408-9404 TEC | Alldatasheet

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1 of 6©20113 Tyco Electronics Corporation, a TE Connectivity Ltd. Company All Rights Reserved TE logo is a trademark. *Trademark. Other products, logos, and company names might be trademarks of their respective owners. Instruction Sheet TOOLING ASSISTANCE CENTER 1-800-722-1111 PRODUCT INFORMATION 1-800-522-6752 This controlled document is subject to change. For latest revision and Regional Customer Service, visit our website at www.te.com LOC B Insertion/Extraction Tool 91285-1 and Replacement Tip Kits 543382-[ ] 408-9404

26 MAR 13 Rev D

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. Figure 1 1. INTRODUCTION This instruction sheet covers the use of Insertion/ Extraction Tool 91285-1 and Replacement Tip Kits 543382 shown in Figure 1. The tool is designed to insert and extract HD-22 and HD-20 contacts used in AMPLIMITE* High Density (HD) Connectors. For information concerning the assembly of AMPLIMITE HD connectors, refer to the instruction sheet packaged with the connector. Read these instructions thoroughly before using the tool. See Section 6, REVISION SUMMARY, for revision information. NOTE All dimensions on this document are in metric units [with U.S. customary units in brackets]. Figures and illustrations are for reference only and are not drawn to scale. 2. DESCRIPTION (Figure 1) The insertion/extraction tool consists of a handle, a cap, six insertion/extraction tips, a plug, and a [.050 in.] hex wrench. The handle of the tool provides storage for the tips, plug, and hex wrench. The insertion/extraction tips convert the tool for the appropriate product and are used to insert or extract connector contacts. Each tip is color coded according to specific type and wire size. The plug is inserted into the widest end of the tip to prevent damage to the tip when it is secured in the tool handle. The hex wrench is used to tighten the setscrew which secures the tip in the tool handle. [.050 In.] Hex Wrench Insertion/Extraction Handle Plug Insertion/Extraction Tips Cap CONTACT SIZE WIRE SIZE (AWG) INSERTION/EXTRACTION TIPS COLOR CODE TYPE PART NUMBER HD-20 28-20 Yellow Insertion 543382-5 HD-20 24-18 Red Extraction 1-543382-0 HD-20 28-24 Brown Extraction 1-543382-1 HD-20 Posted Blue Extraction 543382-6 HD-20 Posted Black Insertion 543382-7 HD-22 28-22 Green Insertion/Extraction 543382-8 NOTE i

  1. Slide thumb over the wire toward the end of the tip. NOTE The wire must be positioned inside the wire slot of the tip. 3. Slide tip over contact wire barrel until the tip butts against the contact shoulder. 4. Align contact with the BACK of the contact cavity. Push contact straight into the contact cavity until the contact bottoms. 5. Remove the insertion tool; then pull back on the wire to ensure that the contact is locked into the contact cavity. 4.2. Extracting A Wire Crimped Contact (Figure 4) 1. Position tool handle between thumb and fingertips, and align contact wire with the wire slot on the tip. Hold wire in this position with your thumb. 2. Slide your thumb over the wire toward the end of the insertion tip. NOTE The wire must be positioned inside the wire slot of the tip. 3. Place tip over the contact post or crimp barrel and slide the tip straight into the contact cavity until the tip bottoms against the contact shoulder. 4. Holding the wire tight against the tool handle, pull back on the tool handle to extract the contact. If you experience difficulty in extracting the contact, repeat Steps 1 through 4. 4.3. Inserting A Posted Contact (Figure 5) 1. Place the contact in the contact cavity. Do NOT push on the contact post. 2. Position the tip over the contact post. Move the tool along the post until the tip butts against the contact stabilizer. Align the tip on the stabilizer as shown in Figure 5. 3. Hold the tool handle, and push the contact post to make certain that the contact is locked in the cavity. NOTE Contacts with tail lengths longer than 10.85 mm [.427 in.] must use yellow color coded insertion tips. Figure 4 NOTE i NOTE i NOTE i Back of Receptacle Connector 205439-1 (Ref) Wire SlotSlide Extraction Tip Over Contact Post or Crimp Barrel Extraction Handle Wire

1.02 [.040] Pin Dia. Back of Connector Contact Post Extraction Tip Groove of Extraction Tip Aligned with Contact Stabilizer

REPLACEMENT PARTS† ITEM COLOR CODE PART NUMBER DESCRIPTION

1 Yellow 543382-5 TIP, Insertion

2 Blue 543382-6 TIP, Extraction

3 Black 543382-7 TIP, Insertion

4 Green 543382-8 TIP, Insertion/Extraction

5 Red 1-543382-0 TIP, Extraction

6 Brown 1-543382-1 TIP, Extraction

7 ----- 2-21006-0 SCREW, Set No. 4-40 X .180 Lg. † Available in packs of 25 only (one plug included in each packet).