Tyco Electronics 69156-1 User manual

Instruction Sheet
Hand Crimping Tools 408--1791
LOC B
1of 6
E2010 Tyco Electronics Corporation, Berwyn, PA
All Rights Reserved
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
i
CAUTION
!
NOTE
i

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
A
CB
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
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
i

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
2
3
4
5
6
7
8
9
10
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
2
6
2
2
1
1
1
2
2
1
24
6
7
4
5
3
2
1
8
9
1
8
9
2
279
[11.0]
Approx. 76
[3.0]
Approx.
Locator Must Move
Freely 0.18 [.007] Max. Gap
10