1--601967--1 [TE]

Application Tooling for Screw-Machine Contacts;
1--601967--1
型号: 1--601967--1
厂家: TE CONNECTIVITY    TE CONNECTIVITY
描述:

Application Tooling for Screw-Machine Contacts

文件: 总17页 (文件大小:235K)
中文:  中文翻译
下载:  下载PDF数据表文档文件
Instruction Sheet  
Application Tooling for  
Screw-Machine Contacts  
408-7516  
10 Mar 11 Rev E  
PROPER USE GUIDELINES  
Cumulative Trauma Disorders can resultfrom the prolonged use ofmanually 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  
Reasons for reissue of this instruction sheet are  
provided in Section 7, REVISION SUMMARY.  
4/8-Indent Hand Crimping Tool  
Insertion/Extraction  
(Typ, Requires Positioner or  
Turret Head)  
Tool (Typ)  
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.  
Extraction Tool (Typ)  
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  
601966--1  
601967--1  
608651--1  
601966--2  
601966--4  
601966--5  
601966--6  
601966--8  
601967--2  
1--601967--2  
Military Spec  
MIL--C--22520/2--01  
MIL--C--22520/1--01  
-- -- --  
AMP-TAPETRONIC* 4/8 Indent Stripper  
Terminator 599406-[ ] (Requires Funnel)  
4/8--Indent Hand  
Crimping Tool  
MIL--C--22520/2--02  
MIL--C--22520/2--06  
MIL--C--22520/2--08  
MIL--C--22520/2--09  
MIL--C--22520/2--23  
MIL--C--22520/1--02  
MIL--C--22520/1--11  
Positioner or  
Turret Head  
MIL--I--81969/1--01  
or MS3156--22  
91066--1  
91067--1  
91067--2  
MIL--I--81969/1--04  
Insertion/Extraction  
Tool  
MIL--I--81969/1--02  
or MS3156--20  
Figure 1  
MIL--I--81969/1--03  
or MS3156--16  
91066--3  
1. INTRODUCTION  
445147--1  
58284--1  
MIL--C--81969/28--02  
MIL--C--81969/28--03  
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.  
Extraction Tool  
MIL--C--81969/28--01  
or MS3178--001  
91074--1  
Figure 2  
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.  
NOTE  
Refer to Figure 3 for proper contact and tooling  
combination. Read the chart from the left page across  
to the right page.  
i
E2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company TOOLING ASSISTANCE CENTER 1--800--722--1111 This controlled document is subject to change.  
1 of 17  
All Rights Reserved  
PRODUCT INFORMATION 1--800--522--6752  
For latest revision and Regional Customer Service,  
TE logo is a trademark.  
visit our website at www.te.com  
LOC B  
*Trademark. Other product names, logos, or company names might be trademarks of their respective owners.  
408-7516  
CONTACT  
Pin  
WIRE  
TOOL  
SELECTOR  
SETTING  
Size  
(AWG)  
Strip  
Length  
Product Line  
Size  
Socket  
Military Spec  
28  
26  
24  
28  
26  
24  
24  
22  
20  
24  
22  
20  
18  
16  
32  
30  
28  
26  
24  
28  
26  
24  
22  
20  
24  
22  
20  
18  
2
2
3
2
2
3
1
2
3
1
2
3
4
5
1
1
2
2
3
2
2
3
2
3
1
2
3
4
201607  
201609  
5.16 [.203]  
5.16 [.203]  
5.16 [.203]  
5.16 [.203]  
201353  
20  
201582  
201584--6  
200334  
200331  
201589  
6.35 [.250]  
5.16 [.203]  
201554  
201334  
Type II Contact  
For Multimate  
Connectors  
5.16 [.203]  
201332  
201611  
5.16 [.203]  
5.16 [.203]  
5.16 [.203]  
6.35 [.250]  
201613  
201578  
201580  
201328  
200679  
201330  
204188  
16  
200681  
200333  
16  
18  
16  
18  
16  
14  
32  
30  
5
4
5
4
5
5
1
1
202507  
202508  
6.35 [.250]  
5.16 [.203]  
200336  
200333  
201570  
201555  
201568  
201554  
Figure 3 (Cont’d)  
2 of 17  
Rev E  
408-7516  
Tooling for Loose Piece Contacts Tooling for Tape Mounted Contacts  
CONNECTOR  
Military Spec  
INSERTION  
TOOL  
EXTRACTION  
TOOL  
Positioner or  
Turret Head  
Hand Crimping  
Tool  
Machine  
Funnel  
58305--1 or  
601967-- 1  
200893--2 or  
91002-- 1  
1--601967--5  
1--601967--5  
1--601967--5  
305183  
305183  
305183  
305183  
58305--1 or  
601967-- 1  
200893--2 or  
91002-- 1  
58305--1 or  
601967-- 1  
200893--2 or  
91002-- 1  
58305--1 or  
601967-- 1  
200893--2 or  
91002-- 1  
1--601967--5  
1--601967--6  
45098 or  
601967--1  
200893--2 or  
91002--1  
305183  
305183  
58305--1 or  
601967--1  
200893--2 or  
91002--1  
1--601967--5  
1--601967--6  
1--601967--5  
1--601967--6  
1--601967--5  
58305--1 or  
601967-- 1  
200893--2 or  
91002-- 1  
305183  
58305--1 or  
601967-- 1  
200893--2 or  
91002-- 1  
305183  
305183  
305183  
1--601967--6  
1--601967--5  
1--601967--5  
58305--1 or  
601967--1  
200893--2 or  
91002--1  
58305--1 or  
601967-- 1  
200893--2 or  
91002-- 1  
1--601967--6  
1--601967--6  
45098 or  
601967-- 1  
200893--2 or  
91002-- 1  
305183  
305183  
1--601967--6  
1--601967--5  
90136--1 or  
601967--1  
200893--2 or  
91002--1  
200893--2 or  
91002--1  
45098 or  
1--601967--6  
305183  
305183  
601967-- 1  
1--601967--6  
1--601967--5  
58305--1 or  
601967--1  
200893--2 or  
91002--1  
Figure 3 (Cont’d)  
Rev E  
3 of 17  
408-7516  
CONTACT  
Pin  
WIRE  
TOOL  
SELECTOR  
SETTING  
Size  
(AWG)  
Strip  
Length  
Product Line  
Size  
Socket  
Military Spec  
28  
26  
24  
26  
24  
24  
22  
20  
18  
16  
18  
18  
16  
2
2
3
2
3
1
2
3
4
5
4
4
5
201609  
5.16 [.203]  
5.16 [.203]  
5.16 [.203]  
5.16 [.203]  
201332  
201328  
200679  
Type II Contact  
For Multimate  
Connectors  
200681  
200336  
204274  
202507  
204219  
200333  
16  
5.16 [.203]  
5.16 [.203]  
5.16 [.203]  
202508  
202725  
202726  
5
18  
201570  
201645  
5
5
5
1
1
2
2
1
2
3
4
5
6
7
14  
201568  
32  
30  
28  
202123  
202124  
3.18 [.125]  
Type VII Contact  
For Subminiature  
Connectors  
26  
22  
20  
30  
28  
204092  
3.18 [.125]  
4.78 [.188]  
26  
24  
24  
Type XIII Contact  
For Terminal  
Junction (TJG)  
Modules  
22  
203669--4  
20  
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  
Rev E  
408-7516  
Tooling for Loose Piece Contacts Tooling for Tape Mounted Contacts  
CONNECTOR  
Military Spec  
INSERTION  
TOOL  
EXTRACTION  
TOOL  
Positioner or  
Turret Head  
Hand Crimping  
Tool  
Machine  
Funnel  
58305--1 or  
601967-- 1  
200893--2 or  
91002-- 1  
1--601967--5  
1--601967--5  
1--601967--5  
305183  
305183  
305183  
305183  
58305--1 or  
601967--1  
200893--2 or  
91002--1  
58305--1 or  
601967-- 1  
200893--2 or  
91002-- 1  
45098 or  
601967--1  
200893--2 or  
91002--1  
1--601967--6  
1--601967--6  
45098 or  
601967-- 1  
200893--2 or  
91002--1  
305183  
1--601967--5  
1--601967--6  
45098 or  
601967--1  
1--601967--6  
1--601967--5  
45098 or  
200893--2 or  
91002-- 1  
305183  
601967-- 1  
1--601966--0  
601966--1  
599406--7  
1--125905--1  
91005--2  
91004--2  
1--601966--0  
-- 601966--2  
601966--1  
601966--1  
599406--7  
599406--7  
HH  
HH  
Figure 3 (Cont’d)  
H Military Spec MIL--I--81969/14  
Rev E  
5 of 17  
408-7516  
CONTACT  
Pin  
WIRE  
TOOL  
SELECTOR  
SETTING  
Size  
(AWG)  
Strip  
Length  
Product Line  
Size  
Socket  
Military Spec  
24  
22  
20  
24  
22  
20  
20  
18  
16  
2
3
4
2
3
4
4
5
5
203840  
4.78 [.188]  
4.78 [.188]  
6.35 [.250]  
20  
Type XV  
For ARINC  
Front Release  
AM, AD, and  
AAP Connectors  
203841  
16  
22  
203884  
26  
24  
3
3
4
3
3
4
4
5
5
6
7
5
6
7
4
5
6
4
5
6
4
5
6
7
8
7
8
204873  
MIL--C--39029/11--144  
3.96 [.156]  
22  
26  
24  
205103  
205904  
MIL--C--39029/12--148  
3.96 [.156]  
3.96 [.156]  
3.96 [.156]  
22  
30  
28  
24  
22  
204938  
MIL--C--39029/11--145  
20  
205116  
MIL--C--39029/12--149  
MIL--C--39029/12--149  
24  
22  
20  
3.96 [.156]  
3.96 [.156]  
6.35 [.250]  
6.35 [.250]  
Type XVII  
For ARINC  
Rear Release  
RM Connectors  
20  
30  
28  
205791  
204978  
206887  
26  
20  
18  
MIL--C--39029/11--146  
MIL--C--39029/12--150  
16  
16  
12  
20  
18  
205117  
16  
14  
205763--5  
6.35 [.250]  
6.35 [.250]  
12  
14  
205851--2  
12  
Figure 3 (Cont’d)  
This wire size is not recommended for use in the machine.  
6 of 17  
Rev E  
408-7516  
Tooling For Loose Piece Contacts Tooling For Tape Mounted Contacts  
CONNECTOR  
Military Spec  
INSERTION  
TOOL  
EXTRACTION  
TOOL  
Positioner or  
Turret Head  
Hand Crimping  
Tool  
Machine  
Funnel  
-- 601967--2  
-- 601967--2  
-- 601967--2  
-- 601966--8  
601967--1  
601967--1  
601967--1  
601966--1  
599406--5  
125905--8  
MIL--C--81659  
MIL--C--8165  
MIL--C--81659  
MIL--C--81659  
91039--1  
91039--1  
91039--3  
91066--1  
91040--1  
91040--1  
91040--3  
91066--1  
599406--5  
599406--5  
599406--7  
125905--8  
125905--6  
1--125905--2  
-- 601966--8  
-- 601966--8  
-- 601966--5  
601966--1  
601966--1  
601966--1  
599406--7  
599406--7  
599406--7  
1--125905--2  
1--125905--2  
91066--1  
91066--1  
91067--2  
91066--1  
91066--1  
91067--2  
125905-- 1  
(Max Insulation  
Dia 1.98 [.078])  
MIL--C--81659  
125905-- 1  
-- 601966--5  
-- 601966--5  
-- 601967--2  
-- 601967--2  
601966--1  
601966--1  
601967--1  
601967--1  
599406--7  
599406--7  
599406--5  
599406--5  
(Max Insulation  
Dia 1.98 [.078])  
91067--2  
91067--2  
91066--3  
91066--3  
91067--2  
91067--2  
91066--3  
91066--3  
MIL--C--81659  
125905--6  
125905--6  
-- 601967--2  
-- 601967--2  
601967--1  
601967--1  
MIL--C--81659  
MIL--C--81659  
445147--1  
445147--1  
Figure 3 (Cont’d)  
Rev E  
7 of 17  
408-7516  
CONTACT  
Pin  
WIRE  
TOOL  
SELECTOR  
SETTING  
Size (AWG,  
See Note)  
Strip  
Product Line  
Size  
Socket  
51781--1  
Military Spec  
Length  
0
RG 214/U  
8
Semi--Rigid  
141  
225837--1  
(408--2348--02)  
1
3
225831--1  
RG 214/U  
8
(408--2348--02)  
RG 141/U,  
58C/U  
226053--1  
(408--2348--01)  
RG 214/U,  
213/U  
225792--1  
225792--3  
225791--1  
225791--2  
8
(408--2348--01)  
RG 58C/U,  
141A/U  
(408--2348--01)  
RG 58C/U,  
141/U  
225790--1  
225790--2  
225790--3  
5
COAXICON*  
Contact For  
ARINC Coaxial  
Connectors  
(408--2348)  
RG 233/U,  
142/U  
5
(408--2348)  
5
Semi--Rigid  
141  
5
(408--2348)  
225790--4  
RG 180B/U  
RG 58C/U  
RG 233/U  
5
(408--2348)  
225796--1  
225796--2  
5
7
9
(408--2348--01)  
5
RG 58C/U,  
141A/U  
225935--1  
5
(408--2348--03)  
Semi--Rigid  
141  
225936--1  
5
(408--2348--03)  
26  
24  
22  
26  
24  
22  
24  
22  
20  
24  
22  
20  
3
3
4
3
3
4
5
6
7
5
6
7
208262  
3.96 [.156]  
3.96 [.156]  
3.96 [.156]  
3.96 [.156]  
22  
20  
208264  
ARINC 600  
208265  
208267  
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  
Rev E  
408-7516  
Tooling for Loose Piece Contacts Tooling for Tape Mounted Contacts  
CONNECTOR  
Military Spec  
INSERTION  
TOOL  
EXTRACTION  
TOOL  
Positioner or  
Turret Head  
Hand Crimping  
Tool  
Machine  
Funnel  
69646  
91040--7  
601966--1and  
220066--1  
220015--1  
601966--1and  
220066--1  
1--601966--8  
220015--1  
601966--1and  
220066--1  
601966--1and  
220066--1  
91074--1  
91074--1  
91074--1  
91074--1  
1--601966--6  
1--601966--6  
1--601966--6  
1--601966--6  
2--601966--6  
1--601966--6  
1--601966--6  
1--601966--6  
601966--1and  
220066--1  
601966--1and  
220066--1  
601966--1and  
220066--1  
601966--1and  
220066--1  
601966--1and  
220066--1  
601966--1and  
220066--1  
91074--1  
91074--1  
601966--1and  
220066--1  
601966--8  
601966--8  
601966--5  
601966--5  
601966--1  
601966--1  
601966--1  
601966--1  
599406--7  
599406--7  
599406--7  
599406--7  
1--125905--2  
1--125905--2  
125905--1  
91066--1  
91066--1  
91067--2  
91067--2  
91066--1  
91066--1  
91067--2  
91067--2  
125905-- 1  
(Max Insulation  
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  
Rev E  
9 of 17  
408-7516  
CONTACT  
Pin  
WIRE  
TOOL  
SELECTOR  
SETTING  
Size (AWG,  
See Note)  
Strip  
Product Line  
ARINC 600  
TRIAXIAL  
Size  
Socket  
Military Spec  
Length  
204978  
208268  
213122  
20  
18  
16  
20  
18  
16  
14  
12  
14  
12  
4
5
6
4
5
6
7
8
7
8
6.35 [.250]  
16  
208270  
6.35 [.250]  
6.35 [.250]  
208271  
213123  
12  
8
208273  
222191  
6.35 [.250]  
MIL--C--39029--95 and  
MIL--C--39029--96  
222190  
206496  
28  
26  
28  
26  
28  
26  
24  
22  
28  
26  
24  
22  
28  
26  
24  
22  
28  
26  
24  
22  
20  
3
4
3
4
1
2
3
4
1
2
3
4
1
2
3
4
5
6
5
6
7
3.96 [.156]  
206496  
3.96 [.156]  
3.96 [.156]  
204370  
MIL--C--39029/58--360  
MIL--C--39029/57--354  
22D  
Type XVII  
For AMPLIMITE*  
HDD Connectors  
204351  
206071  
3.96 [.156]  
3.96 [.156]  
206794  
205089  
206795  
3.96 [.156]  
3.56 [.140]  
20  
MIL--C--39029/64--369  
Figure 3 (Cont’d)  
Note: Unless otherwise specified  
10 of 17  
Rev E  
408-7516  
Tooling for Loose Piece Contacts Tooling for Tape Mounted Contacts  
CONNECTOR  
Military Spec  
INSERTION  
TOOL  
EXTRACTION  
TOOL  
Positioner or  
Turret Head  
Hand Crimping  
Tool  
Machine  
Funnel  
601967--2  
601967--1  
599406--5  
125905--6  
91066--3  
91066--3  
601967--2  
601967--1  
601967--1  
599406--5  
125905--6  
91066--3  
91066--3  
1--601967--2  
445147--1  
1--601967--2  
601967--1  
608650--1  
601966--1  
MIL--C--83527  
445147--1  
58284--1  
91067--1  
601966--6  
601966--4  
599406--7  
599406--7  
125905--2  
125905--2  
91067--1  
91067--1  
601966--1  
601966--1  
91067--1  
91067--1  
601966--6  
601966--4  
601966--4  
599406--7  
599406--7  
599406--7  
125905--2  
125905--2  
MIL--C--24308  
91067--1  
91067--1  
91067--1  
601966--1  
601966--1  
MIL--C--24308  
91067--1  
91067--1  
125905--2  
601966--5  
601966--5  
601966--1  
601966--1  
599406--7  
599406--7  
91067--2  
91067--2  
91067--2  
91067--2  
125905--1  
MIL--C--24308  
Figure 3 (Cont’d)  
Rev E  
11 of 17  
408-7516  
CONTACT  
Pin  
WIRE  
TOOL  
SELECTOR  
SETTING  
Size  
(AWG)  
Strip  
Length  
Product Line  
SIZE  
Socket  
Military Spec  
24  
22  
5
6
7
7
7
5
6
7
7
6
1
1
8
6
7
6
1
2
3
4
4
5
5
6
5
6
7
4
5
6
6
7
1218266--1  
205090  
MIL--C--39029/63--368  
3.56 [.140]  
3.56 [.140]  
3.56 [.140]  
20  
Type XVII  
For AMPLIMITE  
HDD Connectors  
18  
18  
24  
20  
1218267--1  
206793  
22  
20  
211159--1  
211159--2  
211161--1  
211161--2  
8
9.53 [.375]  
9.53 [.375]  
9.53 [.375]  
9.53 [.375]  
10  
12  
212007--1  
212013--1  
213552  
212008--1  
212014--1  
14  
AMPLIMITE  
Power 8 Contact  
8
16  
18  
8
10  
28  
26  
204351--1  
MIL--C--39029/57--354  
3.96 [.156]  
3.18 [.125]  
3.96 [.156]  
24  
22  
22  
28  
26  
861211 or  
863260  
24  
22  
LGH* Contact  
24  
22  
867782  
20  
6.35 [.250]  
6.35 [.250]  
20  
18  
867328  
861080  
MIL--C--39029/12--150  
16  
16  
22 (2)  
16  
4.78 [.188]  
Figure 3 (Cont’d)  
19--strand wire  
Use two size 22 AWG wires  
12 of 17  
Rev E  
408-7516  
Tooling for Loose Piece Contacts Tooling for Tape Mounted Contacts  
CONNECTOR  
Military Spec  
INSERTION  
TOOL  
EXTRACTION  
TOOL  
Positioner or  
Turret Head  
Hand Crimping  
Tool  
Machine  
Funnel  
601966--5  
601966--5  
601966--5  
601966--1  
601966--1  
601966--1  
599406--7  
125905--1  
91067--2  
91067--2  
91067--2  
91067--2  
91067--2  
91067--2  
599406--7  
125905--1  
608651--2  
608651--2  
608668--2  
608651--3  
608651--1  
608651--1  
608668--1  
608651--1  
318813--1  
318813--1  
318813--1  
318813--1  
601966--4  
601966--1  
601966--1  
601966--1  
601967--2  
601967--1  
601967--1  
91067--1  
91066--3  
91067--1  
91066--3  
HH  
Figure 3 (End)  
H Military Spec MIL--C--22520/1--05  
Rev E  
13 of 17  
408-7516  
refer to the data plate on the positioner. Pull the  
selector knob and turn to the proper setting.  
3. TOOLING ASSEMBLY  
3.1. Installing Positioner  
The tool handles must be fully opened when  
changing the positioner selector setting;  
otherwise, damage to the tool will occur.  
CAUTION  
Refer to Figure 4, and proceed as follows:  
!
1. Squeeze the tool handles together, then allow  
the handles to FULLY open.  
3.2. Installing Turret Head  
The tool handles must be fully opened when  
installing the positioner; otherwise, damage to  
the tool will occur.  
CAUTION  
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.  
CAUTION  
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.  
!
2. Depress the turret trigger to release the turret  
from the index position (the turret should be  
extended).  
Installing Positioner  
Bayonet  
Pin  
Outer  
Rim  
Installing Turret Head  
Positioner  
Post  
Turret Trigger  
Retainer Ring  
(Hidden)  
Turret in Locked  
Position  
Back of  
Turret Head  
Safety  
Clip  
Data  
Plate  
Positioner  
Installed  
Selector Knob  
and Dial  
Data  
Plate  
Turret  
Extended  
Socket Head Cap  
Screw (2 Places)  
Index  
Mark  
Ratchet  
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.  
Tool Handles  
5. Determine the selector setting according to the  
contact size and wire size listed in Figure 3 (or  
Figure 5  
14 of 17  
Rev E  
408-7516  
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.  
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.  
4. Rotate the turret until the positioner marked with  
the desired contact size is aligned with the index  
mark.  
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.  
5. Press the turret until it is in the locked position.  
2. When the tool is not in use, keep the handles  
closed, and store the tool in a clean, dry area.  
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.  
5.2. Gaging the Die Opening (Indenters)  
The tool handles must be fully opened when  
changing the positioner selector setting;  
otherwise, damage to the tool will occur.  
CAUTION  
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:  
!
4. CRIMPING PROCEDURE  
1. Remove traces of oil or dirt from the die opening  
and plug gage.  
These tools have a ratchet which ensures proper  
NOTE  
crimping of the contacts. Once engaged, the  
ratchet will NOT release until the tool handles are  
FULLY closed.  
2. Fully close tool handles; then hold in this  
position. DO NOT force beyond initial contact.  
i
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.  
1. Strip the wire according to the wire size listed in  
Figure 3.  
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.  
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.  
CAUTION  
Be careful NOT to crimp the gage element.  
!
Indenter  
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.  
Mating End  
of Contact  
Nameplate  
(Ref)  
For additional information regarding the use of a plug  
gage, refer to 408--7424.  
5.3. Crimp Height Inspection  
Front of Tool  
Allowances for tool stresses and relaxation of  
contact material were calculated into the crimp  
height measurements for military specified  
contacts only.  
NOTE  
Figure 6  
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.  
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:  
5. Remove the crimped contact from the tool.  
Inspect the contact according to the applicable  
application specification (114--series).  
B.C. Ames Company  
Lexington Street  
Waltham, MA 02154  
Rev E  
15 of 17  
408-7516  
Suggested Plug Gage Design  
NO-GO Dia  
Gaging the Die Opening  
GO Dia  
Die  
Opening  
6.35 [.250] Min Typ  
GO  
NO-GO  
Element  
Element  
GAGE ELEMENT  
DIAMETER +0.003 [.0001]  
TOOL  
SELECTOR  
SETTING  
TOOL  
(Military Spec)  
GO element must pass  
completely through the die  
opening.  
NO -GO element may enter  
partially, but must not pass  
completely through the die  
opening.  
GO  
NO-GO  
1
2
0.33 [.013]  
0.41 [.016]  
0.48 [.019]  
0.56 [.022]  
0.66 [.026]  
0.76 [.030]  
0.86 [.034]  
0.46 [.018]  
0.53 [.021]  
0.61 [.024]  
0.69 [.027]  
0.79 [.031]  
0.89 [.035]  
0.99 [.039]  
3
Figure 9  
4
601966--1  
(MIL-C-22520/2-01)  
5
6
To inspect the crimp height, proceed as follows:  
7
D8S  
1
D0.99 [.039]S D1.12 [.044]S  
1. Crimp the contact according to Section 3,  
CRIMPING PROCEDURE.  
1.78 [.070]  
1.91 [.075]  
2.03 [.080]  
2.03 [.080]  
2.16 [.085]  
2.29 [.090]  
2
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.  
3
D4S  
5
D2.16 [.085]S D2.41 [.095]S  
608651--1  
2.34 [.092]  
2.51 [.099]  
2.74 [.108]  
3.00 [.118]  
0.71 [.028]  
0.81 [.032]  
0.91 [.036]  
2.59 [.102]  
2.77 [.109]  
3.00 [.118]  
3.25 [.128]  
0.84 [.033]  
0.94 [.037]  
1.04 [.041]  
6
7
Crimp Height Inspection  
8
1
Crimped  
Contact  
2
3
601967--1  
(MIL-C-22520/1-01)  
and 608668-1  
D4S  
5
D0.99 [.039]S D1.12 [.044]S  
1.14 [.045]  
1.32 [.052]  
1.50 [.059]  
1.73 [.068]  
1.27 [.050]  
1.45 [.057]  
1.63 [.064]  
1.85 [.073]  
Crimp  
Height  
6
7
CRIMP HEIGHT  
TOOL  
8
TOOL 601966-1  
Military Spec  
TOOL 601967-1  
Military Spec  
MIL-C-22520/1-01  
SELECTOR  
SETTING  
S Use for periodic general inspection. The plug gages listed in  
Figure 8 conform to these gage element diameters.  
MIL-C-22520/2-01  
Figure 7  
1
2
3
4
5
6
7
8
0.406--0.533 [.016--.021] 0.813--0.940 [.032--.037]  
0.483--0.610 [.019--.024] 0.914--1.041 [.036--.041]  
0.559--0.686 [.022--.027] 1.016--1.143 [.040--.045]  
0.635--0.762 [.025--.030] 1.092--1.219 [.043--.048]  
0.737--0.864 [.029--.034] 1.245--1.372 [.049--.054]  
0.838--0.965 [.033--.038] 1.422--1.549 [.056--.061]  
0.940--1.067 [.037--.042] 1.600--1.727 [.063--.068]  
1.067--1.194 [.042--.047] 1.829--1.956 [.072--.077]  
For Periodic General Inspection  
TOOL  
SELECTOR  
SETTING  
PLUG GAGE  
TOOL  
(Military Spec)  
601966--1  
601967--1  
608668--1  
608651--1  
8
4
4
4
601968--1  
(MIL-- C-- 22520/3-- 01)  
601968--3  
Figure 8  
Figure 10  
16 of 17  
Rev E  
408-7516  
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 requirements.  
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.  
Rev E  
17 of 17  

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