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Application Tooling for 408- -7516 LOC B 1 of 17E2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company All Rights Reserved TE logo is a trademark. *Trademark. Other product names, logos, or company names might be trademarks of their respective owners. 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 atwww.te.com

10 Mar 11 Rev EScrew- Machine Contacts

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 AMP- -TAPETRONIC* 4/8 Indent Stripper Terminator 599406- -[ ] (Requires Funnel) Tooling for Loose-Piece Contacts 4/8- -Indent Hand Crimping Tool (Typ, Requires Positioner or Turret Head) Tooling for Tape Mounted Contacts Extraction Tool (Typ) Insertion/Extraction Tool (Typ) 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. Read these instructions thoroughly before making any selections. 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. 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. Description Part Number Military Spec 4/8 I d H d 4/8- -Indent Hand Crimping Tool 601967- -1 MIL- -C- -22520/1- -01Crimping Tool P i i Positioner or Turret Head 601966- -6 MIL- -C- -22520/2- -09Turret Head or MS3156- -22 Insertion/Extraction Insertion/Extraction Tool 91067- -2 MIL- -I- -81969/1- -02 or MS3156- -20 or MS3156- -16 Extraction Tool 58284- -1 MIL- -C- -81969/28- -03Extraction Tool or MS3178- -001 Figure 2 Refer to Figure 3 for proper contact and tooling combination. Read the chart from the left page across to the right page. NOTE i

Product Line Size Pin Socket Military Spec Size (AWG) Strip Length TOOL SELECTOR SETTING 28 2 201607 201609 — 26 5.16 [.203] 2 [ ] 28 2 — 201353 — 26 5.16 [.203] 2 [ ] 24 1 201582 201584- -6 — 22 5.16 [.203] 2 [ ] 24 1 200334 200331 — 22 5.16 [.203] 2 [ ] 201589 6 35 [ 250] — 201589 — 16 6.35 [.250] 5 201554 5 16 [ 203] — 201554 — 30 5.16 [.203] 1 201334 — — 28 2 Type II Contact For Multimate 201332 26 5.16 [.203] 2 For Multimate Connectors — 201332 — 24 [ ] 3Connectors 201611 — — 28 2 201613 26 5.16 [.203] 2 — 201613 — 24 [ ] 201578 — — 22 5 16 [ 203] — 201580 — 20 5.16 [.203] 3 200679 201328 — 24 1 201330 — 22 5.16 [.203] 2 204188 — — 20 [ ] 200681 200333 6 35 [ 250] 200681 200333 — 6.35 [.250] 516 [ ] 202507 — — 18 4 — 202508 — 16 5 200336 200333 18 6.35 [.250] 4 200336 200333 — 16 [ ] 201570 201568 — 14 5 201555 — — 32 5 16 [ 203] — 201554 — 30 5.16 [.203] 1 Figure 3 (Cont’d)

Tooling for Loose Piece Contacts Tooling for Tape Mounted Contacts CONNECTOR INSERTION EXTRACTIONPositioner or Turret Head Hand Crimping Tool Machine Funnel CONNECTOR Military Spec INSERTION TOOL EXTRACTION TOOL 1- -601967- -5 58305- -1 or 601967--1 — — — 200893- -2 or 91002--1 305183601967--1 91002--1 1- -601967- -5 58305- -1 or 601967--1 — — — 200893- -2 or 91002--1 305183601967--1 91002--1 1- -601967- -5 58305- -1 or 601967--1 — — — 200893- -2 or 91002--1 305183601967--1 91002--1 1- -601967- -5 58305- -1 or 601967--1 — — — 200893- -2 or 91002--1 305183601967--1 91002--1 1 601967 6 45098 or 200893- -2 or 3051831- -601967- -6 45098 or 601967- -1 — — — 200893 2 or 91002- -1 305183 1 601967 5 58305- -1 or 200893- -2 or 3051831- -601967- -5 58305 1 or 601967- -1 — — — 200893 2 or 91002- -1 305183 1- -601967- -6 1 601967 5 58305- -1 or 601967--1 — — — 200893- -2 or 91002--1 305183 1- -601967- -5 601967--1 91002--1 1- -601967- -6 1 601967 5 58305- -1 or 601967--1 — — — 200893- -2 or 91002--1 305183 1- -601967- -5 601967--1 91002--1 1- -601967- -6 58305- -1 or 200893- -2 or 3051831- -601967- -5 58305 1 or 601967- -1 — — — 200893 2 or 91002- -1 305183 1- -601967- -5 1 601967 6 58305- -1 or 601967--1 — — — 200893- -2 or 91002--1 305183 1- -601967- -6 601967--1 91002--1 1 601967 6 45098 or 200893- -2 or 3051831- -601967- -6 45098 or 601967--1 — — — 200893 2 or 91002--1 305183601967--1 91002--1 1- -601967- -6 90136- -1 or 200893- -2 or 3051831- -601967- -5 90136 1 or 601967- -1 — — — 200893 2 or 91002- -1 305183 200893- -2 or 1- -601967- -6 45098 or 601967--1 — — — 200893 2 or 91002- -1 305183601967--1 1- -601967- -6 58305- -1 or 200893- -2 or 3051831- -601967- -5 58305 1 or 601967- -1 — — — 200893 2 or 91002- -1 305183 Figure 3 (Cont’d)

Product Line Size Pin Socket Military Spec Size (AWG) Strip Length TOOL SELECTOR SETTING 28 2 — 201609 — 26 5.16 [.203] 2 [ ] 201332 5 16 [ 203] — 201332 — 24 5.16 [.203] 3 24 1 200679 201328 — 22 5.16 [.203] 2 [ ] Type II Contact For Multimate 16 200681 200333 — 18 5 16 [ 203] 4For Multimate Connectors 200336 — — 16 5.16 [.203] 5 204274 — — 18 4 202507 — — 18 5.16 [.203] 4 204219 202508 — 16 [ ] 202725 202726 — 18 5.16 [.203] 5 201570 — — 5 201645 — — 14 5.16 [.203] 5 — 201568 — [ ] 32 1 202123 202124 30 3 18 [ 125] 202123 202124 — 28 3.18 [.125] 2 Type VII Contact For Subminiature 22 26 2 For Subminiature Connectors 30 1Connectors 204092 3 18 [ 125] 204092 — — 26 3.18 [.125] 3 24 4 Type XIII Contact 24 5ype Co tact For Terminal Junction (TJG) 20 203669- -4 — — 22 4.78 [.188] 6Junction (TJG) Modules 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.

Tooling for Loose Piece Contacts Tooling for Tape Mounted Contacts CONNECTOR INSERTION EXTRACTIONPositioner or Turret Head Hand Crimping Tool Machine Funnel CONNECTOR Military Spec INSERTION TOOL EXTRACTION TOOL 1- -601967- -5 58305- -1 or 601967--1 — — — 200893- -2 or 91002--1 305183601967--1 91002--1 1 601967 5 58305- -1 or 200893- -2 or 3051831- -601967- -5 58305 1 or 601967- -1 — — — 200893 2 or 91002- -1 305183 1- -601967- -5 58305- -1 or 601967--1 — — — 200893- -2 or 91002--1 305183601967--1 91002--1 1 601967 6 45098 or 200893- -2 or 3051831- -601967- -6 45098 or 601967- -1 — — — 200893 2 or 91002- -1 305183 1 601967 61- -601967- -6 45098 or 601967--1 200893 2 or1- -601967- -5 601967--1 — — — 200893- -2 or 91002- -1 305183 1- -601967- -6 45098 or 601967- -1 91002 1 1 601967 61- -601967- -6 45098 or 601967--1 — — — 200893- -2 or 91002--1 305183 1- -601967- -5 601967--1 91002--1 1 601966 0 601966 1 599406 7 1 125905 1 91005 2 91004 21- -601966- -0 601966- -1 599406- -7 1- -125905- -1 — 91005- -2 91004- -2 1 601966 0 601966 1 599406 71- -601966- -0 601966- -1 599406- -7 — — — — --601966- -2 601966- -1 599406- -7 — — H— H H— H Figure 3 (Cont’d) H Military Spec MIL- -I- -81969/14

Product Line Size Pin Socket Military Spec Size (AWG) Strip Length TOOL SELECTOR SETTING 24 2 203840 — — 22 4.78 [.188] 3 [ ] Type XV For ARINC 20 24 2For ARINC Front Release AM AD d — 203841 — 22 4.78 [.188] 3 AM, AD, and AAP Connectors 20 [ ] 4AAP Connectors 20 4 16 203884 — — 18 6.35 [.250] 5 [ ] 26 3 204873 — MIL- -C- -39029/11- -144 24 3.96 [.156] 3 [ ] 26 3 — 205103 MIL- -C- -39029/12- -148 24 3.96 [.156] 3 [ ] 205904 30 3 96 [ 156] — 205904 — 28 3.96 [.156] 5 24 5 204938 — MIL- -C- -39029/11- -145 22 3.96 [.156] 6 [ ] — 205116 MIL- -C- -39029/12- -149 24 5 Type XVII 20 MIL C 39029/12 149 22 3.96 [.156] 6Type XVII For ARINC Rear Release [ ] 7Rear Release RM Connectors 30 4 205791 206887 — 28 3.96 [.156] 5 [ ] 20 4 204978 — MIL- -C- -39029/11- -146 18 6.35 [.250] 5 [ ] 16 20 4 — 205117 MIL- -C- -39029/12- -150 18 6.35 [.250] 5 [ ] 205763 5 6 35 [ 250] 205851 2 6 35 [ 250] Figure 3 (Cont’d)  This wire size is not recommended for use in the machine.

Tooling For Loose Piece ContactsTooling For Tape Mounted Contacts CONNECTOR INSERTION EXTRACTIONPositioner or Turret Head Hand Crimping Tool Machine Funnel CONNECTOR Military Spec INSERTION TOOL EXTRACTION 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 1 599406 7 1 125905 2 91066 1 91066 1--601966- -8 601966- -1 599406- -7 1- -125905- -2 — 91066- -1 91066- -1 125905--1 --601966- -5 601966- -1 599406- -7 125905--1 (Max Insulation Di 1 98 [ 078]) MIL- -C- -81659 91067- -2 91067- -2( Dia 1.98 [.078]) 125905--1 --601966- -5 601966- -1 599406- -7 125905--1 (Max Insulation Di 1 98 [ 078]) Dia 1.98 [.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 1 MIL C 81659 445147 1--601967- -2 601967- -1 — — MIL- -C- -81659 — 445147- -1 601967 2 601967 1 MIL C 81659 445147 1--601967- -2 601967- -1 — — MIL- -C- -81659 — 445147- -1 Figure 3 (Cont’d)

Product Line Size Pin Socket Military Spec Size (AWG, See Note) Strip Length TOOL SELECTOR SETTING 0 — 51781- -1 — RG 214/U — — 225837- -1 — — Semi- -Rigid 141 — 225831- -1 — RG 214/U  226053- -1 — — RG 141/U, 58C/U 3 — 225792- -1 — RG 214/U, 213/U — 225792- -3 — RG 58C/U, 141A/U COAXICON* Contact For 225790- -1 225791- -1 — RG 58C/U, 141/U (408- -2348) 5 Contact For ARINC Coaxial Connectors 5 225790- -2 225791- -2 — RG 233/U, 142/U (408- -2348) 5 Connectors 5 225790- -3 — — Semi- -Rigid 141 (408- -2348) 5 225790- -4 — — RG 180B/U  (408- -2348) 5 — 225796- -1 — RG 58C/U 7 — 225796- -2 — RG 233/U (408- -2348- -01) 225935- -1 — — RG 58C/U, 141A/U — 225936- -1 — Semi- -Rigid 141 26 3 208262 — — 24 3.96 [.156] 3 [ ] 22 26 3 — 208264 — 24 3.96 [.156] 3 ARINC 600 [ ] ARINC 600 24 5 208265 — — 22 3.96 [.156] 6 [ ] 20 24 5 — 208267 — 22 3.96 [.156] 6 [ ] Figure 3 (Cont’d)  Refer to the instruction sheet (408- -series) packaged with the contact for wire strip length. Note: Unless otherwise specified

Tooling for Loose Piece Contacts Tooling for Tape Mounted Contacts CONNECTOR INSERTION EXTRACTIONPositioner or Turret Head Hand Crimping Tool Machine Funnel CONNECTOR Military Spec INSERTION TOOL EXTRACTION TOOL — 601966- -1and — 601966- -1and 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 125905--1 (Max Insulation Di 1 98 [ 078]) 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

Product Line Size Pin Socket Military Spec Size (AWG, See Note) Strip Length TOOL SELECTOR SETTING 204978 — — 20 4 208268 — — 18 6.35 [.250] 5 213122 — — 16 [ ] 16 20 4 ARINC 600 — 208270 — 18 6.35 [.250] 5 ARINC 600 16 [ ] 208271 — — 14 6 35 [ 250] 213123 — — 12 6.35 [.250] 8 208273 6 35 [ 250] — 208273 — 12 6.35 [.250] 8 TRIAXIAL 8 222190 222191 MIL- -C- -39029- -95 andTRIAXIAL8 222190 222191 MIL C 39029 95 and 206496 3 96 [ 156] 206496 — — 26 3.96 [.156] 4 206496 3 96 [ 156] — 206496 — 26 3.96 [.156] 4 28 1

204370 MIL C 39029/58 360

3 96 [ 156] 204370 — MIL- -C- -39029/58- -360 24 3.96 [.156] 3 22D 22 4 22D 28 1 Type XVII 204351 MIL C 39029/57 354 3 96 [ 156] 2Type XVII For AMPLIMITE* HDD C t — 204351 MIL- -C- -39029/57- -354 24 3.96 [.156] 3 HDD Connectors 22 4 28 1 206071 3 96 [ 156] — 206071 — 24 3.96 [.156] 3 22 4 206794 206795 3 96 [ 156] 206794 206795 — 26 3.96 [.156] 6 20 24 5 205089 — MIL- -C- -39029/64- -369 22 3.56 [.140] 6 [ ] Figure 3 (Cont’d) Note: Unless otherwise specified

Tooling for Loose Piece Contacts Tooling for Tape Mounted Contacts CONNECTOR INSERTION EXTRACTIONPositioner or Turret Head Hand Crimping Tool Machine Funnel CONNECTOR Military Spec INSERTION TOOL EXTRACTION 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 601967 1 445147 11- -601967- -2 601967- -1 — — — — 445147- -1 1 601967 2 601967 1 445147 11- -601967- -2 601967- -1 — — — — 445147- -1 — 608650 1 — — MIL C 83527 — 58284 1608650- -1 MIL- -C- -83527 58284- -1 601966 6 601966 1 599406 7 125905 2 91067 1 91067 1601966- -6 601966- -1 599406- -7 125905- -2 — 91067- -1 91067- -1 601966 4 601966 1 599406 7 125905 2 91067 1 91067 1601966- -4 601966- -1 599406- -7 125905- -2 — 91067- -1 91067- -1 601966 6 601966 1 599406 7 125905 2 MIL C 24308 91067 1 91067 1601966- -6 601966- -1 599406- -7 125905- -2 MIL- -C- -24308 91067- -1 91067- -1 601966 4 601966 1 599406 7 125905 2 MIL C 24308 91067 1 91067 1601966- -4 601966- -1 599406- -7 125905- -2 MIL- -C- -24308 91067- -1 91067- -1 601966 4 601966 1 599406 7 125905 2 91067 1 91067 1601966- -4 601966- -1 599406- -7 125905- -2 — 91067- -1 91067- -1 601966 5 601966 1 599406 7 91067 2 91067 2601966- -5 601966- -1 599406- -7 — — 91067- -2 91067- -2 601966- -5 601966- -1 599406- -7 125905- -1 MIL- -C- -24308 91067- -2 91067- -2 Figure 3 (Cont’d)

Product Line SIZE Pin Socket Military Spec Size (AWG) Strip Length TOOL SELECTOR SETTING 24 5 — 205090 MIL- -C- -39029/63- -368 22 3.56 [.140] 6 [ ] Type XVII For AMPLIMITE 20 1218266 1 1218267 1 18 3 56 [ 140] For AMPLIMITE HDD Connectors 20 1218266- -1 1218267- -1 — 18 3.56 [.140] 7HDD Connectors 24 5 — 206793 — 22 3.56 [.140] 6 [ ] 211159- -1 211161- -1 — 8 9 53 [ 375] 211159- -2 211161- -2 — 10 9.53 [.375] 6 212007 1 212008 1 9 53 [ 375] AMPLIMITE 8 212007- -1 212008- -1 — 14 9.53 [.375] 1AMPLIMITE Power 8 Contact 8 212013 1 212014 1 9 53 [ 375] 212013- -1 212014- -1 — 18 9.53 [.375] 6 213552 9 53 [ 375] 213552 — — 10 9.53 [.375] 6 28 1 204351 1 MIL C 39029/57 354 3 96 [ 156] 22 4 22 28 3 18 [ 125] 861211 or 26 3.18 [.125] 5861211 or 863260 — — 24 5 LGH* Contact 3 96 [ 156] LGH* Contact 24 3.96 [.156] 5 — 867782 — — 22 6 20 6.35 [.250] 7 20 4 — 867328 MIL- -C- -39029/12- -150 18 6.35 [.250] 5 16 16 [ ] 861080 22 (2) 4 78 [ 188] — 861080 — 16 4.78 [.188] 7 Figure 3 (Cont’d)  19- -strand wire  Use two size 22 AWG wires

Tooling for Loose Piece Contacts Tooling for Tape Mounted Contacts CONNECTOR INSERTION EXTRACTIONPositioner or Turret Head Hand Crimping Tool Machine Funnel CONNECTOR Military Spec INSERTION TOOL EXTRACTION TOOL 601966- -5 601966- -1 599406- -7 125905- -1 — 91067- -2 91067- -2 601966 5 601966 1 91067 2 91067 2601966- -5 601966- -1 — — — 91067- -2 91067- -2 601966- -5 601966- -1 599406- -7 125905- -1 — 91067- -2 91067- -2 608651 2 608651 1 318813 1608651- -2 608651- -1 — — — — 318813- -1 608651 2 608651 1 318813 1608651- -2 608651- -1 — — — — 318813- -1 608668 2 608668 1 318813 1608668- -2 608668- -1 — — — — 318813- -1 608651 3 608651 1 318813 1608651- -3 608651- -1 — — — — 318813- -1 601966 4 601966 1601966- -4 601966- -1 — — — — — 601967- -2 601967- -1 — — — 91067- -1 91067- -1 H H 601967 1 91066 3 91066 3H— H 601967- -1 — — — 91066- -3 91066- -3 Figure 3 (End) H Military Spec MIL- -C- -22520/1- -05

1. 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. 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. 7. REVISION SUMMARY S Updated document to corporate requirements.