Instruction Sheet 408-7516 Application Tooling for Screw-Machine Contacts 07 JAN 08 Rev D 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. Tooling for Loose-Piece Contacts 4/8-Indent Hand Crimping Tool Insertion/Extraction (Typ, Requires Positioner or Tool (Typ) Reasons for reissue of this instruction sheet are provided in Section 7, REVISION SUMMARY. 2. DESCRIPTION Turret Head) Extraction Tool (Typ) 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. Tooling for Tape Mounted Contacts Description Part Number AMP-TAPETRONIC* 4/8 Indent Stripper Terminator 599406-[ ] (Requires Funnel) 4/8 I d 4/8-Indent t Hand H d Crimping Tool MIL-C-22520/2-01 601967-1 MIL-C-22520/1-01 608651-1 P Positioner iti or Turret Head Military Spec 601966-1 --- 601966-2 MIL-C-22520/2-02 601966-4 MIL-C-22520/2-06 601966-5 MIL-C-22520/2-08 601966-6 MIL-C-22520/2-09 601966-8 MIL-C-22520/2-23 601967-2 MIL-C-22520/1-02 1-601967-2 MIL-C-22520/1-11 91066-1 91067-1 MIL-I-81969/1-01 or MS3156-22 MIL-I-81969/1-04 Insertion/Extraction Tool Figure 1 91066-3 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. NOTE Extraction Tool MIL-I-81969/1-02 or MS3156-20 MIL-I-81969/1-03 or MS3156-16 445147-1 MIL-C-81969/28-02 58284-1 MIL-C-81969/28-03 91074-1 MIL-C-81969/28-01 or MS3178-001 Figure 2 Dimensions in this instruction sheet are in millimeters [with inches in brackets]. Figures and i 91067-2 illustrations are for reference only and are not drawn to scale. E 2008 Tyco Electronics Corporation, Harrisburg, PA All International Rights Reserved Refer to Figure 3 for proper contact and tooling combination. Read the chart from the left page across to the right page. TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change. PRODUCT INFORMATION 1-800-522-6752 For latest revision and Regional Customer Service, TE logo and Tyco Electronics are trademarks. *Trademark. Other products, logos, and company names used are the property of their respective owners. visit our website at www.tycoelectronics.com 1 of 17 LOC B 408-7516 Application Tooling for Screw-Machine Contacts CONTACT Product Line Size Pin WIRE Socket Military Spec TOOL Size Strip (AWG) Length 28 201607 20 201582 200334 201609 201353 201584-6 200331 26 16 SETTING 2 5.16 [.203] 2 24 3 28 2 26 5.16 [.203] 2 24 3 24 1 22 5.16 [.203] 2 20 3 24 1 22 5.16 [.203] 20 Type II Contact For Multimate Connectors SELECTOR 18 2 3 201589 201554 201334 201332 201611 201613 201578 22 201580 20 200679 201328 24 201330 204188 200681 200333 202507 18 4 202508 16 5 200336 200333 201570 201568 201555 16 32 30 6 35 [.250] 6.35 [ 250] 4 5 16 [.203] 5.16 [ 203] 28 26 5 1 1 2 5.16 [.203] 2 24 3 28 2 26 5.16 [.203] 24 22 3 5 16 [.203] 5.16 [ 203] 16 18 2 3 1 5.16 [.203] 20 18 2 2 3 6 35 [.250] 6.35 [ 250] 6.35 [.250] 4 5 4 16 5 14 5 32 201554 30 5 16 [.203] 5.16 [ 203] 1 1 Figure 3 (Cont'd) 2 of 17 Tyco Electronics Corporation Rev D 408-7516 Application Tooling for Screw-Machine Contacts Tooling for Loose Piece Contacts Tooling for Tape Mounted Contacts Positioner or Turret Head Hand Crimping Tool Machine Funnel CONNECTOR Military Spec INSERTION TOOL EXTRACTION TOOL 1-601967-5 58305-11 or 58305 601967-1 601967 1 200893-22 or 200893 91002-1 91002 1 305183 1-601967-5 58305-11 or 58305 601967-1 601967 1 200893-22 or 200893 91002-1 91002 1 305183 1-601967-5 58305-11 or 58305 601967-1 601967 1 200893-22 or 200893 91002-1 91002 1 305183 1-601967-5 58305-11 or 58305 601967-1 601967 1 200893-22 or 200893 91002-1 91002 1 305183 1 601967 6 1-601967-6 45098 or 601967-1 200893-2 or 91002-1 305183 1 601967 5 1-601967-5 58305-1 or 601967-1 200893-2 or 91002-1 305183 58305-11 or 58305 601967-1 601967 1 200893-22 or 200893 91002-1 91002 1 305183 58305-11 or 58305 601967-1 601967 1 200893-22 or 200893 91002-1 91002 1 305183 58305-1 or 601967-1 200893-2 or 91002-1 305183 58305-11 or 58305 601967-1 601967 1 200893-22 or 200893 91002-1 91002 1 305183 45098 or 601967 1 601967-1 200893-2 or 91002-1 91002 1 305183 90136-1 or 601967-1 200893-2 or 91002-1 305183 45098 or 601967-1 601967 1 1-601967-6 1 601967 5 1-601967-5 1-601967-6 1 601967 5 1-601967-5 1-601967-6 1-601967-5 1-601967-5 1 601967 6 1-601967-6 1 601967 6 1-601967-6 1-601967-6 1-601967-5 1-601967-6 200893-2 or 91002-1 305183 1-601967-6 1-601967-5 58305-1 or 601967-1 200893-2 or 91002-1 305183 Figure 3 (Cont'd) Rev D Tyco Electronics Corporation 3 of 17 408-7516 Application Tooling for Screw-Machine Contacts CONTACT Product Line Size Pin WIRE Socket Military Spec TOOL Size Strip (AWG) Length 28 201609 26 5.16 [.203] 200679 201328 2 5 16 [.203] 5.16 [ 203] 24 3 24 1 22 5.16 [.203] 20 T Type II Contact C t t For Multimate 16 Connectors 200681 200333 18 4 5 16 [.203] 5.16 [ 203] 200336 16 5 204274 18 4 202507 18 204219 202508 16 202725 202726 A A 201570 201645 201568 18 5.16 [.203] 202124 Type VII Contact 5.16 [.203] 14 5.16 [.203] A A A A 1 1 3 18 [.125] 3.18 [ 125] 28 2 26 2 1 28 204092 Type XIII Contact Junction (TJG) 20 203669-4 Modules A A 5 5 30 Connectors 5 5 A A 22 4 5 30 202123 F For T Terminal i l 2 3 32 For Subminiature 2 3 26 201332 SETTING 2 24 SELECTOR 2 3 18 [.125] 3.18 [ 125] 26 3 24 4 24 5 22 20 4.78 [.188] 6 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. 4 of 17 Tyco Electronics Corporation Rev D 408-7516 Application Tooling for Screw-Machine Contacts Tooling for Loose Piece Contacts Positioner or Turret Head Hand Crimping Tool Tooling for Tape Mounted Contacts Machine Funnel CONNECTOR Military Spec INSERTION TOOL EXTRACTION TOOL % % % % % % % % % % % % % % % % % % % % % % % % % H%H H%H Figure 3 (Cont'd) H !# " D # ! ! 5 408-7516 Application Tooling for Screw-Machine Contacts CONTACT Product Line Size Pin WIRE Socket Military Spec TOOL Size Strip (AWG) Length 24 203840 Type XV 22 SELECTOR SETTING 2 4.78 [.188] 3 20 4 24 2 20 For ARINC Front Release 203841 AM AD, AM, AD and d AAP Connectors 16 203884 204873 MIL-C-39029/11-144 22 4.78 [.188] 3 20 4 20 4 18 6.35 [.250] 5 16 5 26 3 24 3.96 [.156] 3 22 4 26 3 22 205103 MIL-C-39029/12-148 24 3.96 [.156] 22 A A 4 4 30 204938 Type XVII 205904 MIL-C-39029/11-145 205116 MIL-C-39029/12-149 MIL C 39029/12 149 MIL-C-39029/12-149 3 96 [.156] 3.96 [ 156] 28 5 24 5 22 3.96 [.156] 7 24 5 3.96 [.156] 20 Rear Release 4 30 205791 204978 206887 MIL-C-39029/11-146 28 6 7 A A RM Connectors 6 20 22 20 F For ARINC 3 3.96 [.156] 5 26 6 20 4 18 6.35 [.250] 5 16 6 20 4 16 205117 MIL-C-39029/12-150 18 6.35 [.250] 16 6 14 205763 5 205763-5 5 7 6 35 [.250] 6.35 [ 250] 12 8 12 14 205851 2 205851-2 7 6 35 [.250] 6.35 [ 250] 12 8 Figure 3 (Cont'd) A This wire size is not recommended for use in the machine. 6 of 17 Tyco Electronics Corporation Rev D 408-7516 Application Tooling for Screw-Machine Contacts Tooling For Loose Piece Contacts Positioner or Turret Head Hand Crimping Tool Tooling For Tape Mounted Contacts Machine Funnel ( $&%! CONNECTOR Military Spec INSERTION TOOL EXTRACTION TOOL + + + + ( $&%! + + + + + + + + Figure 3 (Cont'd) ' D )! %#! $ !#"!#%! 7 ! 408-7516 Application Tooling for Screw-Machine Contacts CONTACT Product Line WIRE Size Pin Socket Military Spec 0 51781-1 225837-1 225831-1 226053-1 225792-1 225792-3 225790-1 225791-1 225790-2 225791-2 225790-3 Strip See Note) Length RG 214/U A 8 Semi-Rigid 141 1 3 COAXICON* RG 214/U RG 141/U, 58C/U RG 214/U, 213/U RG 58C/U, 141A/U RG 58C/U, 141/U Contact For ARINC Coaxial Connectors RG 233/U, 142/U 5 225790-4 225796-1 Semi-Rigid 141 RG 180B/U RG 58C/U 7 TOOL (408-2348-02) A (408-2348-02) A (408-2348-01) A (408-2348-01) A (408-2348-01) A (408-2348) A (408-2348) A (408-2348) A (408-2348) A SETTING 8 8 5 5 5 5 5 (408-2348-01) 225796-2 225935-1 225936-1 RG 233/U RG 58C/U, 141A/U 9 Semi-Rigid 141 5 A (408-2348-03) A (408-2348-03) 26 208262 SELECTOR Size (AWG, 24 5 5 3 3.96 [.156] 3 22 4 26 3 22 208264 24 3.96 [.156] 3 22 4 24 5 ARINC 600 208265 22 3.96 [.156] 6 20 7 24 5 20 208267 22 20 A 3.96 [.156] 6 7 Figure 3 (Cont'd) Refer to the instruction sheet (408-series) packaged with the contact for wire strip length. Note: Unless otherwise specified 8 of 17 Tyco Electronics Corporation Rev D 408-7516 Application Tooling for Screw-Machine Contacts Tooling for Loose Piece Contacts Tooling for Tape Mounted Contacts CONNECTOR Military Spec INSERTION TOOL EXTRACTION TOOL 91040-7 91074-1 91074-1 91074-1 91074-1 91074-1 91074-1 Positioner or Turret Head Hand Crimping Tool Machine Funnel 69646 601966-1 1-601966-8 A 1-601966-6 1-601966-6 2-601966-6 1-601966-6 1-601966-6 1-601966-6 601966-1 A 220066-1 and A 220015-1 601966-1 1-601966-6 and A 220015-1 1-601966-6 A 220066-1 A 220066-1 A 601966-1 A 601966-1 A 601966-1 A 601966-1 A 601966-1 A 601966-1 A 601966-1 A 601966-1 and A A 220066-1 A 220066-1 and A A 220066-1 and A A 220066-1 and A A 220066-1 and A A 220066-1 and A A 220066-1 and A A 220066-1 and A and A 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 601966-5 601966-1 599406-7 (Max Insulation 91067-2 91067-2 125905-1 Di 1.98 Dia 1 98 [.078]) [ 078]) A A A 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 Rev D Tyco Electronics Corporation 9 of 17 408-7516 Application Tooling for Screw-Machine Contacts CONTACT Product Line Size 16 TOOL Size (AWG, Strip See Note) Length Socket Military Spec 204978 20 208268 18 213122 16 6 20 4 208270 18 208271 14 213123 12 208273 14 6.35 [.250] 6.35 [.250] 8 222190 222191 206496 MIL-C-39029-95 and MIL-C-39029-96 28 6 35 [.250] 6.35 [ 250] 204370 206496 MIL C 39029/58 360 MIL-C-39029/58-360 22D Type XVII 204351 MIL C 39029/57 354 MIL-C-39029/57-354 For AMPLIMITE* HDD Connectors C t 206794 206071 206795 20 205089 MIL-C-39029/64-369 28 5 7 8 6 35 [.250] 6.35 [ 250] 7 8 3 96 [.156] 3.96 [ 156] 26 5 6 12 TRIAXIAL SETTING 4 16 12 SELECTOR Pin ARINC 600 WIRE 3 4 3 96 [.156] 3.96 [ 156] 3 26 4 28 1 26 3 96 [.156] 3.96 [ 156] 2 24 3 22 4 28 1 26 3 96 [.156] 3.96 [ 156] 2 24 3 22 4 28 1 26 3 96 [.156] 3.96 [ 156] 2 24 3 22 4 28 3 96 [.156] 3.96 [ 156] 5 26 6 24 5 22 20 3.56 [.140] 6 7 Figure 3 (Cont'd) Note: Unless otherwise specified 10 of 17 Tyco Electronics Corporation Rev D 408-7516 Application Tooling for Screw-Machine Contacts Tooling for Loose Piece Contacts Tooling for Tape Mounted Contacts 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 601967 2 1-601967-2 601967 1 601967-1 445147 1 445147-1 1 601967 2 1-601967-2 601967 1 601967-1 445147 1 445147-1 608650 1 608650-1 MIL C 83527 MIL-C-83527 58284 1 58284-1 601966 6 601966-6 601966 1 601966-1 599406 7 599406-7 125905 2 125905-2 91067 1 91067-1 91067 1 91067-1 601966 4 601966-4 601966 1 601966-1 599406 7 599406-7 125905 2 125905-2 91067 1 91067-1 91067 1 91067-1 601966 6 601966-6 601966 1 601966-1 599406 7 599406-7 125905 2 125905-2 MIL C 24308 MIL-C-24308 91067 1 91067-1 91067 1 91067-1 601966 4 601966-4 601966 1 601966-1 599406 7 599406-7 125905 2 125905-2 MIL C 24308 MIL-C-24308 91067 1 91067-1 91067 1 91067-1 601966 4 601966-4 601966 1 601966-1 599406 7 599406-7 125905 2 125905-2 91067 1 91067-1 91067 1 91067-1 601966 5 601966-5 601966 1 601966-1 599406 7 599406-7 91067 2 91067-2 91067 2 91067-2 601966-5 601966-1 599406-7 125905-1 MIL-C-24308 91067-2 91067-2 Figure 3 (Cont'd) Rev D Tyco Electronics Corporation 11 of 17 408-7516 Application Tooling for Screw-Machine Contacts CONTACT Product Line SIZE Pin WIRE Socket 7 Military Spec TOOL SELECTOR Size Strip (AWG) Length # SETTING $ -/ AE A AE A 4.( " 7 # # $ -,,(&1-/0 7 7 # $ 7 -3(/ -,1%&1 7 7 7 # $ # # $ # # $ # 7 7 # $ # 7 # # $ # # $ # # $ -/ 7 7 -,1%&1 7 7 7 # $ # $ 7 7 7 A AE AE # # $ Figure 3 (Cont'd) 01/%,' 3*/( 0( 13- 0*5( 12 -) ! 3*/(0 4&- +(&1/-,*&0 -/.-/%1*-, (2 D 408-7516 Application Tooling for Screw-Machine Contacts Tooling for Loose Piece Contacts Tooling for Tape Mounted Contacts 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 601966 5 601966-5 601966 1 601966-1 91067 2 91067-2 91067 2 91067-2 601966-5 601966-1 599406-7 125905-1 91067-2 91067-2 608651 2 608651-2 608651 1 608651-1 318813 1 318813-1 608651 2 608651-2 608651 1 608651-1 318813 1 318813-1 608668 2 608668-2 608668 1 608668-1 318813 1 318813-1 608651 3 608651-3 608651 1 608651-1 318813 1 318813-1 601966 4 601966-4 601966 1 601966-1 601966 1 601966-1 601966-1 601967-2 601967-1 91067-1 91067-1 HH 601967 1 601967-1 91066 3 91066-3 91066 3 91066-3 Figure 3 (End) H Military Spec MIL-C-22520/1-05 Rev D Tyco Electronics Corporation 13 of 17 408-7516 Application Tooling for Screw-Machine Contacts 3. TOOLING ASSEMBLY refer to the data plate on the positioner. Pull the selector knob and turn to the proper setting. 3.1. Installing Positioner CAUTION changing the positioner selector setting; Refer to Figure 4, and proceed as follows: 1. Squeeze the tool handles together, then allow the handles to FULLY open. CAUTION 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. Rim 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. CAUTION 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). Installing Positioner Outer The tool handles must be fully opened when Bayonet Installing Turret Head Pin Positioner Post Turret Trigger Retainer Ring (Hidden) Safety Data Clip Plate Turret in Locked Position Back of Positioner Turret Head Installed Selector Knob Data and Dial Plate Turret Ratchet Extended Socket Head Cap Index Screw (2 Places) Mark Retainer Ring (Hidden) Turret Head Installed Back of Tool Selector Knob and Dial Tool Handles Figure 4 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. Back of Tool 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 14 of 17 Tyco Electronics Corporation Tool Handles Figure 5 Rev D 408-7516 Application Tooling for Screw-Machine Contacts 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. 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) CAUTION The tool handles must be fully opened when changing the positioner selector setting; ! otherwise, damage to the tool will occur. 4. CRIMPING PROCEDURE NOTE These tools have a ratchet which ensures proper crimping of the contacts. Once engaged, the i 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. 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. CAUTION Be careful NOT to crimp the gage element. ! Indenter Mating End of Contact Nameplate 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. (Ref) 5.3. Crimp Height Inspection Front of Tool NOTE Figure 6 contact material were calculated into the crimp i 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). Rev D Allowances for tool stresses and relaxation of 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: Tyco Electronics Corporation B.C. Ames Company Lexington Street Waltham, MA 02154 15 of 17 408-7516 Application Tooling for Screw-Machine Contacts Suggested Plug Gage Design NO-GO Dia GO Dia 6.35 [.250] Min Typ TOOL (Military Spec) TOOL GAGE ELEMENT SELECTOR DIAMETER +0.003 [.0001] 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] (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] D8S 1 1.78 [.070] 2.03 [.080] 2 1.91 [.075] 2.16 [.085] 3 2.03 [.080] 2.29 [.090] D4S 608651 1 608651-1 601967-1 (MIL-C-22520/1-01) (MIL C 22520/1 01) and 608668-1 D0.99 [.039]S D1.12 [.044]S D2.16 [.085]S D2.41 [.095]S 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] D4S E E E E E 1.14 [.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] Figure 7 For Periodic General Inspection TOOL SELECTOR SETTING 8 601967-1 4 608668-1 4 608651-1 4 GO Element NO-GO Element NO-GO element may enter completely through the die partially, but must not pass opening. completely through the die opening. 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 Inspection Crimped Contact Crimp Height CRIMP HEIGHT TOOL PLUG GAGE (Military Spec) 601968 1 601968-1 (MIL-C-22520/3-01) 601968-3 TOOL 601967-1 SELECTOR TOOL 601966-1 SETTING Military Spec Military Spec MIL-C-22520/2-01 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 8 16 of 17 Opening GO element must pass Figure 8 conform to these gage element diameters. 601966-1 EE EE EE EE EE Die D0.99 [.039]S D1.12 [.044]S 5 S Use for periodic general inspection. The plug gages listed in TOOL Gaging the Die Opening Figure 10 Tyco Electronics Corporation Rev D 408-7516 Application Tooling for Screw-Machine Contacts 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. 7. REVISION SUMMARY S Updated document to corporate requirement S New format S Deleted duplicate part number in Figure 2 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 SERVICE (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. Rev D Tyco Electronics Corporation 17 of 17