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ManualsBrandsTE CONNECTIVITY ManualsD-SUB ConnectorsD-SUB pin strip Number of pins: 26 Crimp AMPLIMITE HD-22 1 pc(s)

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Instruction Sheet

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PRODUCT INFORMATION

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LOC B

Insertion/Extraction Tool 91285-1

and Replacement Tip Kits 543382-[ ]

408-9404

26 MAR 13 Rev D

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.

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

Summary of content (6 pages)

PAGE 1
Instruction Sheet 408-9404 Insertion/Extraction Tool 91285-1 and Replacement Tip Kits 543382-[ ] 26 MAR 13 Rev D 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. Insertion/Extraction Handle Cap [.050 In.
PAGE 2
408-9404 Insertion/Extraction Tip Wire Slot (Ref) Insertion/Extraction Handle Plug Setscrew (Ref) Bottom of Tool (Ref) Figure 2 3. TOOL ASSEMBLY (Figure 2) Refer to Figure 1 and select the appropriate contact, wire size, and insertion/extraction tip. Proceed as follows: 3. Using the hex wrench, tighten the setscrew to secure the tip in the tool handle. 4. INSERTION/EXTRACTION PROCEDURES 4.1. Inserting A Wire Crimped Contact (Figure 3) 1.
PAGE 3
408-9404 2. Slide thumb over the wire toward the end of the tip. NOTE iNOTE 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.
PAGE 4
08-9404 Back of Connector (Ref) Contact Cavity Contact Post Insertion Tip Butt Tool Tip Against Contact Stabilizer Figure 5 4.4. Extracting A Posted Contact (Figure 6) 1. Place the extraction tip over the contact post. Move the tool along the post until the tip enters the contact cavity. 2. Align the groove of the extraction tip with the contact stabilizer as shown in Figure 6. 3. Push the tip past the stabilizer and straight into the cavity until it bottoms. 4.
PAGE 5
408-9404 1.02 [.040] Pin Dia.
PAGE 6
408-9404 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. 8 ----- 2-26538-5 CAP † Available in packs of 25 only (one plug included in each packet).