MIL-C-26482, Series I Connectors
KPT/KPSE
KPSE Assembly Instructions
Wire
Contact
Size
Size
AWG
Strip
Insulation
Right
20
16
#20-#24
#16-#20
3/16"
1/4"
Wrong
CRIMPING CONTACTS
1. Strip wires according to the table above taking care not to cut or nick
strands.
2. Insert stripped wire into contact crimp pot. Wire must be visible thru
inspection hole.
3. Using correct crimp tool and locator select proper crimp setting for
wire sizer to be crimped; cycle the tool onec to be sure the indentors are
open. Insert contact and wire into locator. Squeeze tool handles firmly
and completely to insure a proper crimp. The tool will not release unless
the crimp indentors in the tool head have been fully actuated. Release
crimped contact and wire from tool. Be certain the wire is visible thru
inspection hole in contact.
CAUTION: Check that none of the contacts are bent or damaged in any
way after crimping.
#16 CONTACTS
COUPLING NUT
FERRULE
ALCOHOL
INSERTION
SHOULDER
TOOL TIP
ENDBELL
#20 CONTACTS
CONTACT INSERTION
1. Remove hardware from plug and receptacle. Slide hardware over wire 2. Use the proper contact insertion tool and slide the tool over the 3. Begining from center cavity and working outwards in
a circular
bundle in proper order for reassembly.
terminal end of the contact. The size 16 contact lies in the tool and the pattern, insert wired contacts into rear of connnector by hand until the
tool tip butts against the contact shoulder. The rear, or insulation front of the contact shoulder is no more than 1/8" from the grommet.
support of the size 20 contact butts against an internal shoulder in the Holding the connector horizontally, position tool behind contact. Push
tool tip.
tool straight into contact cavity until contact snaps into position. A light
NOTE: Apply a small amount of isopropyl alcohol to the insertion tool tip pull on wire will assure that contact is locked securely. Repeat for
while installing contacts.
remaining contacts.
Size
Torque in/lbs.
10-15
8,10,12 and 14
16 and 18
15-25
20,22 and 24
25-35
COMPLETION
4. Use contacts and grommet sealing plugs to fill any empty cavities.
1. Check face of plug or receptacle for proper contact installation.
2. Using mating connector with contacts installed, mate both connector
halves together.
3. Assemble ferrule over the grommet by hand as far as possible.
4 Assemble endbell over ferrule and loosely tighten endbell. Partiallly
loosen (1/4 turn) and retighten to recommended torque limits.
2nd Index Line
Socket Contacts
1st Index Line
Pin Contacts
CONTACT EXTRACTION
1. Slide hardware back over wire bundle. Using proper extraction tool or KPSE: There are two lines on the clip sleeve which are vital to the Carefully place the tool tip over the contact to be extracted until the
extraction end of proper insertion/extraction tool, proceed as follows: contact removal process. The first index line is used for removing pin tool tip touches the insulator face. Carefully rotate the tool until the
contacts while the second index line is for removing socket contacts. index line is slightly below the insulator face. Keep an even pressure
against tool body; push plunger forward with thumb and index finger,
and push the contact out throught the clip. Carefully remove extraction
tool from connnector. Pull wire by hand to compete the removal of
the contact.
Dimensions are shown in inches (millimeters).
Dimensions subject to change.
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