Tooling Guide for Aerospace Wiring Systems T o o l i n g G u i d e f o r A e r o s p a c e W i r i n g S y s t e m s 8 00 4 2 0 01:20 d An I&S OA S99R01e0giC0s:otemrpeany Preface and Table of Contents Daniels tools have been utilized in military aircraft The people behind the DMC name are pleased and aerospace programs for over 60 years (DMC to present our Connector Assembly Tools and founded in 1949). By continuously planning and Accessories on the pages that follow. We believe the adding to our product lines, we are now fulfilling the application data which accompanies each section demands of other high technology fields such as will answer your specific questions concerning telecommunications, fiber optics, lasers, and many tooling; however, we encourage you to contact us other areas of electronic packaging. by telephone or fax for the personal services of our knowledgeable staff of application experts. CONTENTS Battery Powered Hydraulic Open Frame Crimp Tools ...............................................72 Important Facts About Crimping .....................................1 Pneumatic Open Frame Tools .......................................74 Tensile Test Systems ........................................................2 X-Die Pneumatic Tool/Bench Press Hand Tools ...........75 MPT-250B (Motorized 250 lb) ....................................3 Electric Hydraulic Open Frame Crimp Tool ..................76 PT-150H (Manual 150 lb) ...........................................4 HPT-200 (Portable, Manual 200 lb) ...........................5 DMC Y-Dies For A Full Range of Capabilities ..............77 Standard Adjustable Indent Crimp Tool ..........................6 Typical Y-Die Configurations and Applications M22520/1-01 (AF8) Coaxial Contact Tool Selection Guide ..........................78 Miniature Adjustable Indent Crimp Tools ........................8 R.F. Connectors Tool Selection Guide ..........................80 M22520/2-01 (AFM8) .................................................8 Mid-Current Range Adjustable M22520/7-01 (MH860) ...............................................9 Indent Crimp Tools .........................................................92 M22520/34-01 (39-000) .............................................9 Circular Indent Crimp Tools ...........................................96 Battery Powered Hydraulic Indent Crimp Tools ...........10 Special Application Indent Crimp Tools ........................98 Pneumatic Indent Crimp Tools ......................................12 MH835 & MH992 (Fine Tipped Indenter Tools) ......98 Auto-Lift Pneumatic MH800 (Ultra Precision) ...........................................99 Indent Crimp Tools .........................................................14 MH820 (Stainless Steel Indentor) ............................99 SC8 & MH993 (Biased Crimp Tools) .....................100 Large Gage Pneumatic Indent Crimp Tools ..................16 Dedicated Application Indent Crimp Tools .................101 M22520/23-01 (WA23) LH8 (for Burndy YHMM Series Contacts) Large Gage Contact Application Information ...............17 GS217 (MIL-C-22442/32-1 Clamping Ring Crimp Tool) Technical Application Guide for GMT Series Precision Crimp Tools ..............................102 Contacts and Connectors ..............................................22 Battery Powered Hydraulic GMT Crimp Tools ............104 Connector Illustration ..............................................22 Contact Color Code (BIN) ........................................22 DCT Series Crimp Tools ...............................................106 M39029 Contact Quick Location Chart ..................23 Hydrac 3.5 Ton Hydraulic Y-Die Crimp Tool ................108 MIL-STD-1760 Connector Tooling ..........................24 Hydrac 3.5 Ton Hydraulic HD36-Die Crimp Tool ........109 Installing and Removal Tools .........................................56 Hydrac 5.5 Ton Hydraulic HD51-Die Crimp Tool ........112 MIL-I-81969 Hydrac 7 & 12 Ton Hydraulic Crimp Tool Contact Retention Test Tools ........................................62 for HD002, HD485, and HD442 Dies (AS5259) ............114 Contact Gages ................................................................63 Air Powered Hydraulic Pump (HPU11M) .....................116 Unwired Contact Removal Tools ...................................64 Hydrac 7 Ton Dieless Four Indent Crimper .................116 M81969/30 Wire Harness Spoon .....................................................117 BETA Backshell Torque Tools .......................................65 Cable Tie Removal Tools ..............................................117 EMI/RFI Band Application System ................................66 Technical Application Guide for MIL Spec Circular Indent Crimp Tools ..........................69 Terminals and Splices ..................................................118 M22520/4-01 (GS100-1) Hand-Held Pneumatic Wire Stripping Tool .................164 M22520/31-01 (GS200-1) Swaging Tool & Tool Kit ...............................................166 Open Frame Crimp Tools ...............................................70 Wiring System Service Kits ..........................................168 M22520/5-01 (HX4) Limited Warranty ...........................................................172 M22520/10-01 (HX3) DANIELS MANUFACTURING CORP. 526 THORPE RD. • ORLANDO, FL 32824 U.S.A. NOTICE PHONE 407/855-6161 • FAX 407-855-6884 ANY PRICES WE QUOTE VERBALLY OR ANY PRICES APPEARING IN E-MAIL: [email protected] • www.DMCTOOLS.COM OUR PRINTED PRICE LISTS ARE SUBJECT TO CHANGE WITHOUT CAGE CODE: 11851 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 FOR WARRANTY & LIMITATION OF LIABILITY DAMAGES OF ANY NATURE OR KIND, RESULTING FROM THE USE OF INFORMATION SEE PAGE 172 ANY OF OUR PRODUCTS. © Copyright 2012 Daniels Manufacturing Corp. ALL RIGHTS RESERVED www.DMCTools.com Important Facts About Crimping Time Line for Crimp MS3191-4 also introduced the use of Specifications state the requirements TeChnoLogy the double tipped indenter to produce in terms of millivolt drop at a designated 1940s All terminations were soldered an eight indent crimp pattern which has current. (Hard-wired) consistently achieved superior tensile pull The mechanical strength of a crimped 1953 AMP introduced Crimp off values. joint and hence its pull-out force (tensile Barrel Terminals MS3191-4 introduced the concept of strength), varies with the deformation 1957 Cannon Brothers experimented a turret head containing three locators applied. Therefore, by properly shaping with Machined Contacts with which could be used without separating the deformation a high pull-out force can Crimp Barrels any of them from the basic crimp tool. be achieved, i.e. the crimp die of the tool 1960 Buchanan introduced the In 1969 two military specifications for determines the crimp configuration and 4 Indent Crimp Tool with a crimp tools were developed to replace deformation. Ratchet (Ref: MS3191) the existing military drawings. They were The dies in the tool determine the 1963 MS3191-1 was published as the MIL-T-22520C (Navy) and MIL-T-83724 completed crimp configuration which first Crimp Tool Standard. (USAF) which defined a standard size is generally an element of contact and/ 1965 MS3191-4 introduced by crimp tool similar to the MS3191-4, but or connector design. Some of the design Daniels Manufacturing Corp. with an expanded eight step crimp depth considerations are: a) The type of contact, 1969 MIL-T-22520 published range. These specifications also defined a its size, shape, material and function, and dated to replace all miniature crimp tool to crimp conductors b) The type and size of wires to be previous specifications as small as AWG 32. accommodated, c) The type of tooling 1974 Changed to MIL-C-22520, Both documents were combined in into which the configuration must be built. and many Slash Sheets added 1971 into MIL-C-22520D. All previous 1996 Changed to MIL-DTL-22520 military standards for crimp tools were 2010 Changed to AS22520 then cancelled including the MS3191. This list includes specifications for indent crimp tools, terminal lug crimp tools, Crimping: Then AnD noW pneumatic tools, coaxial cable crimp tools The first multi-pin connectors were and connector service kits. terminated by soldering the conductor to MIL-DTL-22520 established a single eighT inDenT non-removable contacts. However, high specification which set forth performance temperature applications and the need for requirements for all crimp tools to be used simple and reliable field service led to the on military standard electrical connectors. introduction of connectors with removable This eliminated the waste and confusion four inDenT contacts. These were crimped onto the which accompanied the overlapping appli- conductor rather than being soldered. cations of many different “standard” crimp The first standard crimp tool developed tools called out by a deluge of unrelated to crimp these new contacts was intro- military drawings. TWo inDenT duced in the early sixties. MS3191-1, a military drawing, defined this tool and The Crimping ConCepT its accessories. The MS3191-1 utilized a four indent crimp pattern together with Crimping is a method of firmly hexAgonAL Crimp a positive stop locator which controlled attaching a terminal or contact end to an the travel of the indenters (crimp depth). electrical conductor by pressure forming The MS3191-1 design was a compro- or reshaping a metal barrel together mise between simplicity of operation and with the conductor. The forming of a CirCuLAr Crimp crimp performance since the crimp depth satisfactory crimp depends on the correct for any given contact was not adjustable combination of conductor, crimp barrel to accommodate the differing diameters and tool. of the conductors to which it would be When applied with a properly matched B Crimp crimped. It was, however, suitable for the tool, a union is established which has crimp connectors of that era. both good electrical and mechanical An improved tool design featuring characteristics. The tool will provide these independently adjustable crimp depths requirements consistently and reliably nesT & inDenT Crimp was soon introduced as MS3191-4. The with repeatability assured by quality cycle MS3191-4 had an internal adjustment, controlled tooling. There are several totally independent of the locator, which common configurations of crimped joint; permitted the selection of seven separate several examples are shown below. CApTive Crimp crimp depths, allowing optimal crimping The electrical resistance of a properly of conductors ranging from AWG 12 to designed and controlled crimped joint 26 regardless of the wire barrel size of should be equal to, or less than, the insuLATion DispLACemenT the contact. resistance of an equal section of wire. © Copyright 2012 Daniels Manufacturing Corp. ALL RIGHTS RESERVED. www.DMCTools.CoM PAGE 1 Tensile Test Systems For Wire Terminations and Similar Applications jaws or other components to make test The PT-150H Manual Wire Crimp Pull sample installation and removal an easy Tester is ideal for testing crimp strength task. up to size 10 for Mil-Spec applications, Models are available with output and size 4 AWG for commercial and display readings in Pounds, Newtons, automotive applications. and/or Kilograms to conform with the The HPT-200 hand-held pull tester requirements of the user’s system. Units blends the accuracy and rugged The DepenDABLe are available for either 115 or 230 volt design of the Alphatron pull testers ALphATron™ TensiLe power input. into a self-contained, portable, TesT sysTem It’s only natural that the company rechargeable battery powered unit. Now available from DMC is a line which supplies the best wire termination It is ideal for testing crimp strength of Electronic Tensile Test Systems tools and equipment would add the very up to size 10 AWG in Mil-Spec which may be used in conjunction best Digital Tensile Testers to further applications, and size 10 AWG in with SPC Programs or other Quality meet the demand for fewer sources and commercial and automotive applications. Control disciplines in both OEM and improved support through a wider range maintenance applications. The electronic of user needs. digital readout displays are a fast and The MPT-250B Motorized Wire Crimp reliable source of test data. Pull Tester is ideal when a constant mpT-250B-sC mo Tor iZeD The rugged construction and the rate of pull is desired. It tests crimp sAfe-T-CABLe™ TesTer portable design of these test machines strength on terminations up to size 8 make any of them a superior choice for in Mil-Spec applications, and size 1/0 The specifications for this model are on-site or laboratory use in an infinite AWG in commercial and automotive the same as MPT-250B. variety of applications. The operation of applications. The MPT-250B-SC is equipped to the equipment is simple yet versatile, test .020″, .032″ and .040″ diameter and DMC will customize the gripping Safe-T-Cable™. GENERAL SPECIFICATIONS MPT-250B PT-150H HPT-200 Capacity 250 lbf 113 kg 150 lbf 68.0 kg 200 lbf 90.7 kg 1112 N 667 N 889 N Accuracy ±0.5% (1/2 of 1%) ±0.5% (1/2 of 1%) ±0.5% (1/2 of 1%) Resolution 0.1 lbf 0.1 lbf 0.1 lbf Display Type Digital Display Digital Display Digital Display moToriZeD puLL TesTers w/Peak w/Peak w/Peak mpT-250B Hold Reading Hold Reading Hold Reading Display LED w/.56" LED w/.56" LED w/.56" high digits high digits high digits Electrical 115 VAC, 50/60 Hz 115 VAC, 50/60 Hz Int. Battery 115 VAC, 50/60 Hz Charger 230 VAC, 50/60 Hz 230 VAC, 50/60 Hz 230 VAC, 50/60 Hz Charger Available operating 50°F to 100°F 50°F to 100°F 50°F to 100°F Temperature (10° to 38°C) (10° to 38°C) (10° to 38°C) mAnuAL puLL TesTers pT-150h DIMENSIONS MPT-250B PT-150H HPT-200 Height 9.5 in. (24.13 cm) 5 in. (12.7 cm) 2 in. (5.08 cm) case width 10 in. (25.4 cm) 8.5 in. (25.4 cm) 9.5 in. (24.13 cm) case Depth 15 in. (38.1 cm) 16 in. (40.6 cm) 6.25 in. (15.87 cm) case weight 26 lbs. (11.78 kg) 15.2 lbs. (6.89 Kg) 2.5 lbs. (1.13 kg) case hAnD-heLD porTABLe puLL TesTer (less options) (less options) and hand unit moDeL hpT-200 PAGE 2 www.DMCTools.CoM © Copyright 2012 Daniels Manufacturing Corp. ALL RIGHTS RESERVED. MPT-250B Motorized Wire Crimp Pull Tester The MPT-250B Motorized Wire Crimp speCifiCATions for The Terminal & Wire Grips Pull Tester has a range from five pounds mpT-250B moToriZeD Custom Grips Available. force to two-hundred and fifty pounds Wire Crimp puLL TesTer Consult DMC for details. (2-113 Kg, 22-1112 N). • Capacity Range 5-250 lbs. You can expect the same precision (2-113 kg, 22-1112 N) and dependability that has established all • Pull Rate: 1 to 10"/min. Push-button SLOTTED TERMINAL GRIP ALPHATRON® testers as the first choice Selectable in 1"/min. Increments. for wire harness builders and component • Pull Rate Accuracy (standard) suppliers throughout the industry. The ± 1/8"/min. @ 1–5"/min. Rate of Pull 250 pound capacity of this tester will ± 1/4"/min. @ 6–10"/min. Rate of Pull extend the range of testing capabilities • Auto-Stop at Wire/Crimp Break Point to size 8 Mil-Spec applications*, and size • Auto Return to Start Position 1/0 AWG in commercial and automotive • 15 Position Slotted Lower applications** (Reference AS7928 and Terminal Grip. UL486 Respectively). • Display Units in Pounds, Kilograms, The portable design (25 pounds, or Newtons 9.5”x10”x16”) and the rugged construc- • Lb/Kg/Newtons Switching Built in p/n 15-3087 tion (machined aluminum and steel) contribute to the versatility and reliability MPT-250B options: Universal Self- of the MPT-250B Pull Tester. A variety of Tightening Cam-Type Lower Grip • Ring RING TERMINAL GRIP* options, including standard and custom Terminal Lower Grip • 7.5–30"/min. (optional) grips for all types of wire terminations are Selectable Rates of Pull in 10 2.5"/min. available on this tester. The operation of Increments • Adjustable Set-point for the tester is simple and has automatic Motor Stop at Pre-Set Force. reset and auto-stop features incorporated into the design. The peak-hold digital dis- play indicates the highest pull force that is measured by the accurate load cell/ digital processor until the reset switch is pressed. * Size 8 MIL Spec wire pull test is typically 220 pounds force. Sample may not break at p/n 15-0066 Consult the factory for more specific 250 pounds. *Some ring terminals are not suitable for this grip. information, and application verification. ** May require special grips due to wire NSN: 6635-01-581-9996 diameter. SELF TIGHTENING GRIP (optional) p/n 15-3202 MINIATURE TERMINAL GRIP (optional) p/n 15-3241 © Copyright 2012 Daniels Manufacturing Corp. ALL RIGHTS RESERVED. www.DMCTools.CoM PAGE 3 PT-150H Wire Crimp Pull Tester The PT-150H Manual Wire Crimp Pull Tester is ideal for testing crimp strength up sTANDARD FEATUREs to size 10 for Mil-Spec applications*, and size 4 AWG for commercial and automotive • Capacity: 150 lb, 667 N, 68 Kg applications**. The PT-150H may be used in conjunction with SPC Programs or other • Display units factory set for Quality Control disciplines in both OEM and maintenance applications. The electronic pounds, newtons or kilograms digital readout display is a fast and reliable source of test data. • Resolution: 0.1 lb The operation of the equipment is simple yet versatile, and DMC will customize the • Accuracy: ± 0.5 % of full scale gripping jaws or other components to make test sample installation and removal an • Digital Display with Peak Hold easy task. • Backlit LCD Display with 0.56” * Size 10 MIL Spec wire pull test is typically 150 pounds force. Sample may not break at 150 High Digits pounds. • Self-Tightening Wire Grip ** May require special grips due to wire diameter. • 15 Position Slotted Terminal Contact Grip • Lever Arm Pull Mechanism OPTIONAL ACCESSORY GRIPS • Ring Terminal Grip (P/N 15-0066) • Self-Tightening Grip (P/N 15-3202) • Right Angle Terminal Grip (P/N 15-3042) PHYSICAL • Weight 15.2 Lbs. (Shipping Weight 21 Lbs.) • Stand Dimensions: H. 5”, W. 8.5”, D. 16” CALIBRATION • New units supplied with certificate of calibration traceable to NIST • Factory calibration available OPTIONAL FEATURES • 230 VAC 50/60 Hz Power (P/N 15-7004) Terminal & Wire Grips Custom Grips Available. Consult DMC for details. SLOTTED TERMINAL GRIP RING TERMINAL GRIP SELF-TIGHTENING GRIP (standard) (optional) (optional) p/n 15-3087 p/n 15-0066 p/n 15-3202 PAGE 4 www.DMCTools.CoM © Copyright 2012 Daniels Manufacturing Corp. ALL RIGHTS RESERVED. HPT-200 Hand Held Wire Crimp Pull Tester The lightweight Alphatron HPT-200 • Portable, lightweight and is a self-contained tester that extends ergonomic design your testing capability to the shop floor. • Built-in NIMH battery, You no longer have to wait for process with charger samples to arrive in the QA Lab. • Up to 14 hour use on Daniels Manufacturing Durable construction and a convenient a single charge Corporation introduces carry case ensure protection. The Low • Low stress tensioning mechanism a portable tensile tester Stress tension ing mechanism makes the • Protective carrying case HPT-200 ver satile and easy to use. A capable of pull testing • Shoulder bag (optional) built in NIHM battery provides up to 14 wire crimps up to 200 • Built-in calibration test hours use on a single charge and the pounds (up to 10 AWG Power Management Circuit allows use • Accuracy: (0.5% of full scale) wire in most cases). during charging. • Resolution: (0.1 pounds) • Display in newtons, or kilograms is THe lAb IS no available longer THe lImIT… UPPER GRIP Standard Terminal Grip It is only natural that the company, SPECIFICATIONS: which is known throughout the world • Capacity: 200 LBF, 90.7 kg, 889N for quality wire termination tools and • Accuracy: ± .5% of full scale equipment would add the very best portable tensile tester to meet your need • Resolution: .1 lbf for fewer sources and improved support • Display Type: Digital display w/ through a wider range of capabilities. peak hold reading The HPT-200 hand held pull tester • Display: LCD w/.56 in. high digits p/n 15-3035 combines the accuracy and rugged • Electrical: 115 VAC 50/60 Hz or design of the Alphatron pull testers into Slot DImEnSIon 12 VDC Int. Battery a portable battery powered unit. We No. size (in.) No. size (in.) • Operating Temperature: follow that up with our expert factory 50°F to 100°F (10° to 38°C) service and calibration. 1 .031 9 .094 • Height: 2 in. (5.08 cm) case The HPT-200 portable tester is 2 .250 10 .188 • Width: 9.5 in. (24.13 cm) case an extension of the Alphatron Wire 3 .047 11 .110 Crimp Pull Tester line of products, • Depth: 6.25 in. (15.87 cm) case 4 .236 12 .172 which include the PT-150H and • Weight: 2.5 lbs. (1.21 kg) case MPT-250B. These testers perform 5 .063 13 .125 and hand unit pull-force measurements on wire 6 .218 14 .158 terminations. The rugged construction 7 .080 15 .141 A 230 volt unit is available. and portable design of these test 8 .203 P/N HPT-200-230 machines make any of them a superior choice for on-site or laboratory use. © Copyright 2012 Daniels Manufacturing Corp. ALL RIGHTS RESERVED. www.DMCTools.CoM PAGE 5 Standard Adjustable Crimp Tool upper rAnge Crimp The precision ratchet controls cycling The adjustable head (P/N UH2-5) is TooL Af8 m22520/1-01 of the tool in both directions of handle ideally suited for lab work and prototype The DMC AF8, qualified to MIL- movement. This assures the same production applications. This head DTL-22520/1*, has virtually limitless accurate crimp every time. It’s like is attached in the same manner as application within the specified wire having a quality control inspector at explained above. The selected contact range of 12 through 26 AwG. Over every work station. is inserted through the entry hole on the a thousand turret heads are available Positive crimp depth is controlled by opposite side of the tool frame from the to adapt the tool frame to your specific an 8 position selector knob conveniently head. The height adjusting screw is then military or proprietary contact/wire located on the tool frame. The operator rotated until the contact is in the proper combination. The 8 impression crimp, simply dials the desired step for the wire position for crimping. The screw can which is standard in the AF8, assures being used. This setting can be secured be secured with the locknut provided. absolute maximum tensile strength with by use of a locking pin or safety wire. Some testing will be necessary to almost every closed barrel contact. The carefully engineered design determine the optimum selector setting Special indent configurations and gaging achieves the absolute maximum for your contact/wire combination. are available upon request. mechanical advantage and the tool’s The AF8 is approximately 93⁄4" x 21⁄2" x For proper operation, the tool must light weight helps minimize operator 11⁄4" and weighs 15 oz. be mated with one of the following fatigue. optional accessories: a military standard A permanent dataplate is affixed to all or non-military turret head (TH-XXX turret heads and positioners. This plate Part No. Series), a military standard or lists specific contact part numbers, the non-military positioner (TP-XXX Part No. corresponding position color code (for Series), or an adjustable head (Part No. 3 position turret heads), and suggested UH2-5). This is done simply by orienting selector depth settings for the wire size the head in the keyed position, and being used. by tightening the hex socket screws provided as part of the head. * Change to SAE AS22520 in process consult DMC for status. PAGE 6 www.DMCTools.CoM © Copyright 2012 Daniels Manufacturing Corp. ALL RIGHTS RESERVED. Other than keeping the unit clean and MILITARY DMC properly stored when not in service, DESCRIPTION NSN P/N P/N no operator maintenance is required. DMC offers complete factory service M22520/1-01 AF8 TOOL FRAME 5120-01-335-8571 by knowledgeable technicians within a M22520/1-02 TH1A TURRET 5120-01-335-8834 reasonable turnaround time. Complete M22520/1-03 TH4 TURRET 5120-01-335-8835 instructions concerning the use, care M22520/1-04 TH163 TURRET 5120-01-335-8836 and warranty are supplied with each M22520/1-05 UH2-5 ADJUSTABLE 5120-01-335-8583 tool. Additional copies are available on POSITIONER request. Pneumatic versions of this tool are M22520/1-06 TP45 POSITIONER 5120-01-335-8584 found on page 12. M22520/1-07 TP85 POSITIONER 5120-01-335-8585 The battery powered versions of this M22520/1-08 TH199S TURRET 5120-00-016-7654 tool are found on page 10. M22520/1-09 TP360 POSITIONER 5120-01-335-8586 M22520/1-10 TP365 POSITIONER 5120-01-335-8587 M22520/1-11 TP465 POSITIONER 5120-01-335-8588 M22520/1-12 TH270 TURRET 5120-01-335-8838 M22520/1-13 TH285 TURRET 5120-01-036-9221 M22520/1-14 TH286 TURRET 5120-01-036-9222 M22520/1-15 TP485 POSITIONER 5120-01-335-8589 M22520/1-16 TP513 POSITIONER 5120-01-335-8590 M22520/1-17 TP651 POSITIONER 5120-01-335-8591 M22520/3-1 G125 GAGE 5220-01-016-6002 DMC1186 M22520/1 Tool Kit The DMC1186 tool kit contains the AF8 tool frame, tool gage, and all mil-spec sTep 1 sTep 2 positioners and turret heads. Also included in the DMC1186 are tool instruction sheets and a tool selection chart. Periodic gaging is recommended to insure accurate calibration. This can be done easily by setting the tool selector knob to position #4, and checking indenter closure with the M22520/3-1 “GO/NO-GO” gage (DMC part no. G125). inserT ConTACT inserT pre-sTrippeD Wire sTep 3 sTep 4 CLose / open hAnDLe remove TerminATeD Wire AssemBLy © Copyright 2012 Daniels Manufacturing Corp. ALL RIGHTS RESERVED. www.DMCTools.CoM PAGE 7 miniature Adjustable Crimp Tools LoWer rAnge Crimp TooL Afm8 m22520/2-01 Qualified to MIL-DTL-22520/2*, the DMC AFM8 is designed for most of the miniature and sub-miniature connector types that are so widely used in electronic systems. The AFM8 meets the need for a miniature tool accommodating wire sizes 20 through 32 AwG. The AFM8 gives a Mil-Standard 8 impression crimp, which assures maximum tensile strength. The cycle controlled precision ratchet assures consistently accurate crimps every time. The tool frame has a built-in 8 step selector knob for ease in dialing the correct crimp depth setting for the wire MILITARY P/N DMC P/N DESCRIPTION NSN being used. M22520/2-01 AFM8 TOOL FRAME 5120-01-335-8572 Positioners adapt the tool frame to M22520/2-02 K1S POSITIONER 5120-01-335-8592 a particular application. The data plate M22520/2-03 K60S POSITIONER 5120-01-335-8593 on each positioner designates which M22520/2-04 K151 POSITIONER 5120-01-335-8594 contacts the positioner accommodates M22520/2-05 K3 POSITIONER 5120-01-335-8595 for its wire size and indicates selector M22520/2-06 K41 POSITIONER 5120-01-335-8624 position. The positioner is easily removed M22520/2-07 K40 POSITIONER 5120-01-335-8625 and changed. M22520/2-08 K13-1 POSITIONER 5120-01-335-8626 Periodic gaging is recommended to M22520/2-09 K42 POSITIONER 5120-01-335-8627 insure accurate calibration. This is easily M22520/2-10 K43 POSITIONER 5120-01-335-8628 accomplished with the M22520/3-1 M22520/2-11 K287 POSITIONER 5120-01-335-8629 “GO/NO-GO” gage (DMC part no. G125) M22520/2-12 K286 POSITIONER 5120-01-335-8630 on SEL setting #8. The AFM8 is 6 3/4" in M22520/2-13 K338 POSITIONER 5120-01-335-8631 length and weighs approximately 10 oz. M22520/2-14 K340 POSITIONER 5120-01-335-8632 Other than keeping the tool clean M22520/2-15 K341 POSITIONER 5120-01-335-8633 and properly stored when not in use, M22520/2-16 K339 POSITIONER 5120-01-335-8634 no operator maintenance is required. M22520/2-17 K342 POSITIONER 5120-01-335-8635 Pneumatic versions of this tool are found M22520/2-18 K343 POSITIONER 5120-01-335-8636 on page 12. M22520/2-19 K330-2 POSITIONER 5120-01-335-8637 M22520/2-20 K331-2 POSITIONER 5120-01-335-8638 M22520/2-21 K332-2 POSITIONER 5120-01-335-8609 M22520/2-22 K212 POSITIONER 5120-01-335-8610 M22520/2-23 K267-1 POSITIONER 5120-01-335-8611 M22520/2-24 K75S-1 POSITIONER 5120-01-335-8612 M22520/2-25 K261-1 POSITIONER 5120-01-335-8613 M22520/2-26 K262-1 POSITIONER 5120-01-335-8614 M22520/2-27 K269-1 POSITIONER 5120-01-335-8615 M22520/2-28 K373-1 POSITIONER 5120-01-335-8616 M22520/2-29 K372-1 POSITIONER 5120-01-335-8617 M22520/2-30 K404 POSITIONER 5120-01-335-8618 M22520/2-31 K406 POSITIONER 5120-01-335-8619 M22520/2-32 K496 POSITIONER 5120-01-335-8620 The DMC274 tool kit contains the M22520/2-33 K74S POSITIONER 5120-01-335-8621 AFM8 tool frame, tool gage, and all M22520/2-34 K323 POSITIONER 5120-01-335-8622 mil-spec positioners. Also included in M22520/2-35 K532-1 POSITIONER 5120-01-335-8623 the DMC274 are tool instruction sheets M22520/2-36 K473 POSITIONER 5120-01-335-8596 and a tool selection chart. M22520/2-37 K709 POSITIONER 5120-01-361-9666 M22520/3-1 G125 GAGE 5220-01-016-6002 ADJUSTABLE SK2/2 5120-01-171-1569 * Change to SAE AS22520 in process consult DMC POSITIONER for status. DMC274 M22520/2 TOOL KIT 5180-01-259-0512 PAGE 8 www.DMCTools.CoM © Copyright 2012 Daniels Manufacturing Corp. ALL RIGHTS RESERVED.