Tooling Guide for Aerospace Wiring Systems - Interstate Connecting ...

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Preface and Table of Contents Daniels 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. CONTENTS Important Facts About Crimping......................................1 Tensile Test Systems........................................................2 MPT-250B (Motorized 250 lb)....................................3 PT-150H (Manual 150 lb)............................................4 HPT-200 (Portable, Manual 200 lb)............................5 Standard Adjustable Indent Crimp Tool..........................6 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 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 Connector Illustration...............................................22 Contact Color Code (BIN)........................................22 M39029 Contact Quick Location Chart...................23 MIL-STD-1760 Connector Tooling...........................24 Installing and Removal Tools..........................................56 MIL-I-81969 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) Open Frame Crimp Tools................................................70 M22520/5-01 (HX4) M22520/10-01 (HX3) 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 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 Typical Y-Die Configurations and Applications 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 (Fine Tipped Indenter Tools).......98 MH800 (Ultra Precision)...........................................99 MH820 (Stainless Steel Indentor).............................99 SC8 & MH993 (Biased Crimp Tools).....................100 Dedicated Application Indent Crimp Tools..................101 LH8 (for Burndy YHMM Series Contacts) GS217 (MIL-C-22442/32-1 Clamping Ring Crimp Tool) 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 Swaging Tool & Tool Kit................................................166 Wiring System Service Kits...........................................168 Limited Warranty...........................................................172 NOTICE 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. © Copyright 2010 Daniels Manufacturing Corp. ALL RIGHTS RESERVED www.DMCTools.com
Important Facts About Crimping Time Line for Crimp Technology 1940s All terminations were soldered (Hard-wired) 1953 AMP introduced Crimp Barrel Terminals 1957 Cannon Brothers experimented with Machined Contacts with Crimp Barrels 1960 Buchanan introduced the 4 Indent Crimp Tool with a Ratchet (Ref: MS3191) 1963 MS3191-1 was published as the first Crimp Tool Standard. 1965 MS3191-4 introduced by Daniels Manufacturing Corp. 1969 MIL-T-22520 published and dated to replace all previous specifications 1974 Changed to MIL-C-22520, and many Slash Sheets added 1996 Changed to MIL-DTL-22520 2010 Changed to AS22520 CRIMPING: THEN AND NOW The first multi-pin connectors were terminated by soldering the conductor to non-removable contacts. However, high temperature applications and the need for simple and reliable field service led to the introduction of connectors with removable contacts. These were crimped onto the conductor rather than being soldered. The first standard crimp tool developed to crimp these new contacts was introduced in the early sixties. MS3191-1, a military drawing, defined this tool and its accessories. The MS3191-1 utilized a four indent crimp pattern together with a positive stop locator which controlled the travel of the indenters (crimp depth). The MS3191-1 design was a compromise between simplicity of operation and crimp performance since the crimp depth for any given contact was not adjustable to accommodate the differing diameters of the conductors to which it would be crimped. It was, however, suitable for the crimp connectors of that era. An improved tool design featuring independently adjustable crimp depths was soon introduced as MS3191-4. The MS3191-4 had an internal adjustment, totally independent of the locator, which permitted the selection of seven separate crimp depths, allowing optimal crimping of conductors ranging from AWG 12 to 26 regardless of the wire barrel size of the contact. MS3191-4 also introduced the use of the double tipped indenter to produce an eight indent crimp pattern which has consistently achieved superior tensile pull off values. MS3191-4 introduced the concept of a turret head containing three locators which could be used without separating any of them from the basic crimp tool. In 1969 two military specifications for crimp tools were developed to replace the existing military drawings. They were MIL-T-22520C (Navy) and MIL-T-83724 (USAF) which defined a standard size crimp tool similar to the MS3191-4, but with an expanded eight step crimp depth range. These specifications also defined a miniature crimp tool to crimp conductors as small as AWG 32. Both documents were combined in 1971 into MIL-C-22520D. All previous military standards for crimp tools were then cancelled including the MS3191. This list includes specifications for indent crimp tools, terminal lug crimp tools, pneumatic tools, coaxial cable crimp tools and connector service kits. MIL-DTL-22520 established a single specification which set forth performance requirements for all crimp tools to be used on military standard electrical connectors. This eliminated the waste and confusion which accompanied the overlapping applications of many different “standard” crimp tools called out by a deluge of unrelated military drawings. THE CRIMPING CONCEPT Crimping is a method of firmly attaching a terminal or contact end to an electrical conductor by pressure forming or reshaping a metal barrel together with the conductor. The forming of a satisfactory crimp depends on the correct combination of conductor, crimp barrel and tool. When applied with a properly matched tool, a union is established which has both good electrical and mechanical characteristics. The tool will provide these requirements consistently and reliably with repeatability assured by quality cycle controlled tooling. There are several common configurations of crimped joint; several examples are shown below. The electrical resistance of a properly designed and controlled crimped joint should be equal to, or less than, the resistance of an equal section of wire. Specifications state the requirements in terms of millivolt drop at a designated current. The mechanical strength of a crimped joint and hence its pull-out force (tensile strength), varies with the deformation applied. Therefore, by properly shaping the deformation a high pull-out force can be achieved, i.e. the crimp die of the tool determines the crimp configuration and deformation. The dies in the tool determine the completed crimp configuration which is generally an element of contact and/ or connector design. Some of the design considerations are: a) The type of contact, its size, shape, material and function, b) The type and size of wires to be accommodated, c) The type of tooling into which the configuration must be built. Eight Indent Four Indent Two Indent Hexagonal Crimp Circular Crimp B Crimp Nest & Indent Crimp Captive Crimp Insulation Displacement © Copyright 2010 Daniels Manufacturing Corp. ALL RIGHTS RESERVED. www.DMCTools.com PAGE 1
Page 1: Tooling Guide for Aerospace Wiring
Page 5 and 6: MPT-250B Motorized Wire Crimp Pull
Page 7 and 8: HPT-200 Hand Held Wire Crimp Pull T
Page 9 and 10: Other than keeping the unit clean a
Page 11 and 12: MIDDLE RANGE INDENT CRIMP TOOL MH86
Page 13 and 14: AFE8-R Remote Head Battery Powered
Page 15 and 16: Header Right Subheadline WA27-309-2
Page 17 and 18: Module System A special module is m
Page 19 and 20: Large Gage Contact Application Guid
Page 21 and 22: PICO* LOCATOR PICO DIE ASSEMBLY 503
Page 23 and 24: PICO* LOCATOR PICO DIE ASSEMBLY DMC
Page 25 and 26: M39029 Contact Quick Location Chart
Page 27 and 28: MIL-DTL-24308 Miniature Rectangular
Page 29 and 30: MIL-DTL-26482 series 2 Circular Bay
Page 31 and 32: HEADER MIL-DTL-26518 SUbheaDER CLAS
Page 33 and 34: MIL-DTL-28804 Rectangular POLARIZED
Page 35 and 36: HEADER MIL-C-38300 SUbheaDER Circul
Page 37 and 38: HEADER MIL-PRF-38999 SUbheaDER seri
Page 39 and 40: HEADER MIL-STD-1760 SUbheaDER (MIL-
Page 41 and 42: AS50151 (formerly MIL-C-5015) serie
Page 43 and 44: MIL-C-81511 series 1 Scoop Proof -
Page 45 and 46: MIL-C-81511 series 3 Scoop proof -
Page 47 and 48: MIL-DTL-81659 series 1 Rectangular
Page 49 and 50: HEADER MIL-C-81703 SUbheaDER series
Page 51 and 52: HEADER MIL-dtl-83527 SUbheaDER (ari
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MIL-DTL-83723 series 3 Circular Bay
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MIL-C-85028 series AS Rectangular -
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HEADER MIL-STD-1549 SUbheaDER Commo
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Installing and Removal Tool Illustr
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MIL-I-81969 Tool Part Number Guide
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PLASTIC INSTALLATION & REMOVAL TOOL
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Header Contact Right Gages Subheadl
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BETA Backshell Accessory Torque Too
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Two-Step Banding Tool System DBS-11
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MIL Spec Circular Indent Crimp Tool
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M22520/5 & 110 Crimp Die Reference
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HXE4-R The HXE4-R Remote Head Batte
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X-Die Pneumatic Tool Bench Press St
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Header Y-Dies For A Right Full Rang
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Coaxial/Shielded Contact Tool Selec
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R.F. Connectors Tool Selection Guid
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The M300BT is designed for pin and
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The M321 is designed for the rail t
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Dedicated Application Circular Crim
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Special Application Indent Crimp To
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Dedicated Application Indent Crimp
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Hand Tool P/N Battery Tool P/N Remo
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GMTExxx-R Remote Head Battery Power
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DCT4 Tool Series Dies DCT4 Tool Ser
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Hydrac Hydraulic 3.5 Ton Crimping
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Electric Hydraulic 3.5 Ton Crimp To
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Header Hydrac Right Subheadline HD
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MS23002* Dies & Gages for MS25036 I
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Wire Harness Tools WIRE HARNESS SPO
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Terminal and Splice Crimp Tooling O
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M7928/1-11 to -19, Size 22 Similar
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M7928/4-111 to -114, Sizes 12 to 10
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M7928/4-152 to -159, Sizes 16 to 10
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M7928/6-1 to -5, Sizes 26 to 10 AWG
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M81824/1-01 to -03, Sizes 26 to 12
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M81824/7-01 to -03, Sizes 26 to 12
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M81824/9-01 to -03, Sizes 26 to 12
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M81824/11-01 to -03, Sizes 26 to 12
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AWG AWG Wire Size mm HEADER MS17143
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MS20659-101 to -106, Sizes 22 to 10
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MS20659-117 to -124, Sizes 1/0 to 4
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MS20659-129 to -134, Sizes 6 to 1 S
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MS20659-140 to -150, Sizes 8 to 1 S
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MS20659-161 to -166, Sizes 22 to 10
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MS21004-8 to -14, Sizes 16 to 14 AW
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MS25036-101 to -110, Sizes 22 to 14
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AWG Wire Size mm Similar Terminal S
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MS25036-132 to -141, Sizes 1/0 to 4
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MS25036-152 to -159, Sizes 22 to 10
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AS5768 Wire Stripper Info The Indus
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ST825 Swaging Tool for Cable (wire
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Kit Applications Military Standard
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Environmental Packaging An analysis
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Ergonomics Challenge Ergonomic guid
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