5. Check the splice crimp section by repeating

Steps 3 and 4 using the proper plug gage.

If die closures conforms to the gage inspections, the

crimp sections are considered dimensionally correct.

If correct, the tool should be lubricated with a thin

coat of any good SAE 20 motor oil and returned to

service. If not correct, the tool must be returned for

further evaluation and repair. Refer to Section 5,

REPLACEMENT AND REPAIR. For additional

information regarding the use of a plug gage, refer

to instruction sheet 408--7424.

4.5. CERTI- CRIMP Ratchet Inspection

The CERTI--CRIMP ratchet feature on Tyco

Electronics hand tools should be checked to ensure

that the ratchet does not release prematurely,

SUGGESTED PLUG GAGE DESIGN - BRAID CRIMP SECTION

SUGGESTED PLUG GAGE DESIGN - SPLICE CRIMP SECTION

DIE SET

NUMBER

GAGE ELEMENT DIMENSIONS “B”

GO NO--GO “R” (Max.)

69156--1 5.055 -- 5.062 [.1990 -- .1993] 5.306 -- 5.309 [.2089 -- .2090] 2.36 [.093]

69241--1 4.470 -- 4.478 [.1760 -- .1763] 4.722 -- 4.724 [.1859 -- .1860] 1.98 [.078]

DIE SET

NUMBER

GAGE ELEMENT DIMENSIONS “B”

GO NO--GO

69156--1

69241--1 1.448 -- 1.455 [.0570 -- .0573] 1.598 -- 1.600 [.0629 -- .0630]

“R”

51 [2.0]

Min. Typ.

GO DIM.

“B”

NO--GO DIM.

“B”

DIE CLOSURE

CONFIGURATION

51 [2.0]

Min. Typ.

GO DIM.

“B”

NO--GO DIM.

“B”

DIE CLOSURE

CONFIGURATION

Figure 5

408- 1791

Hand Crimping Tools 69156- 1 and 69241- 1

5of 6Rev LTyco Electronics Corporation

Inspection of Braid Crimp Section Inspection of Splice Crimp Section

Dies Bottomed

But Not Under

Pressure

“Flats” on NO--GO

Gage Enter

Crimping Surface as

Shown

“GO” gage must

pass completely

through the crimp

section.

“NO--GO” gage may

enter partially, but

must not pass

completely through

the crimp section.

Figure 6

allowing the crimping dies to open before they have

fully bottomed. Obtain a 0.025--mm [.001--in.] shim

that is suitable for checking the clearance between

the bottoming surfaces of the crimping dies. Proceed

as follows:

1. Select the maximum size cable and

corresponding splice from the chart in Figure 2.

Then prepare the cable and wires in accordance

with Paragraph 3.1, Cable / Wire Preparation and

Assembly.

2. Position the splice assembly in the crimping

dies, as described in Paragraph 3.2, Crimping the

Splice Assembly.

3. Hold the splice assembly in place and squeeze

the handles until the CERTI--CRIMP ratchet

releases. Hold the handles in this position,

maintaining just enough tension to keep the dies

closed.

4. Check the clearance between the bottoming

surfaces of the crimping dies. If the clearance is

0.025 mm [.001 in.] or less, the ratchet is

satisfactory. If clearance exceeds 0.025 mm

[.001 in.], the ratchet is out of adjustment and

must be repaired. See Section 5, REPLACEMENT

AND REPAIR.

5. REPLACEMENT AND REPAIR

Replacement parts are listed in Figure 7. Parts other

than those listed in Figure 7 should be replaced by

Tyco Electronics to ensure quality and reliability of the

tool. Order replacement parts through your Tyco

Electronics representative, or call 1--800--526--5142,

408- 1791

Hand Crimping Tools 69156- 1 and 69241- 1

Rev L6 of 6 Tyco Electronics Corporation

or send a facsimile of your purchase order to

1--717--986--7605, or write to:

CUSTOMER SERVICE (38--35)

TYCO ELECTRONICS CORPORATION

PO BOX 3608

HARRISBURG, PA 17105--3608

For tool repair service, please contact a Tyco

Electronics representative at 1--800--526--5136.

6. REVISION SUMMARY

Since the previous release of this document, the logo

has been changed.

Figure 7

REPLACEMENT PARTS

ITEM PART NUMBER DESCRIPTION QTY PER ASSY

1--304197--0

21045--3

8--59558--2

21045--6

2--23620--9

6--59591--7

39364

24088--8

125115--1

307089--3

PIN, Retaining

RING, Retaining

PIN, Retaining

RING, Retaining

PIN, Retaining

COLLAR

SPRING

WASHER, Curved

WASHER

LOCATOR

279

[11.0]

Approx. 76

[3.0]

Approx.

Locator Must Move

Freely 0.18 [.007] Max. Gap

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