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instruction sheet application tooling for 408--7516 loc b 1 of 17 e 2011 tyco electronics corporation, a te connectivity ltd. company all rights reserved te logo is a trademark. *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.te.com 10 mar 11 rev e screw- machine contacts 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 volum e applications. a wide selection of powered application equipment for extended--use, production operations is available. figure 1 amp--tapetronic* 4/8 indent stripper terminator 599406--[ ] (requires funnel) tooling for loose- piece contacts 4/8--indent hand crimping tool (typ, requires positioner or turret head) tooling for tape mounted contacts extraction tool (typ) insertion/extraction tool (typ) 1. introduction this instruction sheet covers tooling selections for crimping, inserting, and extracting screw--machine contacts, and manual application procedures. application procedures for the other tools are packaged with the tool. read these instructions thoroughly before making any selections. dimensions in this instruction sheet are in millimeters [with inches in brackets]. figures and illustrations are for reference only and are not drawn to scale. reasons for reissue of this instruction sheet are provided in section 7, revision summary. 2. description the screw--machine contacts are supplied in loose--piece for manual (4/8--indent hand crimping tools) application and tape mounted for power assisted (machine) application. insertion and extraction tools are used to insert contacts into and extract contacts from connectors. see figure 1. the military uses a standar dized number ing system which pertains to the tools that are qualified to military specifications (spec). refer to figure 2 for a cross--reference of these tools. description part number military spec 4 / 8 i d h d 601966--1 mil--c--22520/2--01 4/8--indent hand c r i m p i n g t o o l 601967--1 mil--c--22520/1--01 c r i m p i n g t o o l 608651--1 -- -- -- 601966--2 mil--c--22520/2--02 601966--4 mil--c--22520/2--06 p i i 601966--5 mil--c--22520/2--08 positioner or t u r r e t h e a d 601966--6 mil--c--22520/2--09 t u r r e t h e a d 601966--8 mil--c--22520/2--23 601967--2 mil--c--22520/1--02 1--601967--2 mil--c--22520/1--11 91066--1 mil--i--81969/1--01 or ms3156--22 i n s e r t i o n / e x t r a c t i o n 91067--1 mil--i--81969/1--04 insertion / extraction tool 91067--2 mil--i--81969/1--02 or ms3156--20 91066--3 mil--i--81969/1--03 or ms3156--16 445147--1 mil--c--81969/28--02 e x t r a c t i o n t o o l 58284--1 mil--c--81969/28--03 e x t r a c t i o n t o o l 91074--1 mil--c--81969/28--01 or ms3178--001 figure 2 refer to figure 3 for proper contact and tooling combination. read the chart from the left page across to the right page. note i
408- 7516 rev e 2 of 17 contact wire tool product line size pin socket military spec size (awg) strip length t o o l selector setting 28 2 201607 201609 ? 26 5.16 [.203] 2 24 [ ] 3 28 2 ? 201353 ? 26 5.16 [.203] 2 24 [ ] 3 2 0 24 1 20 201582 201584--6 ? 22 5.16 [.203] 2 20 [ ] 3 24 1 200334 200331 ? 22 5.16 [.203] 2 20 [ ] 3 2 0 1 5 8 9 18 6 3 5 [ 2 5 0 ] 4 ? 201589 ? 16 6.35 [.250] 5 2 0 1 5 5 4 32 5 1 6 [ 2 0 3 ] 1 ? 201554 ? 30 5.16 [.203] 1 201334 ? ? 28 2 type ii contact f o r m u l t i m a t e 2 0 1 3 3 2 26 5.16 [.203] 2 f or m u l t i mate connectors ? 201332 ? 24 [ ] 3 c o n n e c t o r s 201611 ? ? 28 2 2 0 1 6 1 3 26 5.16 [.203] 2 ? 201613 ? 24 [ ] 3 201578 ? ? 22 5 1 6 [ 2 0 3 ] 2 ? 201580 ? 20 5.16 [.203] 3 1 6 200679 201328 ? 24 1 16 201330 ? 22 5.16 [.203] 2 204188 ? ? 20 [ ] 3 2 0 0 6 8 1 2 0 0 3 3 3 18 6 3 5 [ 2 5 0 ] 4 200681 200333 ? 1 6 6.35 [ .250 ] 5 16 [ ] 5 202507 ? ? 18 4 ? 202508 ? 16 5 2 0 0 3 3 6 2 0 0 3 3 3 18 6.35 [.250] 4 200336 200333 ? 16 [ ] 5 201570 201568 ? 14 5 201555 ? ? 32 5 1 6 [ 2 0 3 ] 1 ? 201554 ? 30 5.16 [.203] 1 figure 3 (cont?d)
408- 7516 3 of 17 rev e tooling for loose piece contacts tooling for tape mounted contacts c o n n e c t o r i n s e r t i o n e x t r a c t i o n positioner or turret head hand crimping tool machine funnel connector military spec insertion tool extraction tool 1--601967--5 58305--1 or 6 0 1 9 6 7 -- 1 ? ? ? 200893--2 or 9 1 0 0 2 -- 1 305183 6 0 1 9 6 7 -- 1 9 1 0 0 2 -- 1 1--601967--5 58305--1 or 6 0 1 9 6 7 -- 1 ? ? ? 200893--2 or 9 1 0 0 2 -- 1 305183 6 0 1 9 6 7 -- 1 9 1 0 0 2 -- 1 1--601967--5 58305--1 or 6 0 1 9 6 7 -- 1 ? ? ? 200893--2 or 9 1 0 0 2 -- 1 305183 6 0 1 9 6 7 -- 1 9 1 0 0 2 -- 1 1--601967--5 58305--1 or 6 0 1 9 6 7 -- 1 ? ? ? 200893--2 or 9 1 0 0 2 -- 1 305183 6 0 1 9 6 7 -- 1 9 1 0 0 2 -- 1 1 6 0 1 9 6 7 6 45098 or 200893--2 or 3 0 5 1 8 3 1--601967--6 4 5 0 9 8 o r 601967--1 ? ? ? 2 0 0 8 9 3 2 o r 91002--1 305183 1 6 0 1 9 6 7 5 58305--1 or 200893--2 or 3 0 5 1 8 3 1--601967--5 5 8 3 0 5 1 o r 601967--1 ? ? ? 2 0 0 8 9 3 2 o r 91002--1 305183 1--601967--6 1 6 0 1 9 6 7 5 58305--1 or 6 0 1 9 6 7 -- 1 ? ? ? 200893--2 or 9 1 0 0 2 -- 1 305183 1--601967--5 6 0 1 9 6 7 -- 1 9 1 0 0 2 -- 1 1--601967--6 1 6 0 1 9 6 7 5 58305--1 or 6 0 1 9 6 7 -- 1 ? ? ? 200893--2 or 9 1 0 0 2 -- 1 305183 1--601967--5 6 0 1 9 6 7 -- 1 9 1 0 0 2 -- 1 1--601967--6 58305--1 or 200893--2 or 3 0 5 1 8 3 1--601967--5 5 8 3 0 5 1 o r 601967--1 ? ? ? 2 0 0 8 9 3 2 o r 91002--1 305183 1--601967--5 1 6 0 1 9 6 7 6 58305--1 or 6 0 1 9 6 7 -- 1 ? ? ? 200893--2 or 9 1 0 0 2 -- 1 305183 1--601967--6 6 0 1 9 6 7 -- 1 9 1 0 0 2 -- 1 1 6 0 1 9 6 7 6 45098 or 200893--2 or 3 0 5 1 8 3 1--601967--6 4 5 0 9 8 o r 6 0 1 9 6 7 -- 1 ? ? ? 2 0 0 8 9 3 2 o r 9 1 0 0 2 -- 1 305183 6 0 1 9 6 7 -- 1 9 1 0 0 2 -- 1 1--601967--6 90136--1 or 200893--2 or 3 0 5 1 8 3 1--601967--5 9 0 1 3 6 1 o r 601967--1 ? ? ? 2 0 0 8 9 3 2 o r 91002--1 305183 200893--2 or 1--601967--6 45098 or 6 0 1 9 6 7 -- 1 ? ? ? 2 0 0 8 9 3 2 o r 91002--1 305183 6 0 1 9 6 7 -- 1 ? 1--601967--6 58305--1 or 200893--2 or 3 0 5 1 8 3 1--601967--5 5 8 3 0 5 1 o r 601967--1 ? ? ? 2 0 0 8 9 3 2 o r 91002--1 305183 figure 3 (cont?d)
408- 7516 rev e 4 of 17 contact wire tool product line size pin socket military spec size (awg) strip length t o o l selector setting 28 2 ? 201609 ? 26 5.16 [.203] 2 24 [ ] 3 2 0 1 3 3 2 26 5 1 6 [ 2 0 3 ] 2 ? 201332 ? 24 5.16 [.203] 3 24 1 200679 201328 ? 22 5.16 [.203] 2 20 [ ] 3 type ii contact f o r m u l t i m a t e 1 6 200681 200333 ? 18 5 1 6 [ 2 0 3 ] 4 f o r m u l t i m a t e connectors 1 6 200336 ? ? 16 5.16 [.203] 5 204274 ? ? 18 4 202507 ? ? 18 5.16 [.203] 4 204219 202508 ? 16 [ ] 5 202725 202726 ? ? 18 ? 5.16 [.203] 5 201570 ? ? 5 201645 ? ? 14 5.16 [.203] 5 ? 201568 ? [ ] 5 ? 32 ? 1 2 0 2 1 2 3 2 0 2 1 2 4 ? 30 ? 3 1 8 [ 1 2 5 ] 1 202123 202124 ? 28 3.18 [.125] 2 type vii contact f o r s u b m i n i a t u r e 2 2 26 2 for subminiature connectors 22 ? 30 ? 1 c o n n e c t o r s 2 0 4 0 9 2 28 3 1 8 [ 1 2 5 ] 2 204092 ? ? 26 3.18 [.125] 3 24 4 type xiii contact 24 5 y p e c o t a c t for terminal j u n c t i o n ( t j g ) 20 203669--4 ? ? 22 4.78 [.188] 6 j u n c t i o n ( t j g ) modules 20 [ ] 7 figure 3 (cont?d) ? this wire size is not recommended for use in the machine. ? refer to the instruction sheet (408--series) packaged with the contact for wire strip length.
408- 7516 5 of 17 rev e tooling for loose piece contacts tooling for tape mounted contacts c o n n e c t o r i n s e r t i o n e x t r a c t i o n positioner or turret head hand crimping tool machine funnel connector military spec insertion tool extraction tool 1--601967--5 58305--1 or 6 0 1 9 6 7 -- 1 ? ? ? 200893--2 or 9 1 0 0 2 -- 1 305183 6 0 1 9 6 7 -- 1 9 1 0 0 2 -- 1 1 6 0 1 9 6 7 5 58305--1 or 200893--2 or 3 0 5 1 8 3 1--601967--5 5 8 3 0 5 1 o r 601967--1 ? ? ? 2 0 0 8 9 3 2 o r 91002--1 305183 1--601967--5 58305--1 or 6 0 1 9 6 7 -- 1 ? ? ? 200893--2 or 9 1 0 0 2 -- 1 305183 6 0 1 9 6 7 -- 1 9 1 0 0 2 -- 1 1 6 0 1 9 6 7 6 45098 or 200893--2 or 3 0 5 1 8 3 1--601967--6 4 5 0 9 8 o r 601967--1 ? ? ? 2 0 0 8 9 3 2 o r 91002--1 305183 1 6 0 1 9 6 7 6 1--601967--6 45098 or 6 0 1 9 6 7 -- 1 2 0 0 8 9 3 2 o r 1--601967--5 6 0 1 9 6 7 -- 1 ? ? ? 200893--2 or 91002--1 305183 1--601967--6 45098 or 601967--1 9 1 0 0 2 1 1 6 0 1 9 6 7 6 1--601967--6 45098 or 6 0 1 9 6 7 -- 1 ? ? ? 200893--2 or 9 1 0 0 2 -- 1 305183 1--601967--5 6 0 1 9 6 7 -- 1 9 1 0 0 2 -- 1 1 6 0 1 9 6 6 0 6 0 1 9 6 6 1 5 9 9 4 0 6 7 1 1 2 5 9 0 5 1 9 1 0 0 5 2 9 1 0 0 4 2 1--601966--0 601966--1 599406--7 1--125905--1 ? 91005--2 91004--2 1 6 0 1 9 6 6 0 6 0 1 9 6 6 1 5 9 9 4 0 6 7 1--601966--0 601966--1 599406--7 ? ? ? ? -- 601966--2 601966--1 599406--7 ? ? h ? h h ? h figure 3 (cont?d) h military spec mil--i--81969/14
408- 7516 rev e 6 of 17 contact wire tool product line size pin socket military spec size (awg) strip length t o o l selector setting 24 2 203840 ? ? 22 4.78 [.188] 3 2 0 20 [ ] 4 type xv f o r a r i n c 20 24 2 f o r a r i n c front release a m a d d ? 203841 ? 22 4.78 [.188] 3 a m, a d, and a a p c o n n e c t o r s 20 [ ] 4 a a p c o n n e c t o r s 20 4 16 203884 ? ? 18 6.35 [.250] 5 16 [ ] 5 26 3 204873 ? mil--c--39029/11--144 24 3.96 [.156] 3 22 [ ] 4 2 2 26 3 22 ? 205103 mil--c--39029/12--148 24 3.96 [.156] 3 22 [ ] 4 2 0 5 9 0 4 ? 30 ? 3 9 6 [ 1 5 6 ] 4 ? 205904 ? 28 3.96 [.156] 5 24 5 204938 ? mil--c--39029/11--145 22 3.96 [.156] 6 20 [ ] 7 ? 205116 mil--c--39029/12--149 24 5 type xvii 20 m i l c 3 9 0 2 9 / 1 2 1 4 9 22 3.96 [.156] 6 t y p e x v i i for arinc r e a r r e l e a s e ? ? mil--c--39029 / 12--149 20 [ ] 7 r e a r r e l e a s e rm connectors ? 30 ? 4 205791 206887 ? 28 3.96 [.156] 5 26 [ ] 6 20 4 204978 ? mil--c--39029/11--146 18 6.35 [.250] 5 1 6 16 [ ] 6 16 20 4 ? 205117 mil--c--39029/12--150 18 6.35 [.250] 5 16 [ ] 6 2 0 5 7 6 3 5 14 6 3 5 [ 2 5 0 ] 7 1 2 205763--5 ? ? 12 6.35 [.250] 8 12 2 0 5 8 5 1 2 14 6 3 5 [ 2 5 0 ] 7 ? 205851--2 ? 12 6.35 [.250] 8 figure 3 (cont?d) ? this wire size is not recommended for use in the machine.
408- 7516 7 of 17 rev e tooling for loose piece contacts tooling for tape mounted contacts c o n n e c t o r i n s e r t i o n e x t r a c t i o n positioner or turret head hand crimping tool machine funnel connector military spec insertion tool extraction tool -- 601967--2 601967--1 599406--5 125905--8 mil--c--81659 91039--1 91040--1 -- 601967--2 601967--1 599406--5 125905--8 mil--c--8165 91039--1 91040--1 -- 601967--2 601967--1 599406--5 125905--6 mil--c--81659 91039--3 91040--3 -- 601966--8 601966--1 599406--7 1--125905--2 mil--c--81659 91066--1 91066--1 -- 601966--8 601966--1 599406--7 1--125905--2 ? 91066--1 91066--1 6 0 1 9 6 6 8 6 0 1 9 6 6 1 5 9 9 4 0 6 7 1 1 2 5 9 0 5 2 9 1 0 6 6 1 9 1 0 6 6 1 -- 601966--8 601966--1 599406--7 1--125905--2 ? 91066--1 91066--1 1 2 5 9 0 5 -- 1 -- 601966--5 601966--1 599406--7 1 2 5 9 0 5 -- 1 (max insulation d i 1 9 8 [ 0 7 8 ] ) mil--c--81659 91067--2 91067--2 ( dia 1.98 [.078 ] ) 1 2 5 9 0 5 -- 1 -- 601966--5 601966--1 599406--7 1 2 5 9 0 5 -- 1 (max insulation d i 1 9 8 [ 0 7 8 ] ) ? 91067--2 91067--2 ( dia 1.98 [.078 ] ) -- 601966--5 601966--1 599406--7 ? ? 91067--2 91067--2 -- 601967--2 601967--1 599406--5 125905--6 mil--c--81659 91066--3 91066--3 -- 601967--2 601967--1 599406--5 125905--6 ? 91066--3 91066--3 6 0 1 9 6 7 2 6 0 1 9 6 7 1 m i l c 8 1 6 5 9 4 4 5 1 4 7 1 -- 601967--2 601967--1 ? ? mil--c--81659 ? 445147--1 6 0 1 9 6 7 2 6 0 1 9 6 7 1 m i l c 8 1 6 5 9 4 4 5 1 4 7 1 -- 601967--2 601967--1 ? ? mil--c--81659 ? 445147--1 figure 3 (cont?d)
408- 7516 rev e 8 of 17 contact wire tool product line size pin socket military spec size (awg, see note) strip length t o o l selector setting 0 ? 51781--1 ? rg 214/u ? ? 1 225837--1 ? ? semi--rigid 141 ? (408--2348--02) 8 1 ? 225831--1 ? rg 214/u ? (408--2348--02) ? 226053--1 ? ? rg 141/u, 58c/u ? (408--2348--01) 8 3 ? 225792--1 ? rg 214/u, 213/u ? (408--2348--01) ? ? 225792--3 ? rg 58c/u, 141a/u ? (408--2348--01) 8 coaxicon* c o n t a c t f o r 225790--1 225791--1 ? rg 58c/u, 141/u ? (408--2348) 5 contact for arinc coaxial connectors 5 225790--2 225791--2 ? rg 233/u, 142/u ? (408--2348) 5 c o n n e c t o r s 5 225790--3 ? ? semi--rigid 141 ? (408--2348) 5 225790--4 ? ? rg 180b/u ? (408--2348) 5 7 ? 225796--1 ? rg 58c/u ? 5 7 ? 225796--2 ? rg 233/u ? ? (408--2348--03) 5 9 ? 225936--1 ? semi--rigid 141 ? (408--2348--03) 5 26 3 208262 ? ? 24 3.96 [.156] 3 2 2 22 [ ] 4 22 26 3 ? 208264 ? 24 3.96 [.156] 3 a r i n c 6 0 0 22 [ ] 4 a rinc 600 24 5 208265 ? ? 22 3.96 [.156] 6 2 0 20 [ ] 7 20 24 5 ? 208267 ? 22 3.96 [.156] 6 20 [ ] 7 figure 3 (cont?d) ? refer to the instruction sheet (408--series) packaged with the contact for wire strip length. note: unless otherwise specified
408- 7516 9 of 17 rev e tooling for loose piece contacts tooling for tape mounted contacts c o n n e c t o r i n s e r t i o n e x t r a c t i o n positioner or turret head hand crimping tool machine funnel connector military spec insertion tool extraction tool ? 69646 ? ? ? ? 91040--7 ? 601966--1 ? and 220066--1 ? ? ? ? ? ? ? 220015--1 ? ? ? ? ? 1--601966--8 ? 601966--1 ? and 220066--1 ? ? ? ? ? ? ? 220015--1 ? ? ? ? ? ? 601966--1 ? and 220066--1 ? ? ? ? ? ? 1--601966--6 ? 601966--1 ? and 220066--1 ? ? ? ? ? 91074--1 1--601966--6 ? 601966--1 ? and 220066--1 ? ? ? ? ? 91074--1 1--601966--6 ? 601966--1 ? and 220066--1 ? ? ? ? ? 91074--1 1--601966--6 ? 601966--1 ? and 220066--1 ? ? ? ? ? 91074--1 2--601966--6 ? 601966--1 ? and 220066--1 ? ? ? ? ? ? 1--601966--6 ? 601966--1 ? and 220066--1 ? ? ? ? ? ? 1--601966--6 ? 601966--1 ? and 220066--1 ? ? ? ? ? 91074--1 1--601966--6 ? 601966--1 ? and 220066--1 ? ? ? ? ? 91074--1 601966--8 601966--1 599406--7 1--125905--2 ? 91066--1 91066--1 601966--8 601966--1 599406--7 1--125905--2 ? 91066--1 91066--1 601966--5 601966--1 599406--7 125905--1 ? 91067--2 91067--2 1 2 5 9 0 5 -- 1 601966--5 601966--1 599406--7 1 2 5 9 0 5 -- 1 (max insulation d i 1 9 8 [ 0 7 8 ] ) ? 91067--2 91067--2 ( dia 1.98 [.078 ] ) figure 3 (cont?d) ? this positioner is used with tool 601966--1 ? this tool crimps only the center contact of the pin or socket ? this tool crimps only the ferrule of the pin or socket
408- 7516 rev e 10 of 17 contact wire tool product line size pin socket military spec size (awg, see note) strip length t o o l selector setting 204978 ? ? 20 4 208268 ? ? 18 6.35 [.250] 5 1 6 213122 ? ? 16 [ ] 6 16 20 4 a r i n c 6 0 0 ? 208270 ? 18 6.35 [.250] 5 a rinc 600 16 [ ] 6 208271 ? ? 14 6 3 5 [ 2 5 0 ] 7 1 2 213123 ? ? 12 6.35 [.250] 8 12 2 0 8 2 7 3 14 6 3 5 [ 2 5 0 ] 7 ? 208273 ? 12 6.35 [.250] 8 t r i a x i a l 8 2 2 2 1 9 0 2 2 2 1 9 1 mil--c--39029--95 and tri a xi a l8 222190 222191 m i l c 3 9 0 2 9 9 5 a n d mil--c--39029--96 ? ? ? 2 0 6 4 9 6 28 3 9 6 [ 1 5 6 ] 3 206496 ? ? 26 3.96 [.156] 4 2 0 6 4 9 6 28 3 9 6 [ 1 5 6 ] 3 ? 206496 ? 26 3.96 [.156] 4 28 1 2 0 4 3 7 0 m i l c 3 9 0 2 9 / 5 8 3 6 0 26 3 9 6 [ 1 5 6 ] 2 204370 ? mil--c--39029 / 58--360 24 3.96 [.156] 3 2 2 d 22 4 22d 28 1 t y p e x v i i 2 0 4 3 5 1 m i l c 3 9 0 2 9 / 5 7 3 5 4 26 3 9 6 [ 1 5 6 ] 2 t y p e x v i i for amplimite* h d d c t ? 204351 mil--c--39029 / 57--354 24 3.96 [.156] 3 hdd connectors 22 4 28 1 2 0 6 0 7 1 26 3 9 6 [ 1 5 6 ] 2 ? 206071 ? 24 3.96 [.156] 3 22 4 2 0 6 7 9 4 2 0 6 7 9 5 28 3 9 6 [ 1 5 6 ] 5 206794 206795 ? 26 3.96 [.156] 6 20 24 5 205089 ? mil--c--39029/64--369 22 3.56 [.140] 6 20 [ ] 7 figure 3 (cont?d) note: unless otherwise specified
408- 7516 11 of 17 rev e tooling for loose piece contacts tooling for tape mounted contacts c o n n e c t o r i n s e r t i o n e x t r a c t i o n positioner or turret head hand crimping tool machine funnel connector military spec insertion tool extraction tool 601967--2 601967--1 599406--5 125905--6 ? 91066--3 91066--3 601967--2 601967--1 599406--5 125905--6 ? 91066--3 91066--3 1 6 0 1 9 6 7 2 6 0 1 9 6 7 1 4 4 5 1 4 7 1 1--601967--2 601967--1 ? ? ? ? 445147--1 1 6 0 1 9 6 7 2 6 0 1 9 6 7 1 4 4 5 1 4 7 1 1--601967--2 601967--1 ? ? ? ? 445147--1 ? 6 0 8 6 5 0 1 ? ? m i l c 8 3 5 2 7 ? 5 8 2 8 4 1 608650--1 mil--c--83527 58284--1 6 0 1 9 6 6 6 6 0 1 9 6 6 1 5 9 9 4 0 6 7 1 2 5 9 0 5 2 9 1 0 6 7 1 9 1 0 6 7 1 601966--6 601966--1 599406--7 125905--2 ? 91067--1 91067--1 6 0 1 9 6 6 4 6 0 1 9 6 6 1 5 9 9 4 0 6 7 1 2 5 9 0 5 2 9 1 0 6 7 1 9 1 0 6 7 1 601966--4 601966--1 599406--7 125905--2 ? 91067--1 91067--1 6 0 1 9 6 6 6 6 0 1 9 6 6 1 5 9 9 4 0 6 7 1 2 5 9 0 5 2 m i l c 2 4 3 0 8 9 1 0 6 7 1 9 1 0 6 7 1 601966--6 601966--1 599406--7 125905--2 mil--c--24308 91067--1 91067--1 6 0 1 9 6 6 4 6 0 1 9 6 6 1 5 9 9 4 0 6 7 1 2 5 9 0 5 2 m i l c 2 4 3 0 8 9 1 0 6 7 1 9 1 0 6 7 1 601966--4 601966--1 599406--7 125905--2 mil--c--24308 91067--1 91067--1 6 0 1 9 6 6 4 6 0 1 9 6 6 1 5 9 9 4 0 6 7 1 2 5 9 0 5 2 9 1 0 6 7 1 9 1 0 6 7 1 601966--4 601966--1 599406--7 125905--2 ? 91067--1 91067--1 6 0 1 9 6 6 5 6 0 1 9 6 6 1 5 9 9 4 0 6 7 9 1 0 6 7 2 9 1 0 6 7 2 601966--5 601966--1 599406--7 ? ? 91067--2 91067--2 601966--5 601966--1 599406--7 125905--1 mil--c--24308 91067--2 91067--2 figure 3 (cont?d)
408- 7516 rev e 12 of 17 contact wire tool product line size pin socket military spec size (awg) strip length t o o l selector setting 24 5 ? 205090 mil--c--39029/63--368 22 3.56 [.140] 6 20 [ ] 7 type xvii f o r a m p l i m i t e 2 0 1 2 1 8 2 6 6 1 1 2 1 8 2 6 7 1 ? 18 ? 3 5 6 [ 1 4 0 ] 7 for a mplimite hdd connectors 20 1218266--1 1218267--1 ? ? 18 ? 3.56 [.140] 7 h d d c o n n e c t o r s 24 5 ? 206793 ? 22 3.56 [.140] 6 20 [ ] 7 211159--1 211161--1 ? 8 9 5 3 [ 3 7 5 ] 7 211159--2 211161--2 ? 10 9.53 [.375] 6 2 1 2 0 0 7 1 2 1 2 0 0 8 1 12 9 5 3 [ 3 7 5 ] 1 a mplimite 8 212007--1 212008--1 ? 14 9.53 [.375] 1 a m p l i m i t e power 8 contact 8 2 1 2 0 1 3 1 2 1 2 0 1 4 1 16 9 5 3 [ 3 7 5 ] 8 212013--1 212014--1 ? 18 9.53 [.375] 6 2 1 3 5 5 2 8 9 5 3 [ 3 7 5 ] 7 213552 ? ? 10 9.53 [.375] 6 28 1 2 0 4 3 5 1 1 m i l c 3 9 0 2 9 / 5 7 3 5 4 26 3 9 6 [ 1 5 6 ] 2 ? 204351--1 mil--c--39029 / 57--354 24 3.96 [.156] 3 2 2 22 4 22 28 3 1 8 [ 1 2 5 ] 4 861211 or 26 3.18 [.125] 5 8 6 1 2 1 1 o r 863260 ? ? 24 5 l g h * c o n t a c t 22 3 9 6 [ 1 5 6 ] 6 lgh * contact 24 3.96 [.156] 5 ? 867782 ? ? 22 6 20 6.35 [.250] 7 20 4 ? 867328 mil--c--39029/12--150 18 6.35 [.250] 5 16 16 [ ] 6 8 6 1 0 8 0 22 (2) ? 4 7 8 [ 1 8 8 ] 6 ? 861080 ? 16 4.78 [.188] 7 figure 3 (cont?d) ? 19--strand wire ? use two size 22 awg wires
408- 7516 13 of 17 rev e tooling for loose piece contacts tooling for tape mounted contacts c o n n e c t o r i n s e r t i o n e x t r a c t i o n positioner or turret head hand crimping tool machine funnel connector military spec insertion tool extraction tool 601966--5 601966--1 599406--7 125905--1 ? 91067--2 91067--2 6 0 1 9 6 6 5 6 0 1 9 6 6 1 9 1 0 6 7 2 9 1 0 6 7 2 601966--5 601966--1 ? ? ? 91067--2 91067--2 601966--5 601966--1 599406--7 125905--1 ? 91067--2 91067--2 6 0 8 6 5 1 2 6 0 8 6 5 1 1 3 1 8 8 1 3 1 608651--2 608651--1 ? ? ? ? 318813--1 6 0 8 6 5 1 2 6 0 8 6 5 1 1 3 1 8 8 1 3 1 608651--2 608651--1 ? ? ? ? 318813--1 6 0 8 6 6 8 2 6 0 8 6 6 8 1 3 1 8 8 1 3 1 608668--2 608668--1 ? ? ? ? 318813--1 6 0 8 6 5 1 3 6 0 8 6 5 1 1 3 1 8 8 1 3 1 608651--3 608651--1 ? ? ? ? 318813--1 6 0 1 9 6 6 4 6 0 1 9 6 6 1 601966--4 601966--1 ? ? ? ? ? 6 0 1 9 6 6 1 ? 601966--1 ? ? ? ? ? ? 601966--1 ? ? ? ? ? 601967--2 601967--1 ? ? ? 91067--1 91067--1 h h 6 0 1 9 6 7 1 9 1 0 6 6 3 9 1 0 6 6 3 h ? h 601967--1 ? ? ? 91066--3 91066--3 figure 3 (end) h military spec mil--c--22520/1--05
408- 7516 rev e 14 of 17 3. tooling assembly 3.1. installing positioner refer to figure 4, and proceed as follows: 1. squeeze the tool handles together, then allow the handles to fully open. the tool handles must be fully opened when installing the positi oner; otherwise, damage to the tool will occur. 2. insert the post of the positioner into the hole in the back of the tool. make sure that the bayonet pin enters the slot in the retainer ring of the tool. figure 4 bayonet pin post data plate outer rim back of tool ratchet tool handles selector knob and dial safety clip positioner installed retainer ring (hidden) installing positioner 3. firmly grip the outer rim of the positioner and push until the spring inside the positioner is depressed, then rotate the positioner clockwise until it stops. 4. insert the tool safety clip into the retainer ring to lock the positioner in place. 5. determine the selector setting according to the contact size and wire size listed in figure 3 (or refer to the data plate on the positioner. pull the selector knob and turn to the proper setting. the tool handles must be fully opened when changing the positioner selector setting; otherwise, damage to the tool will occur. 3.2. installing turret head refer to figure 5, and proceed as follows: 1. squeeze the tool handles together, then allow the handles to fully open. the tool handles must be fully opened when installing the positi oner; otherwise, damage to the tool will occur. 2. depress the turret trigger to release the turret from the index position (the turret should be extended). figure 5 index mark turret extended turret in locked position data plate turret trigger back of turret head positioner socket head cap screw (2 places) back of tool tool handles selector knob and dial turret head installed retainer ring (hidden) installing turret head caution ! caution ! caution !
408- 7516 15 of 17 rev e 3. place the back of the turret head over the retainer ring on the back of the tool. make sure that the turret head is seated, then tighten the two socket head cap screws of the turret head. 4. rotate the turret until the positioner marked with the desired contact size is aligned with the index mark. 5. press the turret until it is in the locked position. 6. determine the selector setting according to the contact size and wire size listed in figure 3. pull the selector knob and turn to the proper setting. the tool handles must be fully opened when changing the positioner selector setting; otherwise, damage to the tool will occur. 4. crimping procedure these tools have a ratchet which ensures proper crimping of the contacts. once engaged, the ratchet will not release until the tool handles are fully closed. 1. strip the wire according to the wire size listed in figure 3. 2. squeeze the tool handles together, then allow the handles to fully open. 3. insert the mating end of the contact into the indenter from the front of the tool until the contact bottoms. refer to figure 6. figure 6 mating end of contact indenter front of tool nameplate (ref) 4. insert the wire into the contact wire barrel. while holding the wire in place, squeeze the tool handles until the ratchet releases. allow the handles to open. 5. remove the crimped contact from the tool. inspect the contact according to the applicable application specification (114--series). 5. maintenance and inspection 5.1. daily maintenance each operator should be aware of, and responsible for, the following steps of daily maintenance, to ensure continuous quality and reliability of each tool. 1. remove dust, moisture, and other contaminants with a clean brush, or soft, lint--free cloth. do not use objects that could damage the tool. 2. when the tool is not in use, keep the handles closed, and store the tool in a clean, dry area. 5.2. gaging the die opening (indenters) this inspection requires the use of a plug gage conforming to the dimensions provided in figure 7. for plug gages used for periodic general inspection, see figure 8. to gage the die opening, proceed as follows: 1. remove traces of oil or dirt from the die opening and plug gage. 2. fully close tool handles; then hold in this position. do not force beyond initial contact. 3. insert go element into the die opening; but do not force it. the go element must pass through the length of the die opening. see figure 9. 4. in the same manner, try to insert the no--go element into the die opening. the no--go element may enter partially, but must not pass completely through the length of the die opening. see figure 9. be careful not to crimp the gage element. if the die opening conforms to the gage inspection, the tool may be considered dimensionally correct and should be lubricated with a thin coat of any good sae 20 motor oil. if the die opening does not conform to the gage inspection, the tool must be returned for further evaluation and repair. for additional information regarding the use of a plug gage, refer to 408--7424. 5.3. crimp height inspection allowances for tool stresses and relaxation of contact material were calculated into the crimp height measurements for military specified contacts only. this inspection requires the use of a micrometer, or equivalent, as shown in figure 10. it is recommended using the micrometer (dial micrometer 27--9) which may be purchased from: b.c. ames company lexington street waltham, ma 02154 caution ! note i caution ! note i
408- 7516 rev e 16 of 17 suggested plug gage design 6.35 [.250] min typ go dia no--go dia tool ( m i l i t a r y s p e c ) tool selector gage element diameter + 0.003 [.0001] ( m i l i tary s pec ) s e l e c t o r setting go no--go 1 0.33 [.013] 0.46 [.018] 2 0.41 [.016] 0.53 [.021] 3 0.48 [.019] 0.61 [.024] 601966--1 4 0.56 [.022] 0.69 [.027] 6 0 1 9 6 6 1 (mil--c--22520/2--01) 5 0.66 [.026] 0.79 [.031] 6 0.76 [.030] 0.89 [.035] 7 0.86 [.034] 0.99 [.039] d 8 s d 0.99 [.039] s d 1.12 [.044] s 1 1.78 [.070] 2.03 [.080] 2 1.91 [.075] 2.16 [.085] 3 2.03 [.080] 2.29 [.090] 6 0 8 6 5 1 1 d 4 s d 2.16 [.085] s d 2.41 [.095] s 608651--1 5 2.34 [.092] 2.59 [.102] 6 2.51 [.099] 2.77 [.109] 7 2.74 [.108] 3.00 [.118] 8 3.00 [.118] 3.25 [.128] 1 0.71 [.028] 0.84 [.033] 2 0.81 [.032] 0.94 [.037] 3 0.91 [.036] 1.04 [.041] 601967--1 ( m i l c 2 2 5 2 0 / 1 0 1 ) d 4 s d 0.99 [.039] s d 1.12 [.044] s (mil--c--22520 / 1--01) and 608668--1 5 1.14 [.045] 1.27 [.050] a n d 6 0 8 6 6 8 - - 1 6 1.32 [.052] 1.45 [.057] 7 1.50 [.059] 1.63 [.064] 8 1.73 [.068] 1.85 [.073] s use for periodic general inspection. the plug gages listed in figure 8 conform to these gage element diameters. figure 7 for periodic general inspection tool tool selector setting plug gage (military spec) 601966--1 8 6 0 1 9 6 8 1 601967--1 4 601968--1 ( m i l -- c -- 2 2 5 2 0 / 3 -- 0 1 ) 608668--1 4 ( m i l -- c -- 2 2 5 2 0 / 3 -- 0 1 ) 608651--1 4 601968--3 figure 8 go element must pass completely through the die opening. no--go element may enter partially, but must not pass completely through the die opening. gaging the die opening die opening go element no--go element figure 9 to inspect the crimp height, proceed as follows: 1. crimp the contact according to section 3, crimping procedure. 2. measure across opposite indents in the contact, then rotate the contact 90 degrees, and measure again. see figure 10. do not go beyond initial contact as this could cause a depression and result in an inaccurate reading. crimp height crimped contact crimp height inspection c r i m p h e i g h t t o o l crimp height tool selector setting tool 601966--1 military spec mil--c--22520/2--01 tool 601967--1 military spec mil--c--22520/1--01 1 0.406--0.533 [.016--.021] 0.813--0.940 [.032--.037] 2 0.483--0.610 [.019--.024] 0.914--1.041 [.036--.041] 3 0.559--0.686 [.022--.027] 1.016--1.143 [.040--.045] 4 0.635--0.762 [.025--.030] 1.092--1.219 [.043--.048] 5 0.737--0.864 [.029--.034] 1.245--1.372 [.049--.054] 6 0.838--0.965 [.033--.038] 1.422--1.549 [.056--.061] 7 0.940--1.067 [.037--.042] 1.600--1.727 [.063--.068] 8 1.067--1.194 [.042--.047] 1.829--1.956 [.072--.077] figure 10
408- 7516 17 of 17 rev e 3. check the height of the crimped contact against the crimp height dimensions shown in figure 10. if the crimp height conforms to that shown, the tool is considered dimensionally correct. lubricate the tool with a thin coat of any good sae 20 motor oil and return it to service. 6. replacement and repair order replacement parts through your te 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 te representative at 1--800--526--5136. 7. revision summary s updated document to corporate requirements.

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