Instruction Sheet Application Tooling for Screw-Machine Contacts 408-7516 14 FEB 18 Rev F 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. 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. NOTE Read these instructions thoroughly before making any selections. NOTE 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). 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.  Refer to Figure 3 for proper contact and tooling combination. Note: Read the chart from the left page across to the right page. © 2018 TE Connectivity Ltd. family of companies. PRODUCT INFORMATION 1-800-522-6752 This controlled document is subject to change. 1 of 19 All Rights Reserved. For latest revision and Regional Customer Service, *Trademark visit our website at www.te.com. TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and/or company names may be trademarks of their respective owners. 408-7516 Part Description Military Spec Number 601966 1 MIL C 22520/2 01 601967 1 MIL C 22520/1 01 4/8 Indent Hand 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 or Turret Head 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 MIL I 81969/1 01 or MS3156 22 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 58284 1 MIL C 81969/28 03 Extraction Tool 91074 1 MIL C 81969/28 01 or MS3178 001 Figure 2 2 of 19 Rev F 408-7516 Figure 3 (cont’d) 3 of 19 Rev F 408-7516 Figure 3 (cont’d) 4 of 19 Rev F 408-7516 Figure 3 (cont’d) 5 of 19 Rev F 408-7516 Figure 3 (cont’d) 6 of 19 Rev F 408-7516 Figure 3 (cont’d) 7 of 19 Rev F 408-7516 Figure 3 (cont’d) 8 of 19 Rev F 408-7516 Figure 3 (cont’d) 9 of 19 Rev F 408-7516 Figure 3 (cont’d) 10 of 19 Rev F 408-7516 Figure 3 (cont’d) 11 of 19 Rev F 408-7516 Figure 3 (cont’d) 12 of 19 Rev F 408-7516 Figure 3 (cont’d) 13 of 19 Rev F 408-7516 Figure 3 (End) 14 of 19 Rev F 408-7516 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. 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. Note: Make sure the bayonet pin enters the slot in the retainer ring of the tool. 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. 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. CAUTION 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. 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). 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. 15 of 19 Rev F 408-7516 Figure 5 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. 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 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 (see Figure 6). Figure 6 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 114 Series Application Specification. 16 of 19 Rev F 408-7516 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 specified in Figure 7. For plug gages used for periodic general inspection, see Figure 8. Figure 7 17 of 19 Rev F 408-7516 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). 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). NOTE 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 Instruction Sheet 408-7424. 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) TE CONNECTIVITY CORPORATION PO BOX 3608 HARRISBURG PA 17105-3608 For customer repair service, contact a TE Representative at 1-800-526-5136. 18 of 19 Rev F 408-7516 7. REVISION SUMMARY  Updated format, logo and enterprise name  Moved some figures due to formatting changes  Figure 10 removed  Section 5.3. removed 19 of 19 Rev F