Tooling Guide for Aerospace Wiring Systems

An & ISO A Re S91 900 Co gis 00 1:2 m te :20 00 pa re 0 8 ny d 4

Preface and Table of ContentsDaniels tools have been utilized in military aircraft and aerospace programs for over 60 years (DMC founded in 1949). By continuously planning and adding to our product lines, we are now fulfilling the demands of other high technology fields such as telecommunications, fiber optics, lasers, and many other areas of electronic packaging. The people behind the DMC name are pleased to present our Connector Assembly Tools and Accessories on the pages that follow. We believe the application data which accompanies each section will answer your specific questions concerning tooling; however, we encourage you to contact us by telephone or fax for the personal services of our knowledgeable staff of application experts.Battery Powered Hydraulic Open Frame Crimp Tools ...............................................72 Pneumatic Open Frame Tools .......................................74 X-Die Pneumatic Tool/Bench Press Hand Tools ...........75 Electric Hydraulic Open Frame Crimp Tool ..................76 DMC Y-Dies For A Full Range of Capabilities ..............77 TypicalY-DieConfigurationsandApplications Coaxial Contact Tool Selection Guide ..........................78 R.F. Connectors Tool Selection Guide ..........................80 Mid-Current Range Adjustable Indent Crimp Tools .........................................................92 Circular Indent Crimp Tools ...........................................96 Special Application Indent Crimp Tools ........................98 MH835&MH992(FineTippedIndenterTools)......98 MH800(UltraPrecision) ..........................................99 . MH820(StainlessSteelIndentor)............................99 SC8&MH993(BiasedCrimpTools).....................100 LH8(forBurndyYHMMSeriesContacts) GS217(MIL-C-22442/32-1ClampingRingCrimpTool)

CONTENTSImportant Facts About Crimping .....................................1 Tensile Test Systems ........................................................2 MPT-250B(Motorized250lb) ...................................3 . PT-150H(Manual150lb)...........................................4 HPT-200(Portable,Manual200lb)...........................5 M22520/1-01(AF8) Miniature Adjustable Indent Crimp Tools ........................8 M22520/2-01(AFM8) ................................................8 . M22520/7-01(MH860)..............................................9 . M22520/34-01(39-000).............................................9

Standard Adjustable Indent Crimp Tool ..........................6

Battery Powered Hydraulic Indent Crimp Tools ...........10 Pneumatic Indent Crimp Tools ......................................12 Auto-Lift Pneumatic Indent Crimp Tools .........................................................14 Large Gage Pneumatic Indent Crimp Tools ..................16 M22520/23-01(WA23) Large Gage Contact Application Information ...............17 Technical Application Guide for Contacts and Connectors ..............................................22 ConnectorIllustration..............................................22 ContactColorCode(BIN).......................................22 . M39029ContactQuickLocationChart..................23 MIL-STD-1760ConnectorTooling..........................24 MIL-I-81969

Dedicated Application Indent Crimp Tools .................101

GMT Series Precision Crimp Tools ..............................102 Battery Powered Hydraulic GMT Crimp Tools............104 DCT Series Crimp Tools ...............................................106 Hydrac 3.5 Ton Hydraulic Y-Die Crimp Tool ................108 Hydrac 3.5 Ton Hydraulic HD36-Die Crimp Tool ........109 Hydrac 5.5 Ton Hydraulic HD51-Die Crimp Tool ........112 Hydrac 7 & 12 Ton Hydraulic Crimp Tool for HD002, HD485, and HD442 Dies (AS5259) ............114 Air Powered Hydraulic Pump (HPU11M) .....................116 Hydrac 7 Ton Dieless Four Indent Crimper .................116 Wire Harness Spoon .....................................................117 Cable Tie Removal Tools..............................................117 Technical Application Guide for Terminals and Splices ..................................................118 Hand-Held Pneumatic Wire Stripping Tool .................164 Swagging Tool & Tool Kit .............................................166 Connector Service Maintenance/Support Kits ...........168 Limited Warranty ...........................................................172

Installing and Removal Tools .........................................56 Contact Retention Test Tools ........................................62 Contact Gages ................................................................63 Unwired Contact Removal Tools ...................................64 M81969/30 BETA Backshell Torque Tools .......................................65 EMI/RFI Band Application System ................................66 MIL Spec Circular Indent Crimp Tools ..........................69 M22520/4-01(GS100-1) M22520/31-01(GS200-1) M22520/5-01(HX4) M22520/10-01(HX3)

Open Frame Crimp Tools ...............................................70

DANIELS MANUFACTURING CORP.

526 THORPE RD. ORLANDO, FL 32824 U.S.A. PHONE 407/855-6161 FAX 407-855-6884 E-MAIL: DMC@DMCTOOLS.COM www.DMCTOOLS.COM CAGE CODE: 11851

FOR WARRANTY & LIMITATION OF LIABILITY INFORMATION SEE PAGE 172

ANY PRICES WE QUOTE VERBALLY OR ANY PRICES APPEARING IN OUR PRINTED PRICE LISTS ARE SUBJECT TO CHANGE WITHOUT PRIOR NOTICE. IF YOU NEED FIRM PRICES FOR FUTURE DELIVERIES YOU SHOULD REQUEST A WRITTEN QUOTATION FROM OUR SALES OFFICE. WE ARE NOT LIABLE FOR CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY NATURE OR KIND, RESULTING FROM THE USE OF ANY OF OUR PRODUCTS.

NOTICE

Copyright 2010 Daniels Manufacturing Corp. ALL RIGHTS RESERVED

www.DMCTools.com

Important Facts About CrimpingTime Line for Crimp TeChnoLogy1940s 1953 1957 1960 1963 1965 1969 1974 1996 2010 Allterminationsweresoldered (Hard-wired) AMPintroducedCrimp BarrelTerminals. CannonBrothersexperimented withMachinedContactswith CrimpBarrels Buchananintroducedthe 4IndentCrimpToolwitha Ratchet(Ref:MS3191) MS3191-1waspublishedasthe firstCrimpToolStandard. MS3191-4introducedby DanielsManufacturingCorp.. MIL-T-22520published anddatedtoreplaceall previousspecifications. ChangedtoMIL-C-22520, andmanySlashSheetsadded. ChangedtoMIL-DTL-22520. ChangedtoAS22520. MS3191-4alsointroducedtheuseof thedoubletippedindentertoproduce aneightindentcrimppatternwhichhas consistentlyachievedsuperiortensilepull offvalues. MS3191-4introducedtheconceptof aturretheadcontainingthreelocators whichcouldbeusedwithoutseparating anyofthemfromthebasiccrimptool. In1969twomilitaryspecificationsfor crimptoolsweredevelopedtoreplace theexistingmilitarydrawings.Theywere MIL-T-22520C(Navy)andMIL-T-83724 (USAF)whichdefinedastandardsize crimptoolsimilartotheMS3191-4,but withanexpandedeightstepcrimpdepth range.Thesespecificationsalsodefineda miniaturecrimptooltocrimpconductors assmallasAWG32. Bothdocumentswerecombinedin 1971intoMIL-C-22520D.Allprevious militarystandardsforcrimptoolswere thencancelledincludingtheMS3191. Thislistincludesspecificationsforindent crimptools,terminallugcrimptools, pneumatictools,coaxialcablecrimptools andconnectorservicekits. MIL-DTL-22520establishedasingle specificationwhichsetforthperformance requirementsforallcrimptoolstobeused onmilitarystandardelectricalconnectors. Thiseliminatedthewasteandconfusion whichaccompaniedtheoverlappingapplicationsofmanydifferentstandardcrimp toolscalledoutbyadelugeofunrelated militarydrawings. Specificationsstatetherequirements intermsofmillivoltdropatadesignated current. Themechanicalstrengthofacrimped jointandhenceitspull-outforce(tensile strength),varieswiththedeformation applied.Therefore,byproperlyshaping thedeformationahighpull-outforcecan beachieved,i.e.thecrimpdieofthetool determinesthecrimpconfigurationand deformation. Thediesinthetooldeterminethe completedcrimpconfigurationwhich isgenerallyanelementofcontactand/ orconnectordesign.Someofthedesign considerationsare:a)Thetypeofcontact, itssize,shape,materialandfunction, b)Thetypeandsizeofwirestobe accommodated,c)Thetypeoftooling intowhichtheconfigurationmustbebuilt.

Crimping: Then AnD noWThefirstmulti-pinconnectorswere terminatedbysolderingtheconductorto non-removablecontacts.However,high temperatureapplicationsandtheneedfor simpleandreliablefieldserviceledtothe introductionofconnectorswithremovable contacts.Thesewerecrimpedontothe conductorratherthanbeingsoldered. Thefirststandardcrimptooldeveloped tocrimpthesenewcontactswasintroducedintheearlysixties.MS3191-1, amilitarydrawing,definedthistooland itsaccessories.TheMS3191-1utilized afourindentcrimppatterntogetherwith apositivestoplocatorwhichcontrolled thetraveloftheindenters(crimpdepth). TheMS3191-1designwasacompromisebetweensimplicityofoperationand crimpperformancesincethecrimpdepth foranygivencontactwasnotadjustable toaccommodatethedifferingdiameters oftheconductorstowhichitwouldbe crimped.Itwas,however,suitableforthe crimpconnectorsofthatera. Animprovedtooldesignfeaturing independentlyadjustablecrimpdepths wassoonintroducedasMS3191-4.The MS3191-4hadaninternaladjustment, totallyindependentofthelocator,which permittedtheselectionofsevenseparate crimpdepths,allowingoptimalcrimping ofconductorsrangingfromAWG12to 26regardlessofthewirebarrelsizeof thecontact. Copyright 2010 Daniels Manufacturing Corp.

Eight indEnt

Four indEnt

two indEnt

The Crimping ConCepTCrimpingisamethodoffirmly attachingaterminalorcontactendtoan electricalconductorbypressureforming orreshapingametalbarreltogether withtheconductor.Theformingofa satisfactorycrimpdependsonthecorrect combinationofconductor,crimpbarrel andtool. Whenappliedwithaproperlymatched tool,aunionisestablishedwhichhas bothgoodelectricalandmechanical characteristics.Thetoolwillprovidethese requirementsconsistentlyandreliably withrepeatabilityassuredbyqualitycycle controlledtooling.Thereareseveral commonconfigurationsofcrimpedjoint; severalexamplesareshownbelow. Theelectricalresistanceofaproperly designedandcontrolledcrimpedjoint shouldbeequalto,orlessthan,the resistanceofanequalsectionofwire.www.DMCTools.CoM

hExagonal Crimp

CirCular Crimp

B Crimp

nEst & indEnt Crimp

CaptivE Crimp

insulation displaCEmEnt

ALL RIGHTS RESERVED.

PAGE 1

Tensile Test Systems

For Wire Terminations and Similar Applicationsjawsorothercomponentstomaketest sampleinstallationandremovalaneasy task. Modelsareavailablewithoutput displayreadingsinPounds,Newtons, and/orKilogramstoconformwiththe requirementsoftheuserssystem.Units areavailableforeither115or230volt powerinput. Itsonlynaturalthatthecompany whichsuppliesthebestwiretermination toolsandequipmentwouldaddthevery bestDigitalTensileTesterstofurther meetthedemandforfewersourcesand improvedsupportthroughawiderrange ofuserneeds. TheMPT-250BMotorizedWireCrimp PullTesterisidealwhenaconstant rateofpullisdesired.Ittestscrimp strengthonterminationsuptosize8 inMil-Specapplications,andsize1/0 AWGincommercialandautomotive applications. ThePT-150HManualWireCrimpPull Testerisidealfortestingcrimpstrength uptosize10forMil-Specapplications, andsize4AWGforcommercialand automotiveapplications. TheHPT-200hand-heldpulltester blendstheaccuracyandrugged designoftheAlphatronpulltesters intoaself-contained,portable, rechargeablebatterypoweredunit. Itisidealfortestingcrimpstrength uptosize10AWGinMil-Spec applications,andsize10AWGin commercialandautomotiveapplications.

The DepenDABLe ALphATron TenSiLe TeST SySTemNowavailablefromDMCisaline ofElectronicTensileTestSystems whichmaybeusedinconjunction withSPCProgramsorotherQuality ControldisciplinesinbothOEMand maintenanceapplications.Theelectronic digitalreadoutdisplaysareafastand reliablesourceoftestdata. Theruggedconstructionandthe portabledesignofthesetestmachines makeanyofthemasuperiorchoicefor on-siteorlaboratoryuseinaninfinite varietyofapplications.Theoperationof theequipmentissimpleyetversatile, andDMCwillcustomizethegripping

mpt-250B-sC motoriZEd saFE-t-CaBlE tEstErThe specifications for this model are the same as MPT-250B. The MPT-250B-SC is equipped to test .020, .032 and .040 diameter Safe-T-Cable.

GENERAL SPECIFICATIONSMPT-250B Capacity Accuracy ResolutionmotoriZEd pull tEstErs mpt-250B

PT-150H 150 lbf 68.0 kg 667 N 0.5% (1/2 of 1%) 0.1 lbf Digital Display w/Peak Hold Reading LED w/.56" high digits 115 VAC 50/60 Hz 230 VAC 50/60 Hz 50F to 100F (10 to 38C)

HPT-200 200 lbf 90.7 kg 889 N 0.5% (1/2 of 1%) 0.1 lbf Digital Display w/Peak Hold Reading LED w/.56" high digits 115 VAC 50/60 Hz 230 VAC Int. Battery 50F to 100F (10 to 38C)

250 lbf 113 kg 1112 N 0.5% (1/2 of 1%) 0.1 lbf Digital Display w/Peak Hold Reading

Display Type

Display Electrical

LED w/.56" high digits 115 VAC 50/60 Hz 230 VAC 50/60 Hz

operatingmanual pull tEstErs pt-150h

50F to 100F (10 to 38C)

Temperature

DIMENSIONSMPT-250B Height width Depth weighthand-hEld portaBlE pull tEstEr modEl hpt-200

PT-150H 5 in. (18.9 cm) 8.5 in. (25.4 cm) 16 in. (27.9 cm) 15.2 lbs. (6.89 Kg) (less options)

HPT-200 2 in. (5.08 cm) case 9.5 in. (24.13 cm) case 6.25 in. (15.87 cm) case 2.5 lbs. (1.21 kg) case and hand unitALL RIGHTS RESERVED.

9.5 in. (24.13 cm) 10 in. (25.4 cm) 15 in. (43.2 cm) 26 lbs. (11.78 kg) (less options)

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Copyright 2010 Daniels Manufacturing Corp.

MPT-250B

Motorized Wire Crimp Pull TesterTheMPT-250BMotorizedWireCrimp PullTesterhasarangefromfivepounds forcetotwo-hundredandfiftypounds (2-113Kg,22-1112N). Youcanexpectthesameprecision anddependabilitythathasestablishedall ALPHATRONtestersasthefirstchoice forwireharnessbuildersandcomponent suppliersthroughouttheindustry.The 250poundcapacityofthistesterwill extendtherangeoftestingcapabilities tosize8Mil-Specapplications*,andsize 1/0AWGincommercialandautomotive applications**(ReferenceAS7928and UL486Respectively). Theportabledesign(25pounds, 9.5x10x16)andtheruggedconstruction(machinedaluminumandsteel) contributetotheversatilityandreliability oftheMPT-250BPullTester.Avarietyof options,includingstandardandcustom gripsforalltypesofwireterminationsare availableonthistester.Theoperationof thetesterissimpleandhasautomatic resetandauto-stopfeaturesincorporated intothedesign.Thepeak-holddigitaldisplayindicatesthehighestpullforcethat ismeasuredbytheaccurateloadcell/ digitalprocessoruntiltheresetswitchis pressed. Consultthefactoryformorespecific information,andapplicationverification. NSN:6635-01-581-9996

SpeCifiCATionS for The mpT-250B moToriZeD Wire Crimp pULL TeSTerCapacityRange5-250lbs. (2-113kg,22-1112N) PullRate:1to10"/min.Push-button Selectablein1"/min.Increments. PullRateAccuracy 1/8"/min.@15"/min.RateofPull 1/4"/min.@610"/min.RateofPull Auto-StopatWire/CrimpBreakPoint AutoReturntoStartPosition 15PositionSlottedLower TerminalGrip. DisplayUnitsinPounds,Kilograms, orNewtons Lb/Kg/NewtonsSwitchingBuiltin MPT-250B options:UniversalSelfTighteningCam-TypeLowerGripRing TerminalLowerGrip7.530"/min. SelectableRatesofPullin102.5"/min. IncrementsAdjustableSet-pointfor MotorStopatPre-SetForce.

CustomGripsAvailable. ConsultDMCfordetails.

Terminal & Wire Grips

SLOTTED TERMINAL GRIP (standard)

p/n 15-3087

RING TERMINAL GRIP* (optional)

*Size8MILSpecwirepulltestistypically 220poundsforce.Samplemaynotbreakat 250pounds. **Mayrequirespecialgripsduetowire diameter.

p/n 15-0066*Someringterminalsarenotsuitableforthisgrip.

SELF TIGHTENING GRIP (optional)

p/n 15-3202

MINIATURE TERMINAL GRIP (optional)

p/n 15-3241 Copyright 2010 Daniels Manufacturing Corp. ALL RIGHTS RESERVED. www.DMCTools.CoM

PAGE 3

PT-150H

Wire Crimp Pull TesterThePT-150HManualWireCrimpPullTesterisidealfortestingcrimpstrengthup tosize10forMil-Specapplications*,andsize4AWGforcommercialandautomotive applications**.ThePT-150HmaybeusedinconjunctionwithSPCProgramsorother QualityControldisciplinesinbothOEMandmaintenanceapplications.Theelectronic digitalreadoutdisplayisafastandreliablesourceoftestdata. Theoperationoftheequipmentissimpleyetversatile,andDMCwillcustomizethe grippingjawsorothercomponentstomaketestsampleinstallationandremovalan easytask.*Size10MILSpecwirepulltestistypically150poundsforce.Samplemaynotbreakat150 pounds. **Mayrequirespecialgripsduetowirediameter.

sTANDARD FEATUREs Capacity:150lb,667N,68Kg Displayunitsfactorysetfor pounds,newtonsorkilograms Resolution:0.1lb Accuracy:0.5%offullscale DigitalDisplaywithPeakHold BacklitLCDDisplaywith0.56 HighDigits Self-TighteningWireGrip 15PositionSlottedTerminal ContactGrip LeverArmPullMechanism OPTIONALACCESSORYGRIPS RingTerminalGrip(P/N15-0066) Self-TighteningGrip(P/N15-3202) RightAngleTerminalGrip (P/N15-3042) PHYSICAL Weight15.2Lbs. (ShippingWeight21Lbs.) StandDimensions: H.5,W.8.5,D.16 CALIBRATION Newunitssuppliedwithcertificate ofcalibrationtraceabletoNIST Factorycalibrationavailable OPTIONALFEATURES 230VAC50/60HzPower (P/N15-7004)

Terminal & Wire GripsSLOTTED TERMINAL GRIP (standard)

CustomGripsAvailable.ConsultDMCfordetails.

RING TERMINAL GRIP (optional)

SELF-TIGHTENING GRIP (optional)

p/n 15-3087

p/n 15-0066

p/n 15-3202

PAGE 4

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HPT-200

Hand Held Wire Crimp Pull Tester

Daniels Manufacturing Corporation introduces a portable tensile tester capable of pull testing wire crimps up to 200 pounds (up to 10 AWG wire in most cases).

ThelightweightAlphatronHPT-200 isaself-containedtesterthatextends yourtestingcapabilitytotheshopfloor. Younolongerhavetowaitforprocess amplestoarriveintheQALab. s Durableconstructionandaconvenient carrycaseensure rotection.The ow p L Stressensionngmechanismmakesthe t i HPT-200ver atileandeasytouse.A s builtinNIHM atteryprovidesupto14 b hoursuseonasinglechargeandthe PowerManagementCircuitallowsuse duringcharging.

THe lAb IS no longer THe lImITItisonlynaturalthatthe ompany, c whichisknownthroughouttheworld for ualitywireterminationtoolsand q equipmentwouldaddtheverybest portabletensiletestertomeetyourneed forfewersourcesandimprovedsupport throughawiderrangeofcapabilities. TheHPT-200handheldpulltester combinestheaccuracyandrugged designoftheAlphatronpulltestersinto aportablebatterypoweredunit.We followthatupwithourexpertfactory serviceand alibration. c TheHPT-200portabletesteris anextensionoftheAlphatronWire CrimpPullTesterlineofproducts, whichincludethePT-150Hand MPT-250B.Thesetestersperform pull-forcemeasurementsonwire terminations.Theruggedconstruction andportabledesignofthesetest machinesmakeanyofthemasuperior choiceforon-siteorlaboratoryuse.

Portable, lightweight and ergonomic design Built-in NIMH battery, with charger Up to 14 hour use on a single charge Low stress tensioning mechanism Protective carrying case Shoulder bag (optional) Built-in calibration test Accuracy: (0.5% of full scale) Resolution: (0.1 pounds) Display in newtons, or kilograms is available

Standard Terminal Grip

UPPER GRIP

SPECIFICATIONS:Capacity:200LBF,90.7kg,889N Accuracy:.5%offullscale Resolution:.1lbf DisplayType:Digitaldisplayw/ peakholdreading Display:LCDw/.56in. high igits d Electrical:115VAC50/60Hzor 12VDCInt.Battery OperatingTemperature: 50Fto100F(10to38C) Height:2in.(5.08cm)case Width:9.5in.(24.13cm)case Depth:6.25in.(15.87cm)case Weight:2.5lbs.(1.21kg)case andhandunit A230voltunitisavailable. P/NHPT-200-230

p/n 15-3035

Slot DImEnSIonNo. 1 2 3 4 5 6 7 8 size (in.) .031 .250 .047 .236 .063 .218 .080 .203 No. 9 10 11 12 13 14 15 size (in.) .094 .188 .110 .172 .125 .158 .141

Copyright 2010 Daniels Manufacturing Corp.

ALL RIGHTS RESERVED.

www.DMCTools.CoM

PAGE 5

Standard Adjustable Crimp TooluppEr rangE Crimp tool aF8 m22520/1-01TheDMCAF8,qualifiedtoMILDTL-22520/1*,hasvirtuallylimitless applicationwithinthespecifiedwire range of 12 through 26 AwG.Over athousandturretheadsareavailable toadaptthetoolframetoyourspecific militaryorproprietarycontact/wire combination.The8impressioncrimp, whichisstandardintheAF8,assures absolutemaximumtensilestrengthwith almosteveryclosedbarrelcontact. Specialindentconfigurationsandgaging areavailableuponrequest. Forproperoperation,thetoolmust bematedwithoneofthefollowing optionalaccessories:amilitarystandard ornon-militaryturrethead(TH-XXX PartNo.Series),amilitarystandardor non-militarypositioner(TP-XXXPartNo. Series),oranadjustablehead(PartNo. UH2-5).Thisisdonesimplybyorienting theheadinthekeyedposition,and bytighteningthehexsocketscrews providedaspartofthehead. Theprecisionratchetcontrolscycling ofthetoolinbothdirectionsofhandle movement.Thisassuresthesame accuratecrimpeverytime.Itslike havingaqualitycontrolinspectorat everyworkstation. Positivecrimpdepthiscontrolledby an8positionselectorknobconveniently locatedonthetoolframe.Theoperator simplydialsthedesiredstepforthewire beingused.Thissettingcanbesecured byuseofalockingpinorsafetywire. Thecarefullyengineereddesign achievestheabsolutemaximum mechanicaladvantageandthetools lightweighthelpsminimizeoperator fatigue. Apermanentdataplateisaffixedtoall turretheadsandpositioners.Thisplate listsspecificcontactpartnumbers,the correspondingpositioncolorcode(for 3positionturretheads),andsuggested selectordepthsettingsforthewiresize beingused. Theadjustablehead(P/NUH2-5)is ideallysuitedforlabworkandprototype productionapplications.Thishead isattachedinthesamemanneras explainedabove.Theselectedcontact isinsertedthroughtheentryholeonthe oppositesideofthetoolframefromthe head.Theheightadjustingscrewisthen rotateduntilthecontactisintheproper positionforcrimping.Thescrewcan besecuredwiththelocknutprovided. Sometestingwillbenecessaryto determinetheoptimumselectorsetting foryourcontact/wirecombination. TheAF8isapproximately934"x212"x 114"andweighs15oz.

*ChangetoSAEAS22520inprocessconsultDMCforstatus.

PAGE 6

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ALL RIGHTS RESERVED.

Otherthankeepingtheunitcleanand properlystoredwhennotinservice, nooperatormaintenanceisrequired. DMCofferscompletefactoryservice byknowledgeabletechnicianswithina reasonableturnaroundtime.Complete instructionsconcerningtheuse,care andwarrantyaresuppliedwitheach tool.Additionalcopiesareavailableon request. Pneumaticversionsofthistoolare foundonpage12. Thebatterypoweredversionsofthis toolarefoundonpage10.

MILITARY P/NM22520/1-01 M22520/1-02 M22520/1-03 M22520/1-04 M22520/1-05 M22520/1-06 M22520/1-07 M22520/1-08 M22520/1-09 M22520/1-10 M22520/1-11 M22520/1-12 M22520/1-13 M22520/1-14 M22520/1-15 M22520/1-16 M22520/1-17 M22520/3-1

DMC P/NAF8 TH1A TH4 TH163 UH2-5 TP45 TP85 TH199S TP360 TP365 TP465 TH270 TH285 TH286 TP485 TP513 TP651 G125 DMC1186

DESCRIPTIONTOOL FRAME TURRET TURRET TURRET ADJUSTABLE POSITIONER POSITIONER POSITIONER TURRET POSITIONER POSITIONER POSITIONER TURRET TURRET TURRET POSITIONER POSITIONER POSITIONER GAGE M22520/1 Tool Kit

NSN5120-01-335-8571 5120-01-335-8834 5120-01-335-8835 5120-01-335-8836 5120-01-335-8583 5120-01-335-8584 5120-01-335-8585 5120-00-016-7654 5120-01-335-8586 5120-01-335-8587 5120-01-335-8588 5120-01-335-8838 5120-01-036-9221 5120-01-036-9222 5120-01-335-8589 5120-01-335-8590 5120-01-335-8591 5220-01-016-6002

TheDMC1186toolkitcontainstheAF8 toolframe,toolgage,andallmil-spec positionersandturretheads.Alsoincluded intheDMC1186aretoolinstruction sheetsandatoolselectionchart. Periodicgagingisrecommended toinsureaccuratecalibration.This canbedoneeasilybysettingthe toolselectorknobtoposition#4, andcheckingindenterclosurewith theM22520/3-1GO/NO-GOgage (DMCpartno.G125).

STep 1

STep 2

insErt ContaCt

insErt prE-strippEd wirE

STep 3

STep 4

ClosE / opEn handlE

rEmovE tErminatEd wirE assEmBly

Copyright 2010 Daniels Manufacturing Corp.

ALL RIGHTS RESERVED.

www.DMCTools.CoM

PAGE 7

miniature Adjustable Crimp ToolslowEr rangE Crimp tool aFm8 m22520/2-01QualifiedtoMIL-DTL-22520/2*, theDMCAFM8isdesignedformost oftheminiatureandsub-miniature connectortypesthataresowidely usedinelectronicsystems.TheAFM8 meetstheneedforaminiaturetool accommodatingwire sizes 20 through 32 AwG. TheAFM8givesaMil-Standard 8impressioncrimp,whichassures maximumtensilestrength.Thecycle controlledprecisionratchetassures consistentlyaccuratecrimpseverytime. Thetoolframehasabuilt-in8step selectorknobforeaseindialingthe correctcrimpdepthsettingforthewire beingused. Positionersadaptthetoolframeto aparticularapplication.Thedataplate oneachpositionerdesignateswhich contactsthepositioneraccommodates foritswiresizeandindicatesselector position.Thepositioneriseasilyremoved andchanged. Periodicgagingisrecommendedto insureaccuratecalibration.Thisiseasily accomplishedwiththeM22520/3-1 GO/NO-GOgage(DMCpartno.G125) onSELsetting#8.TheAFM8is63/4"in lengthandweighsapproximately10oz. Otherthankeepingthetoolclean andproperlystoredwhennotinuse, nooperatormaintenanceisrequired. Pneumatic versions of this tool are found on page 12.

MILITARY P/NM22520/2-01 M22520/2-02 M22520/2-03 M22520/2-04 M22520/2-05 M22520/2-06 M22520/2-07 M22520/2-08 M22520/2-09 M22520/2-10 M22520/2-11 M22520/2-12 M22520/2-13 M22520/2-14 M22520/2-15 M22520/2-16 M22520/2-17 M22520/2-18 M22520/2-19 M22520/2-20 M22520/2-21 M22520/2-22 M22520/2-23 M22520/2-24 M22520/2-25 M22520/2-26 M22520/2-27 M22520/2-28 M22520/2-29 M22520/2-30 M22520/2-31 M22520/2-32 M22520/2-33 M22520/2-34 M22520/2-35 M22520/2-36 M22520/2-37 M22520/3-1

DMC P/NAFM8 K1S K60S K151 K3 K41 K40 K13-1 K42 K43 K287 K286 K338 K340 K341 K339 K342 K343 K330-2 K331-2 K332-2 K212 K267-1 K75S-1 K261-1 K262-1 K269-1 K373-1 K372-1 K404 K406 K496 K74S K323 K532-1 K473 K709 G125 SK2/2 DMC274

DESCRIPTIONTOOL FRAME POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER GAGE ADJUSTABLE POSITIONER M22520/2 TOOL KIT

NSN5120-01-335-8572 5120-01-335-8592 5120-01-335-8593 5120-01-335-8594 5120-01-335-8595 5120-01-335-8624 5120-01-335-8625 5120-01-335-8626 5120-01-335-8627 5120-01-335-8628 5120-01-335-8629 5120-01-335-8630 5120-01-335-8631 5120-01-335-8632 5120-01-335-8633 5120-01-335-8634 5120-01-335-8635 5120-01-335-8636 5120-01-335-8637 5120-01-335-8638 5120-01-335-8609 5120-01-335-8610 5120-01-335-8611 5120-01-335-8612 5120-01-335-8613 5120-01-335-8614 5120-01-335-8615 5120-01-335-8616 5120-01-335-8617 5120-01-335-8618 5120-01-335-8619 5120-01-335-8620 5120-01-335-8621 5120-01-335-8622 5120-01-335-8623 5120-01-335-8596 5120-01-361-9666 5220-01-016-6002 5120-01-171-1569 5180-01-259-0512

TheDMC274toolkitcontainsthe AFM8toolframe,toolgage,andall mil-specpositioners.Alsoincludedin theDMC274aretoolinstructionsheets andatoolselectionchart.

*ChangetoSAEAS22520inprocessconsultDMC forstatus.

PAGE 8

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miDDLe rAnge inDenT Crimp TooL mh860 m22520/7-01QualifiedtoMIL-DTL-22520/7*,the DMCMH860isarecentadditiontothe militaryspecification.Itwasdevelopedto meetthedemonstratedneedforsupportingthemajorityofelectricalsystemswith oneversatilecrimptoolframe. TheMH860acceptstheentiremiddle wirerangeof16through28AWG,with positionerswhichadaptittovirtuallyall applicationsconsistentwithothersinthe MIL-DTL-22520family. Pneumaticversionsofthistoolare foundonpage12.

MIL 860 PART NUMBERS MILITARY P/NM22520/7-01 M22520/7-02 M22520/7-03 M22520/7-04 M22520/7-05 M22520/7-06 M22520/7-07 M22520/7-08 M22520/7-09 M22520/7-10 M22520/7-11 M22520/7-12 M22520/7-13 M22520/3-3

DMC P/NMH860 86-1S 86-2 86-3 86-4 86-5 86-6 86-7 86-11S 86-12S 86-19 86-20 86-21 G145 86-37 DMC123

DESCRIPTIONTOOL FRAME POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER POSITIONER GAGE ADJUSTABLE POSITIONER M22520/7 TOOL KIT

NSN5120-01-335-8573 5120-01-335-8597 5120-01-335-8598 5120-01-335-8599 5120-01-335-8600 5120-01-335-8601 5120-01-335-8602 5120-01-335-8603 5120-01-335-8604 5120-01-335-8605 5120-01-335-8606 5120-01-335-8607 5120-01-335-8608 5120-00-338-0378 5180-01-355-5616

TheDMC123toolkitcontainsthe MH860toolframe,toolgage,andall mil-specpositioners.Alsoincludedin theDMC123aretoolinstructionsheets andatoolselectionchart.*ChangetoSAEAS22520inprocessconsultDMC forstatus.

MIL-DTL-28840 TOOLING PART NUMBERS MILITARY P/NM22520/34-01 M22520/34-02 M22520/35 M81969/33-01 M81969/33-02 M81969/34-01

DMC P/N39-000 39-102 G345 DAK55-22SA DAK55-22JA DRK56-22A DMC782

DESCRIPTIONBASIC CRIMP TOOL POSITIONER GAGE INST. TOOL (STRAIGHT) INST. TOOL (OFFSET) REMOVAL TOOL MIL-C-28840 TOOL KIT

NSN5120-01-242-3516 5120-01-242-1041 5220-01-392-1065 5120-01-230-1506 5120-01-335-8666 5120-01-230-1507 5180-01-363-1391

thE mil-dtl-28840 toolingMIL-DTL-28840connectorswere developedfortheNavy,forusewith jacketedcableforshipboardapplications. Theyareahighdensitycircularconnector seriesutilizingahighshockthreaded couplingsystemwithfrontrelease crimpedcontacts. FortheseconnectorsDMChasadded anewcrimpingtooltoitsrange,the M22520/34-01.PAGE 9

Copyright 2010 Daniels Manufacturing Corp.

ALL RIGHTS RESERVED.

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battery Powered Hydraulic Indent Crimp ToolsgeT The porTABiLiTy of A hAnD TooL WiTh The STAminA of A poWer TooL!DMCispleasedtopresentourbatterypoweredhydraulictoolstocrimpMIL-C-39029,MIL-C-39012,andafullrangeof proprietarycontactsontocopperandaluminumcable12 through 26 AwG.ThesetoolsareequivalenttoDMCs AF8(M22520/1-01)handtoolandusethesameturretheads,positioners,andotheraccessories.

Afe8BTheAFE8BBatteryPoweredHydraulic IndentCrimpToolisahandheld, self-containedindentcrimptool.The crimphead,battery,andpumpunit arecontainedinoneergonomictool bodyandweighsabout4pounds.Itis equivalenttoDMCsAF8handtooland usesthesameturretheads,positioners, andotheraccessories. Tool INClUDEs:CarryingCase,Two 18vBatteries(p/nHDE-LI-B),OneBattery Charger(p/nHDE-LI-120C). FEATUREs Ergonomicdesignallows one-handedoperation Indentersautomaticallyopen whencrimpiscomplete Headrotates350degrees RedLEDtodisplayunits currentstatus CRIMP CAPACITIES Max.CrimpForce:1.5Tons (13.3kN) Avg.CrimpTime:2seconds Avg.CrimpsperCharge: Approx.150(dependingonsizeand typeofcontactwire AFE8B SPECIFICATIONS Length:14.75(375mm) Width:2.87(72.9mm) Depth:4.5(114.3mm) Mass/Weight(w/battery):3.92lb(1.78kg) SoundLevel:75db(A)at1meter Vibration: