Instruction Sheet

Application Tooling for 408-- 7516

Screw- Machine Contacts 10 Mar 11 Rev E

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 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 Tool (Typ)
Turret Head) 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
Extraction Tool (Typ) 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 Military Spec
AMP-- TAPETRONIC* 4/8 Indent Stripper 601966--1 MIL--C--22520/2--01
Terminator 599406-- [ ] (Requires Funnel) 4/8--Indent
4/8 I d Hand
H d
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
601966--5 MIL--C--22520/2--08
Positioner
P ii or
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
MIL--I--81969/1--01
91066--1
or MS3156--22
91067--1 MIL--I--81969/1--04
Insertion/Extraction
Tool MIL--I--81969/1--02
Figure 1 91067--2
or MS3156--20
MIL--I--81969/1--03
91066--3
1. INTRODUCTION or MS3156--16
This instruction sheet covers tooling selections for 445147--1 MIL--C--81969/28--02
crimping, inserting, and extracting screw--machine 58284--1 MIL--C--81969/28--03
contacts, and manual application procedures. Extraction Tool
Application procedures for the other tools are MIL--C--81969/28--01
91074--1
packaged with the tool. Read these instructions or MS3178--001
thoroughly before making any selections. Figure 2
NOTE Dimensions in this instruction sheet are in
millimeters [with inches in brackets]. Figures and Refer to Figure 3 for proper contact and tooling
i illustrations are for reference only and are not
drawn to scale.
combination. Read the chart from the left page across
to the right page.

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 [Link] LOC B
*Trademark. Other product names, logos, or company names might be trademarks of their respective owners.
 408- 7516

CONTACT WIRE TOOL

Size Strip SELECTOR
Product Line Size Pin Socket Military Spec SETTING
(AWG) Length

28 2
201607 201609 — 26 5.16 [.203]
[ ] 2
24 3
28 2
— 201353 — 26 5.16 [.203]
[ ] 2
24 3
24 1
20
201582 201584--6 — 22 5.16 [.203]
[ ] 2
20 3
24 1
200334 200331 — 22 5.16 [.203]
[ ] 2
20 3
18 4
— 201589 — 6 35 [.250]
6.35 [ 250]
16 5
32 1
— 201554 — 5 16 [.203]
5.16 [ 203]
30 1
201334 — — 28 2
Type II Contact 26 5.16 [.203]
[ ] 2
For Multimate — 201332 —
Connectors 24 3
201611 — — 28 2
26 5.16 [.203]
[ ] 2
— 201613 —
24 3
201578 — — 22 2
5 16 [.203]
5.16 [ 203]
— 201580 — 20 3
200679 201328 — 24 1
16
201330 — 22 5.16 [.203]
[ ] 2
—
204188 — 20 3
18 4
200681 200333 — 6 35 [[.250]
6.35 250]]
16 5
202507 — — 18 4
— 202508 — 16 5
18 6.35 [.250]
[ ] 4
200336 200333 —
16 5
201570 201568 — 14 5
201555 — — 32 1
5 16 [.203]
5.16 [ 203]
— 201554 — 30 1
Figure 3 (Cont’d)

2 of 17 Rev E
 408- 7516

Tooling for Loose Piece Contacts Tooling for Tape Mounted Contacts
CONNECTOR INSERTION EXTRACTION
Positioner or Hand Crimping Military Spec TOOL TOOL
Machine Funnel
Turret Head Tool

58305--1 or 200893--2 or
1--601967--5 — — — 305183
601967--1 91002--1

58305--1 or 200893--2 or
1--601967--5 — — — 305183
601967--1 91002--1

1--601967--5 58305--1 or — — — 200893--2 or 305183

601967--1 91002--1

58305--1 or 200893--2 or
1--601967--5 — — — 305183
601967--1 91002--1

45098 or 200893 2 or
200893--2
1 601967 6
1--601967--6 — — — 305183
601967--1 91002--1

58305 1 or
58305--1 200893 2 or
200893--2
1 601967 5
1--601967--5 — — — 305183
601967--1 91002--1

1--601967--6
58305--1 or 200893--2 or
— — — 305183
1 601967 5
1--601967--5 601967--1 91002--1

1--601967--6
58305--1 or 200893--2 or
— — — 305183
1 601967 5
1--601967--5 601967--1 91002--1

1--601967--6 58305 1 or
58305--1 200893 2 or
200893--2
— — — 305183
1--601967--5 601967--1 91002--1

1--601967--5
58305--1 or 200893--2 or
— — — 305183
1 601967 6
1--601967--6 601967--1 91002--1

45098 or 200893 2 or
200893--2
1 601967 6
1--601967--6 — — — 305183
601967--1 91002--1
1--601967--6 90136 1 or
90136--1 200893 2 or
200893--2
— — — 305183
1--601967--5 601967--1 91002--1

200893 2 or
200893--2
45098 or 91002--1
1--601967--6 — — — 305183
601967--1
—
1--601967--6 58305 1 or
58305--1 200893 2 or
200893--2
— — — 305183
1--601967--5 601967--1 91002--1
Figure 3 (Cont’d)

Rev E 3 of 17
 408- 7516

CONTACT WIRE TOOL

Size Strip SELECTOR
Product Line Size Pin Socket Military Spec SETTING
(AWG) Length
28 2
— 201609 — 26 5.16 [.203]
[ ] 2
24 3
26 2
— 201332 — 5 16 [.203]
5.16 [ 203]
24 3
24 1
200679 201328 — 22 5.16 [.203]
[ ] 2
20 3
Type II Contact 200681 200333 — 18 4
For Multimate 16 5 16 [.203]
5.16 [ 203]
Connectors 200336 — — 16 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
30 1
202123 202124 — 3 18 [.125]
3.18 [ 125]
28 2
Type VII Contact 26 2
For Subminiature 22
Connectors 30 1
28 2
204092 — — 3 18 [.125]
3.18 [ 125]
26 3
24 4
Type
ype XIII Contact
Co tact 24 5
For Terminal 20 203669--4 — — 22 4.78 [.188]
[ ] 6
Junction (TJG)
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.

4 of 17 Rev E
 408- 7516

Tooling for Loose Piece Contacts Tooling for Tape Mounted Contacts
CONNECTOR INSERTION EXTRACTION
Positioner or Hand Crimping Military Spec TOOL TOOL
Machine Funnel
Turret Head Tool

58305--1 or 200893--2 or
1--601967--5 — — — 305183
601967--1 91002--1

58305 1 or
58305--1 200893 2 or
200893--2
1 601967 5
1--601967--5 — — — 305183
601967--1 91002--1

1--601967--5 58305--1 or — — — 200893--2 or 305183

601967--1 91002--1

45098 or 200893 2 or
200893--2
1 601967 6
1--601967--6 601967--1 — — — 91002--1 305183

1 601967 6
1--601967--6 45098 or
601967--1 200893--22 or
200893
1--601967--5 — — — 305183
91002--1
91002 1
45098 or
1--601967--6
601967--1

1 601967 6
1--601967--6 45098 or 200893--2 or
— — — 305183
601967--1 91002--1
1--601967--5

1 601966 0
1--601966--0 601966 1
601966--1 599406 7
599406--7 1 125905 1
1--125905--1 — 91005 2
91005--2 91004 2
91004--2

1 601966 0
1--601966--0 601966 1
601966--1 599406 7
599406--7 — — — —

--601966--2 601966--1 599406--7 — — H—H H—H

Figure 3 (Cont’d)
H Military Spec MIL--I--81969/14

Rev E 5 of 17
 408- 7516

CONTACT WIRE TOOL

Size Strip SELECTOR
Product Line Size Pin Socket Military Spec SETTING
(AWG) Length

24 2
203840 — — 22 4.78 [.188]
[ ] 3
20 4
Type XV 20
24 2
For ARINC
Front Release — 203841 — 22 4.78 [.188]
[ ] 3
AM AD,
AM, AD andd
20 4
AAP Connectors
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
26 3
22
— 205103 MIL--C--39029/12--148 24 3.96 [.156]
[ ] 3
22 4
30 4
— 205904 — 3 96 [.156]
3.96 [ 156]
28 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 22 3.96 [.156]
[ ] 6
For ARINC — — MIL C 39029/12 149
MIL--C--39029/12--149
20 7
Rear Release
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
16 6
16
20 4
— 205117 MIL--C--39029/12--150 18 6.35 [.250]
[ ] 5
16 6
14 7
205763 5
205763--5 — — 6 35 [.250]
6.35 [ 250]
12 8
12
14 7
— 205851 2
205851--2 — 6 35 [.250]
6.35 [ 250]
12 8
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 INSERTION EXTRACTION
Positioner or Hand Crimping Military Spec TOOL TOOL
Machine Funnel
Turret Head 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

--601966--8
601966 8 601966 1
601966--1 599406 7
599406--7 1 125905 2
1--125905--2 — 91066 1
91066--1 91066 1
91066--1

125905--1
--601966--5 601966--1 599406--7 (
(Max Insulation MIL--C--81659 91067--2 91067--2
Di 1.98
Dia 1 98 [.078])
[ 078])

125905--1
--601966--5 601966--1 599406--7 (
(Max Insulation — 91067--2 91067--2
Di 1.98
Dia 1 98 [.078])
[ 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

--601967--2
601967 2 601967 1
601967--1 — — MIL C 81659
MIL--C--81659 — 445147 1
445147--1

--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 WIRE TOOL

Size (AWG, Strip SELECTOR
Product Line Size Pin Socket Military Spec SETTING
See Note) Length
0 — 51781--1 — RG 214/U — —
Semi--Rigid 
225837--1 — — 8
141 (408--2348--02)
1

— 225831--1 — RG 214/U —
(408--2348--02)
RG 141/U, 
226053--1 — — 8
58C/U (408--2348--01)
RG 214/U, 
3 — 225792--1 — —
213/U (408--2348--01)
RG 58C/U, 
— 225792--3 — 8
141A/U (408--2348--01)
RG 58C/U, 
COAXICON* 225790--1 225791--1 — 5
141/U (408--2348)
Contact For
ARINC Coaxial RG 233/U, 
225790--2 225791--2 — 5
Connectors 142/U (408--2348)
5
Semi--Rigid 
225790--3 — — 5
141 (408--2348)
— — 
225790--4 RG 180B/U 5
(408--2348)
— —
225796--1 RG 58C/U 5

7
— (408--2348--01)
225796--2 — RG 233/U 5

RG 58C/U, 
225935--1 — — 5
141A/U (408--2348--03)
9
Semi--Rigid 
— 225936--1 — 5
141 (408--2348--03)
26 3
208262 — — 24 3.96 [.156]
[ ] 3
22 4
22
26 3
— 208264 — 24 3.96 [.156]
[ ] 3
22 4
ARINC 600
24 5
208265 — — 22 3.96 [.156]
[ ] 6
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

8 of 17 Rev E
 408- 7516

Tooling for Loose Piece Contacts Tooling for Tape Mounted Contacts
CONNECTOR INSERTION EXTRACTION
Positioner or Hand Crimping Military Spec TOOL TOOL
Machine Funnel
Turret Head Tool
— 69646 — — — — 91040--7
601966--1 and
— — — — — —
220066--1
—
220015--1 — — — — —

601966--1 and
1--601966--8 — — — — —
220066--1
—
220015--1 — — — — —

601966--1 and
— — — — — —
220066--1
601966--1 and
1--601966--6 — — — — 91074--1
220066--1
601966--1 and — — — — 91074--1
1--601966--6
220066--1
601966--1 and — — — — 91074--1
1--601966--6
220066--1
601966--1 and
1--601966--6 — — — — 91074--1
220066--1
601966--1 and
2--601966--6 — — — — —
220066--1
601966--1 and — — — — —
1--601966--6
220066--1
601966--1 and
1--601966--6 — — — — 91074--1
220066--1
601966--1 and
1--601966--6 — — — — 91074--1
220066--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

125905--1
601966--5 601966--1 599406--7 (
(Max Insulation — 91067--2 91067--2
Di 1.98
Dia 1 98 [.078])
[ 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 WIRE TOOL

Size (AWG, Strip SELECTOR
Product Line Size Pin Socket Military Spec SETTING
See Note) Length
204978 — — 20 4
208268 — — 18 6.35 [.250]
[ ] 5
213122 — — 16 6
16
20 4
— 208270 — 18 6.35 [.250]
[ ] 5
ARINC 600
16 6
208271 — — 14 7
6 35 [.250]
6.35 [ 250]
213123 — — 12 8
12
14 7
— 208273 — 6 35 [.250]
6.35 [ 250]
12 8
MIL C 39029 95 and
MIL--C--39029--95
TRIAXIAL 8 222190 222191 — — —
MIL--C--39029--96
28 3
206496 — — 3 96 [.156]
3.96 [ 156]
26 4
28 3
— 206496 — 3 96 [.156]
3.96 [ 156]
26 4
28 1
26 2
204370 — MIL C 39029/58 360
MIL--C--39029/58--360 3 96 [.156]
3.96 [ 156]
24 3
22 4
22D
28 1
26 2
Type XVII — 204351 MIL C 39029/57 354
MIL--C--39029/57--354 3 96 [.156]
3.96 [ 156]
For AMPLIMITE* 24 3
HDD CConnectors
t
22 4
28 1
26 2
— 206071 — 3 96 [.156]
3.96 [ 156]
24 3
22 4
28 5
206794 206795 — 3 96 [.156]
3.96 [ 156]
26 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

10 of 17 Rev E
 408- 7516

Tooling for Loose Piece Contacts Tooling for Tape Mounted Contacts
CONNECTOR INSERTION EXTRACTION
Positioner or Hand Crimping Military Spec TOOL TOOL
Machine Funnel
Turret Head 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 E 11 of 17
 408- 7516

CONTACT WIRE TOOL

Size Strip SELECTOR
Product Line SIZE Pin Socket Military Spec SETTING
(AWG) Length
24 5
— 205090 MIL--C--39029/63--368 22 3.56 [.140]
[ ] 6
20 7
Type XVII 18 7
For AMPLIMITE 20 1218266 1
1218266--1 1218267 1
1218267--1 — 3 56 [.140]
3.56 [ 140]
HDD Connectors 18 7
24 5
— 206793 — 22 3.56 [.140]
[ ] 6
20 7
211159--1 211161--1 — 8 7
9 53 [.375]
9.53 [ 375]
211159--2 211161--2 — 10 6
12 1
212007 1
212007--1 212008 1
212008--1 — 9 53 [.375]
9.53 [ 375]
AMPLIMITE 14 1
8
Power 8 Contact 16 8
212013 1
212013--1 212014 1
212014--1 — 9 53 [.375]
9.53 [ 375]
18 6
8 7
213552 — — 9 53 [.375]
9.53 [ 375]
10 6
28 1
26 2
— 204351 1
204351--1 MIL C 39029/57 354
MIL--C--39029/57--354 3 96 [.156]
3.96 [ 156]
24 3
22 4
22
28 4
3 18 [.125]
3.18 [ 125]
861211 or 26 5
— —
863260 24 5
22 6
LGH* Contact 3 96 [.156]
3.96 [ 156]
24 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
22 (2) 6
— 861080 — 4 78 [.188]
4.78 [ 188]
16 7
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 INSERTION EXTRACTION
Positioner or Hand Crimping Military Spec TOOL TOOL
Machine Funnel
Turret Head 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

H H
H—H 601967 1
601967--1 — — — 91066 3
91066--3 91066 3
91066--3

Figure 3 (End)
H Military Spec MIL--C--22520/1--05

Rev E 13 of 17
 408- 7516

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 The tool handles must be fully opened when
CAUTION
Refer to Figure 4, and proceed as follows: changing the positioner selector setting;

1. Squeeze the tool handles together, then allow

! otherwise, damage to the tool will occur.

the handles to FULLY open.

3.2. Installing Turret Head
CAUTION The tool handles must be fully opened when Refer to Figure 5, and proceed as follows:
installing the positioner; otherwise, damage to
1. Squeeze the tool handles together, then allow
! the tool will occur.
the handles to FULLY open.
CAUTION The tool handles must be fully opened when
2. Insert the post of the positioner into the hole in installing the positioner; otherwise, damage to
the back of the tool. Make sure that the bayonet
pin enters the slot in the retainer ring of the tool. ! the tool will occur.

2. Depress the turret trigger to release the turret

from the index position (the turret should be
Installing Positioner
extended).
Outer Bayonet
Rim Pin
Installing Turret Head

Post Positioner
Turret Trigger
Retainer Ring Turret in Locked
(Hidden) Position
Safety Back of
Data Clip Positioner Turret Head
Plate Installed
Selector Knob Data
and Dial Plate
Turret
Extended Socket Head Cap
Ratchet Index Screw (2 Places)
Mark

Retainer Ring
(Hidden) Turret Head
Back of Tool Installed

Selector Knob
and Dial
Tool Handles

Figure 4

3. Firmly grip the outer rim of the positioner and

Back of Tool
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. 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 5. MAINTENANCE AND INSPECTION
retainer ring on the back of the tool. Make sure that
the turret head is seated, then tighten the two 5.1. Daily Maintenance
socket head cap screws of the turret head. Each operator should be aware of, and responsible
for, the following steps of daily maintenance, to
4. Rotate the turret until the positioner marked with ensure continuous quality and reliability of each tool.
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
5. Press the turret until it is in the locked position. use objects that could damage the tool.
6. Determine the selector setting according to the 2. When the tool is not in use, keep the handles
contact size and wire size listed in Figure 3. Pull closed, and store the tool in a clean, dry area.
the selector knob and turn to the proper setting.
5.2. Gaging the Die Opening (Indenters)
CAUTION The tool handles must be fully opened when This inspection requires the use of a plug gage
changing the positioner selector setting; conforming to the dimensions provided in Figure 7.
! otherwise, damage to the tool will occur. 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
NOTE These tools have a ratchet which ensures proper and plug gage.
crimping of the contacts. Once engaged, the 2. Fully close tool handles; then hold in this
i ratchet will NOT release until the tool handles are
FULLY closed.
position. DO NOT force beyond initial contact.
3. Insert GO element into the die opening; but do
1. Strip the wire according to the wire size listed in not force it. The GO element must pass through
Figure 3. the length of the die opening. See Figure 9.

2. Squeeze the tool handles together, then allow 4. In the same manner, try to insert the NO--GO
the handles to FULLY open. element into the die opening. The NO--GO element
may enter partially, but must not pass completely
3. Insert the mating end of the contact into the through the length of the die opening. See
indenter from the FRONT of the tool until the Figure 9.
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,
Mating End the tool may be considered dimensionally correct and
of Contact 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.
Nameplate For additional information regarding the use of a plug
(Ref) gage, refer to 408--7424.

5.3. Crimp Height Inspection

Front of Tool
NOTE Allowances for tool stresses and relaxation of
Figure 6 contact material were calculated into the crimp
i height measurements for military specified
contacts only.
4. Insert the wire into the contact wire barrel. While
holding the wire in place, squeeze the tool handles This inspection requires the use of a micrometer, or
until the ratchet releases. Allow the handles to equivalent, as shown in Figure 10. It is recommended
open. using the micrometer (Dial Micrometer 27--9) which
may be purchased from:
5. Remove the crimped contact from the tool.
B.C. Ames Company
Inspect the contact according to the applicable Lexington Street
application specification (114--series). Waltham, MA 02154

Rev E 15 of 17
 408- 7516

Suggested Plug Gage Design Gaging the Die Opening

GO Dia NO-- GO Dia Die
Opening

6.35 [.250] Min Typ

GO NO-- GO
TOOL GAGE ELEMENT Element Element
TOOL DIAMETER +0.003 [.0001]
SELECTOR GO element must pass NO-- GO element may enter
(Military Spec) SETTING GO NO-- GO completely through the die partially, but must not pass
1 0.33 [.013] 0.46 [.018] opening. completely through the die
2 0.41 [.016] 0.53 [.021] opening.
3 0.48 [.019] 0.61 [.024]
Figure 9
601966--11
601966 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] To inspect the crimp height, proceed as follows:
D8S D0.99 [.039]S D1.12 [.044]S 1. Crimp the contact according to Section 3,
1 1.78 [.070] 2.03 [.080] CRIMPING PROCEDURE.
2 1.91 [.075] 2.16 [.085] 2. Measure across opposite indents in the contact,
3 2.03 [.080] 2.29 [.090] then rotate the contact 90 degrees, and measure
again. See Figure 10. DO NOT go beyond initial
D4S D2.16 [.085]S D2.41 [.095]S contact as this could cause a depression and result
608651 1
608651--1
5 2.34 [.092] 2.59 [.102] in an inaccurate reading.
6 2.51 [.099] 2.77 [.109]
7 2.74 [.108] 3.00 [.118] Crimp Height Inspection
8 3.00 [.118] 3.25 [.128]
1 0.71 [.028] 0.84 [.033]
Crimped
2 0.81 [.032] 0.94 [.037] Contact
3 0.91 [.036] 1.04 [.041]
601967--1 D4S D0.99 [.039]S D1.12 [.044]S
(MIL - C
(MIL- C-- 22520/1
22520/1-- 01)
and 608668--1
608668--1 5 1.14 [.045] 1.27 [.050] Crimp
6 1.32 [.052] 1.45 [.057] Height
7 1.50 [.059] 1.63 [.064]
CRIMP HEIGHT
8 1.73 [.068] 1.85 [.073] TOOL
SELECTOR TOOL 601966-- 1 TOOL 601967-- 1
S Use for periodic general inspection. The plug gages listed in SETTING Military Spec Military Spec
Figure 8 conform to these gage element diameters. MIL-- C-- 22520/2-- 01 MIL-- C-- 22520/1-- 01
Figure 7 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]
For Periodic General Inspection
3 0.559--0.686 [.022--.027] 1.016--1.143 [.040--.045]
TOOL
PLUG GAGE 4 0.635--0.762 [.025--.030] 1.092--1.219 [.043--.048]
TOOL SELECTOR
(Military Spec)
SETTING
5 0.737--0.864 [.029--.034] 1.245--1.372 [.049--.054]
601966--1 8
601968 1
601968--1 6 0.838--0.965 [.033--.038] 1.422--1.549 [.056--.061]
601967--1 4
(MIL--C--22520/3--01) 7 0.940--1.067 [.037--.042] 1.600--1.727 [.063--.068]
608668--1 4
608651--1 4 601968--3 8 1.067--1.194 [.042--.047] 1.829--1.956 [.072--.077]

Figure 8 Figure 10

16 of 17 Rev E
 408- 7516

3. Check the height of the crimped contact against 7. REVISION SUMMARY

the crimp height dimensions shown in Figure 10. If
the crimp height conforms to that shown, the tool is
S Updated document to corporate requirements.
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.

Rev E 17 of 17