Instruction Sheet Insertion/Extraction Tool 91285-1 408-9404 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 Cap Handle .050 In. Hex Wrench Insertion/Extraction Tips Plug INSERTION/EXTRACTION TIPS CONTACT SIZE WIRE SIZE (AWG) 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 Figure 1 illustrations are for reference only and are not drawn to 1. INTRODUCTION scale. This instruction sheet covers the use of Insertion/ Extraction Tool 91285-1 and Replacement Tip Kits 2. DESCRIPTION (Figure 1) 543382 shown in Figure 1. The tool is designed to insert and extract HD-22 and HD-20 contacts used in The insertion/extraction tool consists of a handle, a AMPLIMITE* High Density (HD) Connectors. cap, six insertion/extraction tips, a plug, and a .050 in. hex wrench. The handle of the tool provides For information concerning the assembly of storage for the tips, plug, and hex wrench. The AMPLIMITE HD connectors, refer to the instruction insertion/extraction tips convert the tool for the sheet packaged with the connector. appropriate product and are used to insert or extract connector contacts. Each tip is color coded according Read these instructions thoroughly before using the to specific type and wire size. The plug is inserted into tool. the widest end of the tip to prevent damage to the tip See Section 6, REVISION SUMMARY, for revision when it is secured in the tool handle. The hex wrench information. is used to tighten the setscrew which secures the tip in the tool handle. NOTE NOTE All dimensions on this document are in metric units with i U.S. customary units in brackets . Figures and 20113 Tyco Electronics Corporation, a TE Connectivity Ltd. Company TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change. 1 of 6 All Rights Reserved PRODUCT INFORMATION 1-800-522-6752 For latest revision and Regional Customer Service, TE logo is a trademark. visit our website at www.te.com *Trademark. Other products, logos, and company names might be trademarks of their respective owners. LOC B408-9404 Insertion/Extraction Tip Wire Slot (Ref) Insertion/Extraction Handle Plug Setscrew (Ref) Bottom of Tool (Ref) Figure 2 3. Using the hex wrench, tighten the setscrew to 3. TOOL ASSEMBLY (Figure 2) secure the tip in the tool handle. Refer to Figure 1 and select the appropriate contact, wire size, and insertion/extraction tip. Proceed as 4. INSERTION/EXTRACTION PROCEDURES follows: 4.1. Inserting A Wire Crimped Contact (Figure 3) 1. Insert plug into the widest end of the insertion/ extraction tip. 1. Position tool handle between thumb and fingertips, then place wire over the wire slot of the 2. Slide the insertion/extraction tip into the end of tip. Hold wire in this position with your thumb. the tool handle with the orientation latch positioned toward the bottom of the tool. Back of Receptacle Connector 205439-1 Wire Butt Tool Tip Against Contact Shoulder Insertion Tip Contact Cavity Wire Slot Insertion Handle Figure 3 Rev D 2 of 6