Instruction Sheet
Application Tooling for 408-7516
LOC B
1
of 17
E
2008 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property 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
07 JAN 08 Rev D
Screw-Machine Contacts
PROPER USE GUIDELINES
CumulativeTraumaDisorderscanresultfromthe prolongeduseofmanually poweredhandtools.Hand toolsareintendedfor occasionaluseandlowvolume
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 standardized numbering 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
4/8Id tH d
601966-1 MIL-C-22520/2-01
4/8-Indent Hand
Crimping Tool
601967-1 MIL-C-22520/1-01
Crimping Tool
608651-1 ---
601966-2 MIL-C-22520/2-02
601966-4 MIL-C-22520/2-06
P iti
601966-5 MIL-C-22520/2-08
Positioner or
Turret Head
601966-6 MIL-C-22520/2-09
Turret Head
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
Insertion/Extraction
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
Extraction Tool
58284-1 MIL-C-81969/28-03
Extraction Tool
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
Application Tooling for Screw-Machine Contacts
Rev
D2
of 17 Tyco Electronics Corporation
CONTACT WIRE TOOL
Product Line Size Pin Socket Military Spec Size
(AWG) Strip
Length
SELECTOR
SETTING
28 2
201607 201609 Ċ 26 5.16 [.203] 2
24 3
28 2
Ċ 201353 Ċ 26 5.16 [.203] 2
24 3
20
24 1
20
201582 201584-6 Ċ 22 5.16 [.203] 2
20 3
24 1
200334 200331 Ċ 22 5.16 [.203] 2
20 3
201589
18
6 35 [ 250]
4
Ċ
201589
Ċ16
6
.
35 [
.
250]
5
201554
32
5 16 [ 203]
1
Ċ
201554
Ċ30
5
.
16 [
.
203]
1
201334 Ċ Ċ 28 2
Type II Contact
For Multimate
201332
26 5.16 [.203] 2
F
or
M
u
lti
ma
t
e
Connectors Ċ
201332
Ċ24 3
201611 Ċ Ċ 28 2
201613
26 5.16 [.203] 2
Ċ
201613
Ċ24 3
201578 Ċ Ċ 22
5 16 [ 203]
2
Ċ 201580 Ċ 20
5
.
16 [
.
203]
3
16
200679 201328 Ċ 24 1
16
201330 Ċ 22 5.16 [.203] 2
204188 Ċ Ċ20 3
200681
200333
18
6 35 [ 250]
4
200681
200333
Ċ
16
6
.
35 [
.
250]
5
16
5
202507 Ċ Ċ 18 4
Ċ 202508 Ċ 16 5
200336
200333
18 6.35 [.250] 4
200336
200333
Ċ16 5
201570 201568 Ċ 14 5
201555 Ċ Ċ 32
5 16 [ 203]
1
Ċ 201554 Ċ 30
5
.
16 [
.
203]
1
Figure 3 (Cont’d)
408-7516
Application Tooling for Screw-Machine Contacts
3
of 17Rev
D
Tyco Electronics Corporation
Tooling for Loose Piece Contacts Tooling for Tape Mounted Contacts
CONNECTOR
INSERTION
EXTRACTION
Positioner or
Turret Head Hand Crimping
Tool Machine Funnel
CONNECTOR
Military Spec
INSERTION
TOOL
EXTRACTION
TOOL
58305 1
200893 2
1-601967-5 58305-1 or
601967
-
1
Ċ Ċ Ċ 200893-2 or
91002
-
1
305183
601967 1
91002 1
58305 1
200893 2
1-601967-5 58305-1 or
601967
-
1
Ċ Ċ Ċ 200893-2 or
91002
-
1
305183
601967 1
91002 1
58305 1
200893 2
1-601967-5 58305-1 or
601967
-
1
Ċ Ċ Ċ 200893-2 or
91002
-
1
305183
601967 1
91002 1
58305 1
200893 2
1-601967-5 58305-1 or
601967
-
1
Ċ Ċ Ċ 200893-2 or
91002
-
1
305183
601967 1
91002 1
1 601967 6
45098 or 200893-2 or
305183
1
-
601967
-
6
601967-1 Ċ Ċ Ċ 91002-1
305183
1 601967 5
58305-1 or 200893-2 or
305183
1
-
601967
-
5
601967-1 Ċ Ċ Ċ 91002-1
305183
1-601967-6
58305 1
200893 2
1 601967 5
58305-1 or
601967
-
1
Ċ Ċ Ċ 200893-2 or
91002
-
1
305183
1
-
601967
-
5
601967 1
91002 1
1-601967-6
58305 1
200893 2
1 601967 5
58305-1 or
601967
-
1
Ċ Ċ Ċ 200893-2 or
91002
-
1
305183
1
-
601967
-
5
601967 1
91002 1
1-601967-6 58305-1 or 200893-2 or
305183
1-601967-5 601967-1 Ċ Ċ Ċ 91002-1
305183
1-601967-5
58305 1
200893 2
1 601967 6
58305-1 or
601967
-
1
Ċ Ċ Ċ 200893-2 or
91002
-
1
305183
1
-
601967
-
6
601967 1
91002 1
1 601967 6
45098 or 200893-2 or
305183
1
-
601967
-
6
601967
-
1
Ċ Ċ Ċ
91002
-
1
305183
601967 1
91002 1
1-601967-6 90136-1 or 200893-2 or
305183
1-601967-5 601967-1 Ċ Ċ Ċ 91002-1
305183
45098
200893-2 or
1-601967-6 45098 or
601967
-
1
Ċ Ċ Ċ 91002-1 305183
601967 1
Ċ
1-601967-6 58305-1 or 200893-2 or
305183
1-601967-5 601967-1 Ċ Ċ Ċ 91002-1
305183
Figure 3 (Cont’d)
408-7516
Application Tooling for Screw-Machine Contacts
Rev
D4
of 17 Tyco Electronics Corporation
CONTACT WIRE TOOL
Product Line Size Pin Socket Military Spec Size
(AWG) Strip
Length
SELECTOR
SETTING
28 2
Ċ 201609 Ċ 26 5.16 [.203] 2
24 3
201332
26
5 16 [ 203]
2
Ċ
201332
Ċ24
5
.
16 [
.
203]
3
24 1
200679 201328 Ċ 22 5.16 [.203] 2
TIICtt
20 3
Type II Contact
For Multimate
16
200681 200333 Ċ 18
5 16 [ 203]
4
For Multimate
Connectors
16
200336 Ċ Ċ 16
5
.
16 [
.
203]
5
204274 Ċ Ċ 18 4
202507 Ċ Ċ 18 5.16 [.203] 4
204219 202508 Ċ 16 5
202725 202726 Ċ
Á
18
Á
5.16 [.203] 5
201570 Ċ Ċ 5
201645 Ċ Ċ 14 5.16 [.203] 5
Ċ 201568 Ċ 5
À
32
À
1
202123
202124
À
30
À
3 18 [ 125]
1
202123
202124
Ċ28
3
.
18 [
.
125]
2
Type VII Contact
For Subminiature
22
26 2
For Subminiature
Connectors
22
À
30
À
1
204092
28
3 18 [ 125]
2
204092
Ċ Ċ 26
3
.
18 [
.
125]
3
24 4
Type XIII Contact
FT il
24 5
For Terminal
Junction (TJG)
20 203669-4 Ċ Ċ 22 4.78 [.188] 6
Junction (TJG)
Modules 20 7
Figure 3 (Cont’d)
À
This wire size is not recommended for use in the machine.
Á
Refer to the instruction sheet (408-series) packaged with the contact for wire strip length.
408-7516
Application Tooling for Screw-Machine Contacts
5
"
D
# ! !
Tooling for Loose Piece Contacts Tooling for Tape Mounted Contacts
CONNECTOR
INSERTION
EXTRACTION
Positioner or
Turret Head Hand Crimping
Tool Machine Funnel
CONNECTOR
Military Spec
INSERTION
TOOL
EXTRACTION
TOOL
% % %
% % %
% % %
% % %
% % %
% % %
%
% % % %
% %
H
%
HH
%
H
Figure 3 (Cont’d)
H
!#
408-7516
Application Tooling for Screw-Machine Contacts
Rev
D6
of 17 Tyco Electronics Corporation
CONTACT WIRE TOOL
Product Line Size Pin Socket Military Spec Size
(AWG) Strip
Length
SELECTOR
SETTING
24 2
203840 Ċ Ċ 22 4.78 [.188] 3
20
20 4
Type XV
For ARINC
20
24 2
For ARINC
Front Release
AM AD d
Ċ 203841 Ċ 22 4.78 [.188] 3
AM, AD, and
AAP Connectors
20 4
AAP Connectors
20 4
16 203884 Ċ Ċ 18 6.35 [.250] 5
16 5
26 3
204873 Ċ MIL-C-39029/11-144 24 3.96 [.156] 3
22 4
22
26 3
22
Ċ 205103 MIL-C-39029/12-148 24 3.96 [.156] 3
22 4
205904
À
30
À
3 96 [ 156]
4
Ċ
205904
Ċ28
3
.
96 [
.
156]
5
24 5
204938 Ċ MIL-C-39029/11-145 22 3.96 [.156] 6
20 7
Ċ 205116 MIL-C-39029/12-149 24 5
Type XVII
F ARINC
20
MIL C 39029/12 149
22 3.96 [.156] 6
For ARINC
Rear Release
Ċ Ċ
MIL
-
C
-
39029/12
-
149
20 7
Rear Release
RM Connectors
À
30
À
4
205791 206887 Ċ 28 3.96 [.156] 5
26 6
20 4
204978 Ċ MIL-C-39029/11-146 18 6.35 [.250] 5
16
16 6
16
20 4
Ċ 205117 MIL-C-39029/12-150 18 6.35 [.250] 5
16 6
205763 5
14
6 35 [ 250]
7
12
205763
-
5
Ċ Ċ 12
6
.
35 [
.
250]
8
12
205851 2
14
6 35 [ 250]
7
Ċ
205851
-
2
Ċ12
6
.
35 [
.
250]
8
Figure 3 (Cont’d)
À
This wire size is not recommended for use in the machine.
408-7516
Application Tooling for Screw-Machine Contacts
7
! '
D
)! %#! $ !#"!#%!
Tooling For Loose Piece Contacts Tooling For Tape Mounted Contacts
CONNECTOR
INSERTION
EXTRACTION
Positioner or
Turret Head Hand Crimping
Tool Machine Funnel
CONNECTOR
Military Spec
INSERTION
TOOL
EXTRACTION
TOOL
+
+
( $&%!
( $&%!
+
+ +
+
+ +
+
+ +
+
Figure 3 (Cont’d)
408-7516
Application Tooling for Screw-Machine Contacts
Rev
D8
of 17 Tyco Electronics Corporation
CONTACT WIRE TOOL
Product Line Size Pin Socket Military Spec Size (AWG,
See Note) Strip
Length
SELECTOR
SETTING
0 Ċ 51781-1 Ċ RG 214/U Ċ Ċ
1
225837-1 Ċ Ċ Semi-Rigid
141
Á
(408-2348-02) 8
1
Ċ 225831-1 Ċ RG 214/U
Á
(408-2348-02) Ċ
226053-1 Ċ Ċ RG 141/U,
58C/U
Á
(408-2348-01) 8
3Ċ 225792-1 Ċ RG 214/U,
213/U
Á
(408-2348-01) Ċ
Ċ 225792-3 Ċ RG 58C/U,
141A/U
Á
(408-2348-01) 8
COAXICON*
Contact For
225790-1 225791-1 Ċ RG 58C/U,
141/U
Á
(408-2348) 5
Contact For
ARINC Coaxial
Connectors
5
225790-2 225791-2 Ċ RG 233/U,
142/U
Á
(408-2348) 5
5
225790-3 Ċ Ċ Semi-Rigid
141
Á
(408-2348) 5
225790-4 Ċ Ċ RG 180B/U
Á
(408-2348) 5
7
Ċ225796-1 ĊRG 58C/U
Á
5
7
Ċ225796-2 Ċ RG 233/U
Á
(408-2348-01) 5
9
225935-1 Ċ Ċ RG 58C/U,
141A/U
Á
(408-2348-03) 5
9
Ċ 225936-1 Ċ Semi-Rigid
141
Á
(408-2348-03) 5
26 3
208262 Ċ Ċ 24 3.96 [.156] 3
22
22 4
22
26 3
Ċ 208264 Ċ 24 3.96 [.156] 3
ARINC 600
22 4
ARINC 600
24 5
208265 Ċ Ċ 22 3.96 [.156] 6
20
20 7
20
24 5
Ċ 208267 Ċ 22 3.96 [.156] 6
20 7
Figure 3 (Cont’d)
Á
Refer to the instruction sheet (408-series) packaged with the contact for wire strip length.
Note:
Unless otherwise specified
408-7516
Application Tooling for Screw-Machine Contacts
9
of 17Rev
D
Tyco Electronics Corporation
Tooling for Loose Piece Contacts Tooling for Tape Mounted Contacts
CONNECTOR
INSERTION
EXTRACTION
Positioner or
Turret Head Hand Crimping
Tool Machine Funnel
CONNECTOR
Military Spec
INSERTION
TOOL
EXTRACTION
TOOL
Ċ 69646 Ċ Ċ Ċ Ċ 91040-7
Ċ601966-1
Ã
and
220066-1
Ä
Ċ Ċ Ċ Ċ Ċ
Ċ220015-1 Ċ Ċ Ċ Ċ Ċ
1-601966-8
Â
601966-1
Ã
and
220066-1
Ä
Ċ Ċ Ċ Ċ Ċ
Ċ220015-1 Ċ Ċ Ċ Ċ Ċ
Ċ601966-1
Ã
and
220066-1
Ä
Ċ Ċ Ċ Ċ Ċ
1-601966-6
Â
601966-1
Ã
and
220066-1
Ä
Ċ Ċ Ċ Ċ 91074-1
1-601966-6
Â
601966-1
Ã
and
220066-1
Ä
Ċ Ċ Ċ Ċ 91074-1
1-601966-6
Â
601966-1
Ã
and
220066-1
Ä
Ċ Ċ Ċ Ċ 91074-1
1-601966-6
Â
601966-1
Ã
and
220066-1
Ä
Ċ Ċ Ċ Ċ 91074-1
2-601966-6
Â
601966-1
Ã
and
220066-1
Ä
Ċ Ċ Ċ Ċ Ċ
1-601966-6
Â
601966-1
Ã
and
220066-1
Ä
Ċ Ċ Ċ Ċ Ċ
1-601966-6
Â
601966-1
Ã
and
220066-1
Ä
Ċ Ċ Ċ Ċ 91074-1
1-601966-6
Â
601966-1
Ã
and
220066-1
Ä
Ċ Ċ Ċ Ċ 91074-1
601966-8 601966-1 599406-7 1-125905-2 Ċ 91066-1 91066-1
601966-8 601966-1 599406-7 1-125905-2 Ċ 91066-1 91066-1
601966-5 601966-1 599406-7 125905-1 Ċ 91067-2 91067-2
125905
-
1
601966-5 601966-1 599406-7
125905-1
(Max Insulation
Di 1 98 [ 078])
Ċ 91067-2 91067-2
Dia 1.98 [.078])
Figure 3 (Cont’d)
Â
This positioner is used with Tool 601966-1
Ã
This tool crimps only the center contact of the pin or socket
Ä
This tool crimps only the ferrule of the pin or socket
408-7516
Application Tooling for Screw-Machine Contacts
Rev
D10
of 17 Tyco Electronics Corporation
CONTACT WIRE TOOL
Product Line Size Pin Socket Military Spec Size (AWG,
See Note) Strip
Length
SELECTOR
SETTING
204978 Ċ Ċ 20 4
208268 Ċ Ċ 18 6.35 [.250] 5
16
213122 Ċ Ċ 16 6
16
20 4
ARINC 600
Ċ 208270 Ċ 18 6.35 [.250] 5
ARINC 600
16 6
208271 Ċ Ċ 14
6 35 [ 250]
7
12
213123 Ċ Ċ 12
6
.
35 [
.
250]
8
12
208273
14
6 35 [ 250]
7
Ċ
208273
Ċ12
6
.
35 [
.
250]
8
TRIAXIAL
8
222190
222191
MIL-C-39029-95 and
TRIAXIAL
8
222190
222191
MIL-C-39029-96 Ċ Ċ Ċ
206496
28
3 96 [ 156]
3
206496
Ċ Ċ 26
3
.
96 [
.
156]
4
206496
28
3 96 [ 156]
3
Ċ
206496
Ċ26
3
.
96 [
.
156]
4
28 1
204370
MIL C 39029/58 360
26
3 96 [ 156]
2
204370
Ċ
MIL
-
C
-
39029/58
-
360
24
3
.
96 [
.
156]
3
22D
22 4
22D
28 1
Type XVII
204351
MIL C 39029/57 354
26
3 96 [ 156]
2
Type XVII
For AMPLIMITE*
HDD C t
Ċ
204351
MIL
-
C
-
39029/57
-
354
24
3
.
96 [
.
156]
3
HDD Connectors 22 4
28 1
206071
26
3 96 [ 156]
2
Ċ
206071
Ċ24
3
.
96 [
.
156]
3
22 4
206794
206795
28
3 96 [ 156]
5
206794
206795
Ċ26
3
.
96 [
.
156]
6
20 24 5
205089 Ċ MIL-C-39029/64-369 22 3.56 [.140] 6
20 7
Figure 3 (Cont’d)
Note:
Unless otherwise specified
408-7516
Application Tooling for Screw-Machine Contacts
11
of 17Rev
D
Tyco Electronics Corporation
Tooling for Loose Piece Contacts Tooling for Tape Mounted Contacts
CONNECTOR
INSERTION
EXTRACTION
Positioner or
Turret Head Hand Crimping
Tool Machine Funnel
CONNECTOR
Military Spec
INSERTION
TOOL
EXTRACTION
TOOL
601967-2 601967-1 599406-5 125905-6 Ċ 91066-3 91066-3
601967-2 601967-1 599406-5 125905-6 Ċ 91066-3 91066-3
1 601967 2
601967 1
445147 1
1
-
601967
-
2
601967
-
1
Ċ Ċ Ċ Ċ
445147
-
1
1 601967 2
601967 1
445147 1
1
-
601967
-
2
601967
-
1
Ċ Ċ Ċ Ċ
445147
-
1
Ċ
608650 1
Ċ Ċ
MIL C 83527
Ċ
58284 1
608650
-
1
MIL
-
C
-
83527
58284
-
1
601966 6
601966 1
599406 7
125905 2
91067 1
91067 1
601966
-
6
601966
-
1
599406
-
7
125905
-
2
Ċ
91067
-
1
91067
-
1
601966 4
601966 1
599406 7
125905 2
91067 1
91067 1
601966
-
4
601966
-
1
599406
-
7
125905
-
2
Ċ
91067
-
1
91067
-
1
601966 6
601966 1
599406 7
125905 2
MIL C 24308
91067 1
91067 1
601966
-
6
601966
-
1
599406
-
7
125905
-
2
MIL
-
C
-
24308
91067
-
1
91067
-
1
601966 4
601966 1
599406 7
125905 2
MIL C 24308
91067 1
91067 1
601966
-
4
601966
-
1
599406
-
7
125905
-
2
MIL
-
C
-
24308
91067
-
1
91067
-
1
601966 4
601966 1
599406 7
125905 2
91067 1
91067 1
601966
-
4
601966
-
1
599406
-
7
125905
-
2
Ċ
91067
-
1
91067
-
1
601966 5
601966 1
599406 7
91067 2
91067 2
601966
-
5
601966
-
1
599406
-
7
Ċ Ċ
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
Application Tooling for Screw-Machine Contacts
(2
D12
-) 4&- +(&1/-,*&0 -/.-/%1*-,
CONTACT WIRE TOOL
Product Line SIZE Pin Socket Military Spec Size
(AWG) Strip
Length
SELECTOR
SETTING
7 #$
4.( "
-/
Æ
Å
# $
-/
-,,(&1-/0
7
Æ
Å
#
$
7 7 #$
7
# $
7
#
$
# $
7
#
$
-3(/ -,1%&1
# $
7
#
$
# $
7 7
#
$
# $
7
#
$
# $
-/
#
$
7 7
-,1%&1
# $
-,1%&1
#
$
7 7 7
#$
7 #$
Æ
# $
7
7
#
$
Figure 3 (Cont’d)
Å
01/%,' 3*/(
Æ
0( 13- 0*5( ! 3*/(0
408-7516
Application Tooling for Screw-Machine Contacts
13
of 17Rev
D
Tyco Electronics Corporation
Tooling for Loose Piece Contacts Tooling for Tape Mounted Contacts
CONNECTOR
INSERTION
EXTRACTION
Positioner or
Turret Head Hand Crimping
Tool Machine Funnel
CONNECTOR
Military Spec
INSERTION
TOOL
EXTRACTION
TOOL
601966-5 601966-1 599406-7 125905-1 Ċ 91067-2 91067-2
601966 5
601966 1
91067 2
91067 2
601966
-
5
601966
-
1
Ċ Ċ Ċ
91067
-
2
91067
-
2
601966-5 601966-1 599406-7 125905-1 Ċ 91067-2 91067-2
608651 2
608651 1
318813 1
608651
-
2
608651
-
1
Ċ Ċ Ċ Ċ
318813
-
1
608651 2
608651 1
318813 1
608651
-
2
608651
-
1
Ċ Ċ Ċ Ċ
318813
-
1
608668 2
608668 1
318813 1
608668
-
2
608668
-
1
Ċ Ċ Ċ Ċ
318813
-
1
608651 3
608651 1
318813 1
608651
-
3
608651
-
1
Ċ Ċ Ċ Ċ
318813
-
1
601966 4
601966 1
601966
-
4
601966
-
1
Ċ Ċ Ċ Ċ Ċ
601966 1
Ċ
601966
-
1
Ċ Ċ Ċ Ċ Ċ
Ċ 601966-1 Ċ Ċ Ċ Ċ Ċ
601967-2 601967-1 Ċ Ċ Ċ 91067-1 91067-1
HH
601967 1
91066 3
91066 3
H
Ċ
H
601967
-
1
Ċ Ċ Ċ
91066
-
3
91066
-
3
Figure 3 (End)
H
Military Spec MIL-C-22520/1-05
408-7516
Application Tooling for Screw-Machine Contacts
Rev
D14
of 17 Tyco Electronics Corporation
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 positioner; 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 positioner; 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
Application Tooling for Screw-Machine Contacts
15
of 17Rev
D
Tyco Electronics Corporation
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
W altham, MA 02154
CAUTION
!
NOTE
i
CAUTION
!
NOTE
i
408-7516
Application Tooling for Screw-Machine Contacts
Rev
D16
of 17 Tyco Electronics Corporation
Suggested Plug Gage Design
6.35 [.250] Min Typ
GO Dia NO-GO Dia
TOOL
(Military Spec)
TOOL
SELECTOR
GAGE ELEMENT
DIAMETER +0.003 [.0001]
(Military Spec)
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 40.56 [.022] 0.69 [.027]
(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
SD
0.99 [.039]
SD
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]
608651 1
D
4
SD
2.16 [.085]
SD
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
(MIL C 22520/1 01)
D
4
SD
0.99 [.039]
SD
1.12 [.044]
S
(MIL
-
C
-
22520/1
-
01)
and 608668-1 51.14 [.045] 1.27 [.050]
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
601968 1
601967-1 4
601968
-
1
(MIL
-
C
-
22520/3
-
01)
608668-1 4
(MIL-C-22520/3-01)
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
É
É
É
É
É
É
ÉÉ
ÉÉ
ÉÉ
ÉÉ
ÉÉ
ÉÉ
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
CRIMP HEIGHT
TOOL
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
Application Tooling for Screw-Machine Contacts
17
of 17Rev
D
Tyco Electronics Corporation
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 Tyco
Electronics Representative, or call 1–800–526–5142,
or send a facsimile of your purchase order to
717–986–7605, or write to:
CUSTOMER SER VICE (038–035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105–3608
For customer repair service, contact a Tyco
Electronics Representative at 1–800–526–5136.
7. REVISION SUMMARY
S
Updated document to corporate requirement
S
New format
S
Deleted duplicate part number in Figure 2
