Tyco Electronics 69547 User manual

©2011 Tyco Electronics Corporation, Berwyn, PA
All Rights Reserved
TE logo and Tyco Electronics are trademarks.
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Instruction Sheet
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
1of 4
LOC B

Straight Action Hand Tool (SAHT)
Assembly 69547 408-2155
15 FEB 11 Rev C
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
1. INTRODUCTION
SAHT Assembly 69547 is used to crimp Crimp-On
Receptacle 67263-[ ] onto stranded copper wire sizes
26 through 22 AWG with an insulation diameter range
of 0.86 through 1.37 mm [.034 through .054 in.].
Dimensions in this instruction sheet are in
millimeters [with inches in brackets]. Figures are
not drawn to scale.

Reasons for reissue are provided in Section 6,
REVISION SUMMARY.
2. DESCRIPTION (See Figure 1)
The tool is coated with preservative to prevent rust
and corrosion. Wipe this preservative from the tool,
particularly from the crimping surfaces.
The front of the tool, into which the receptacle is
inserted, is marked with the tool part number. The
back of the tool, into which the wire is inserted, is
marked with crimp symbols.
The hand tool consists of a U-head and handle. The
U-head features two movable dies (wire anvil and
insulation anvil) and two fixed dies (wire crimper and
insulation crimper). When closed, the dies form a
crimping chamber.
This tool is a member of the CERTI–CRIMP* hand
crimping tool family. The ratchet ensures full crimping
of the receptacle. Once engaged, the ratchet will not
release until the handles have been FULLY closed.
The dies bottom before the ratchet releases. This
ensures maximum electrical and tensile
performance of the crimp. DO NOT re-adjust the
ratchet.
3. CRIMPING PROCEDURE
1. Strip the wire according to the dimension shown
in Figure 2. DO NOT use wire with nicked, cut, or
missing conductors.
Figure 2
U-Head
Wire Anvil and Insulation
Anvil (Movable Dies)
Wire Crimper and Insulation
Crimper (Fixed Dies)
Tool Part Number
(Front of Tool)
Ratchet
Handle
NOTE
i
RECEPTACLE
WIRE
Side
Range
(AWG)
Insulation
Diameter Range
Strip
Length
67263-[ ] 26-22 0.86 - 1.37
[.034 - .054] 3.57 [.141]
CAUTION
!
Wire
Barrel
Locator
Slot
Insulation
Barrel Strip Length
(See Table)

408-2155
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Rev C
2. Squeeze the tool handles until the ratchet
releases. Allow the handles to open FULLY.
3. Insert the receptacle into the crimping chamber
with the “U” shape of the insulation barrel facing the
crimper dies. Position the receptacle so that the tool
locator enters the locator slot of the receptacle. See
Figure 3.
4. Holding the receptacle in position, squeeze the
tool handles until the insulation anvil starts entry into
the insulation crimper. DO NOT deform the
insulation barrel or wire barrel.
5. Insert the stripped wire into the insulation barrel
until the wire butts against the locator wire stop. See
Figure 3.
Figure 3
6. Squeeze the tool handles until the ratchet
releases. Allow the handles to open FULLY.
7. Remove the receptacle from the tool, and visually
inspect the crimp according to Figure 4.
4. MAINTENANCE AND INSPECTION
It is recommended that a maintenance and inspection
program be performed periodically to ensure
dependable and uniform terminations. Though
recommendations call for at least one inspection a
month, 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 arrival at your facility to ensure that
the tool has not been damaged during shipment.
Figure 4
4.1. Daily Maintenance
1. The hand tool should be immersed (handles
partially closed) in a reliable commercial degreasing
compound to remove accumulated dirt, grease, and
foreign matter. When degreasing compound is not
available, the tool may be wiped clean with a soft,
lint-free cloth. DO NOT use hard or abrasive 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. When the tool is not in use, keep handles closed
to prevent objects from becoming lodged in the
dies. Store the tool in a clean, dry area.
4.2. Lubrication
Keep all pins, pivot points, and bearing surfaces
lubricated with any good SAE 20 motor oil as follows:
Tools used in daily production - lubricate daily
Tools used daily (occasionally) - lubricate weekly
Tools used weekly - lubricate monthly
Wipe excess oil from the tool, particularly from the
crimping area. Oil transferred from the crimping area
onto certain terminations may affect the electrical
characteristics of an application.
A. Visual Inspection
1. Close the tool handles until the ratchet releases
and then allow them to open freely. If they do not
open quickly and fully, the tool must be repaired.
See Section 5, REPLACEMENT AND REPAIR.
2. Inspect the head and dies for worn, cracked, or
broken areas. If damage is evident, the tool must be
repaired. See Section 5, for REPLACEMENT AND
REPAIR.
Tool Locator in
Receptacle
Locator Slot
Crimper
Dies
Wire Insulation
Against Locator
Front of
Tool
1
2
3
4
1
2
3
4
Wire Barrel Seam Closed to
Confine All Conductors
Wire Insulation Does Not Enter Wire Barrel
End of Wire is Flush With (or Extends
Slightly Past) End of Wire Barrel
Insulation Barrel Wrapped Around,
But Not Cutting Into, Wire Insulation

408-2155
3of 4
Rev C
4.3. Ratchet Inspection
Check the ratchet to ensure that the ratchet does not
release prematurely, allowing the dies to open before
they have fully bottomed. Proceed as follows:
1. Remove traces of oil or dirt from the bottoming
surfaces of the dies.
2. Obtain a 0.025 [.001] shim that is suitable for
checking the clearance between the bottoming
surfaces of the dies.
3. Select a receptacle and maximum size wire for
the receptacle.
4. Position the receptacle in the crimping chamber
according to Section 3, CRIMPING PROCEDURE.
Holding the wire in place, squeeze the tool handles
together until the ratchet releases. Hold the tool
handles in this position, maintaining just enough
pressure to keep the dies closed.
5. Check the clearance between the bottoming
surfaces of the dies. If the clearance is 0.025 [.001]
or less, the ratchet is satisfactory. If clearance
exceeds 0.025 [.001], the ratchet is out of
adjustment and must be repaired. See Section 5,
REPLACEMENT AND REPAIR.
4.4. Gaging the Crimping Chamber (Insulation Dies)
This inspection requires the use of the plug gage
conforming to the dimensions provided in Figure 5. To
gage the crimping chamber for the insulation barrel
crimp, proceed as follows:
1. Remove traces of oil or dirt from the crimping
chamber and plug gage.
2. Close the tool handles until the crimping surfaces
of the dies have bottomed; then hold in this position.
DO NOT force beyond initial contact.
3. Insert GO element into the crimping chamber; but
do not force it. The GO element must pass through
the length of the crimping chamber. See Figure 5.
4. In the same manner, try to insert the NO-GO
element into the crimping chamber. The NO-GO
element may enter partially, but must not pass
completely through the length of the crimping
chamber.
If the crimping chamber conforms to the gage
inspection, the insulation dies may be considered
dimensionally correct and should be lubricated with a
THIN coat of any good SAE 20 motor oil. If the
crimping chamber does NOT conform to the gage
inspection, the tool must be repaired.
For additional information regarding the use of a plug
gage, refer to 408-7424.
Figure 5
4.5. Crimp Height Inspection (Wire Dies)
This inspection requires the use of a modified
micrometer with a spindle and modified anvil as shown
in Figure 6. It is recommended using the Crimp Height
Comparator RS-1019-5LP which can be purchased
from:
Shearer Industrial Supply Co. at 717-767-7575
VALCO at 610-691-3205
Proceed as follows:
1. Select a receptacle and maximum size wire for
the receptacle.
2. Refer to Section 3, CRIMPING PROCEDURE,
and crimp the receptacle accordingly.
3. Using a crimp height comparator, measure the
wire barrel crimp height as shown in Figure 6. If the
crimp height conforms to that height, the tool is
considered dimensionally correct. If not, the tool
must be returned to repair. See Section 5,
REPLACEMENT AND REPAIR.
GAGE ELEMENT DIAMETER
GO NO-GO
1.3081-1.3106 [.0515-.0516] 1.4833-1.4859 [.0584-.0585]
Suggested Plug Gage Design
for Insulation Dies
25.4 [1.0]
Min
Die Closure
Configuration
NO-GO DiameterGO Diameter
Inspection of Crimping Chamber (Insulation Dies)
Crimping
Chamber
GO Element NO-GO Element
GO element must pass
completely through the
crimping chamber.
NO-GO element may enter
partially, but must not pass
completely through the
crimping chamber.

408-2155
4of 4
Rev C
Figure 6
For additional information concerning the use of the
crimp height comparator, refer to 408-7424.
5. REPLACEMENT AND REPAIR
Customer-replaceable parts are listed in Figure 7.
A complete inventory should be stocked and
controlled to prevent lost time when replacement of
parts is necessary. Parts other than those listed should
be replaced by Tyco Electronics to ensure quality and
reliability. Order replacement parts through your
representative, or call 1-800-526-5142, or send a
facsimile of your purchase order to 717-986-7605, or
write to:
CUSTOMER SERVICE (038-035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105-3608
For customer repair service, contact a representative
at 1-800-526-5136.
6. REVISION SUMMARY
Since the last revision to this document, the following
changes were made:
•Added Proper Use Guidelines to first page.
•Updated document to corporate requirements.
Figure 7
Crimp Height Inspection (Wire Dies)
Spindle Point
Centered on
Wire Barrel
Opposite Seam
Modified
Anvil
0.76 ±0.03
[.030 ±.001]
Nominal
Crimp Height
REPLACEMENT PARTS
ITEM PART NUMBER DESCRIPTION QTY PER TOOL
1 125115-1 SPACER 4
2 21045-3 RING, Retaining 4
3 125077-3 PIN, Retaining 2
12
3
89 [3.5]
(Handles Closed)
289 [11.38]
19.05 [.75]