Amphenol Aerospace

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38999, Series I LJT, II JT, III TV, & SJT Assembly Instructions Amphenol Aerospace Wire Stripping Stripping Dimensions 1. Strip wire to required length. (See Figure at right). When using hot wire stripping, do not wipe melted insulation material on wire strands; with mechanical strippers do not cut Wire Size or nick strands. A 2. See Table 1 for proper finished outside wire dimensions. 3. Twist strands together to form a firm bundle. 4. Insert stripped wire into contact applying slight pressure until wire insulation Table 1 butts against wire well. Check inspection hole to see that wire strands are visible. If there are strayed wire strands, entire wire end should be re-twisted. Contact Size When wire is stripped and properly installed into contact, the next step is to crimp the wire inside the contact by using the proper crimping tool. Crimping See table on preceding page for recommended M22520 series crimping tools, turret head or positioner selection settings according to contact size, part number and wire gauge size. 1. Insert stripped wire into contact crimp pot. Wire must be visible through inspection hole. 2. Using correct crimp tool and locator, cycle the tool once to be sure the indentors are open, insert contact and wire into locator. Squeeze tool handles firmly and completely to insure a proper crimp. The tool will not release unless the crimp indentors in the tool head have been fully actuated. 3. Release crimped contact and wire from tool. Be certain the wire is visible through inspection hole in contact. Contact Insertion 1. First remove hardware from the plug and receptacle and slide the hardware over wires in proper sequence. Series III TV Series II JT Series I LJT SJT VISUAL INSPECTION HOLE 2. Use proper plastic or metal insertion tool for corresponding contact. (Consult Insertion Tool table on preceding page). Slide correct tool (with plastic tool use colored end) over wire insulation and slide forward until tool bottoms against rear contact shoulder. Wire Dimension (inches)** Min. Max. 10 .135 .162 12 .097 .142 16 .065 .109 20 .040 .077 22 .034 .060 22M, 22D .030 .050 ** Min. diameters to insure moisture proof assembly; max. diameters to permit use of metal removal tools. Examples of M22520 Series Crimping Tools: Shown top: tool used for small size 22, 22D and 22M contacts. Shown bottom: tool used for size 20, 16 or 12 contacts and has a positioner that can be dialed for each contact size. 3. Next align the tool and contact up to the properly identified cavity at rear of connector plug. Use firm, even pressure; do not use excessive pressure. It is recommended to start at the center cavity. Contact must be aligned with grommet hole and not inserted at an angle. Push forward until contact is felt to snap into position within insert. A 22. 22M, 22D .125 (3.18) 20 .188 (4.77) 16 .188 (4.77) 12 .188 (4.77) 38999 III HD Dualok II I SJT Accessories Aquacon Herm/Seal PCB HIgH SPeeD Fiber Optics Contacts Connectors Cables eMI Filter Transient 26482 Matrix 2 83723 III Matrix|Pyle 26500 Pyle 5015 Crimp Rear Release Matrix 22992 Class L Back- Shells Plastic tool with contact in proper position. Options Others Note: All plastic tools are double-ended. The colored side is the insertion tool and the white side is the removal tool. Metal tool with contact. Continued on next page. Contact Amphenol Aerospace for more information at 800-678-0141 • www.amphenol-aerospace.com 123
Amphenol Aerospace 38999, Series I LJT, II JT, III TV, & SJT Installation Instructions, cont. 38999 III HD Dualok II I SJT Accessories Aquacon Herm/Seal PCB HIgH SPeeD Fiber Optics Contacts Connectors Cables Series III TV Series II JT Series I LJT SJT Contact Insertion, cont. 4. Remove tool and pull back lightly on wire, making sure contact stays properly seated and isn’t dragged back with the tool. Repeat operation with remainder of contacts to be inserted, beginning with the center cavity and working outward in alternating rows. 5. After all contacts are inserted, fill any empty cavities with wire sealing plugs. (Refer to sealing plug charts for Series III on page 18, for Series I & II and SJT see page 19. 6. Reassemble plug or receptacle hardware - slide forward and tighten using connector pliers. Connector holding tools are recommended while tightening back accessories. When using strain relief, center wires at bar clamp. Slide clamp grommet into position and tighten clamp bar screws. When tightening screws, pressure should be applied in the same direction that clamp is threaded to rear threads of connector. When not using clamp grommet, build up wire bundle with vinyl tape so clamp bar will maintain pressure on wires. eMI Filter Transient CAUTION, when inserting or removing contacts, do not spread or rotate tool tips. 26482 Matrix 2 83723 III Matrix|Pyle 5015 26500 Crimp Rear Pyle Release Matrix Contact Removal 1. Remove hardware from plug or receptacle and slide hardware back along wire bundle. 2. Use proper plastic or metal removal tool for corresponding contact. (Consult Removal Tool table on page 135). Slide correct size tool over wire insulation. 3. Insert plastic or metal removal tool into contact cavity until tool tips enter rear grommet and come to a positive stop. Hold tool tip firmly against positive stop on contact shoulder. Grip wire and simultaneously remove tool and contact. (On occasion, it may be necessary to remove tool, rotate 90° and reinsert.) 22992 Class L Use white end of plastic tool for removal of contacts. Removal of contacts with metal tool. Options Others Back- Shells 124 Contact Amphenol Aerospace for more information at 800-678-0141 • www.amphenol-aerospace.com
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Amphenol Products for Military, Aer
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Amphenol Aerospace Amphenol Aerospa
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Amphenol Aerospace Amphenol New Pro
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Amphenol Aerospace MIL-DTL-38999, S
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Amphenol MIL-DTL-38999, Series III,
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38999 HD Dualok II I SJT EMI Filter
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Amphenol Aerospace Boeing BACC63 Ho
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38999 III HD Dualok II I SJT Access
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Amphenol Aerospace D38999/29 & D389
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EMI Filter Transient 26482 Matrix 2
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38999 III HD Dualok TV01( II CTV01(
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Amphenol Aerospace Custom Designed
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Amphenol Aerospace JT00R (MS27472)
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Amphenol Fiber Optic Interconnects
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Amphenol Aerospace 90° Multi-Mode
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Amphenol Aerospace CF38999 Multi-Ch
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Amphenol Aerospace Fiber Optic Cabl
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Amphenol Aerospace Cable Systems wi
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Amphenol Aerospace Cable Usage Guid
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Amphenol EMI/EMP Filter Protection
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Amphenol Aerospace EMI Capabilities
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Amphenol Aerospace Assembly Instruc
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Amphenol Aerospace Accessories - C
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Amphenol MIL-DTL-5015, Matrix ® TA
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Backshells from Amphenol PCD TABLE
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Amphenol Backshells Quick Reference
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Amphenol Aerospace

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