D20419-80 Datasheet, PDF (138/386 Pages) ITT Industries – Military/Aerospace

MIL-C-38999 Series I, II, III Connectors
Wire Stripping
Strip insulation from end of wire to be crimped.
A
(See table for proper stripping dimensions.) Do not
cut or damage wire strands.
Contact Crimping
VISUAL INSPECTION HOLE
KJL/KJ/KJA
Wire Size
A
22D or 22M*
.125 (3.18)
20
.188 (4.77)
16
.188 (4.77)
12
.188 (4.77)
* Inactive, not recommended for new design, replacement only.
1. Insert stripped wire into contact crimp pot. Wire must be
visible thru 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.
Contact Insertion
3. Release crimped contact and wire from tool. Be certain the
wire is visible thru inspection hole in contact.
1. Remove hardware from plug or receptacle and slip over wire
bundle in proper order for reassembly.
2. Using proper plastic or metal insertion tool for corresponding
contact, position wire in tip of the tool so that the tool tip butts up
against the contact shoulder.
3. Press tool against contact shoulder and, with firm and even
pressure, insert wired contact and tool tip into center contact
cavity. A slight click may be heard as metal retaining tines snap
into place behind contact shoulder.
Contact Extraction
4. Remove tool and pull back lightly on wire to make sure
contact is properly seated. 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, Ressemble plug or receptacle hardware.
1. Remove hardware from plug or receptacle and slide
hardware back along wire bundle.
2. Using plastic or metal extraction tool with proper color code
corresponding to contact size, place wire in tool.
3. Insert tool into contact cavity until tool tip botoms against the
contact shoulder, expanding clip retaining tines.
4. Hold wire firmly in tool and extract wired contact and tool.
Repeat operation for all contacts to be extracted.
5. Fill any empty wire cavities with wire sealing plugs, and
6. Reassemble plug or receptacle.
Dimensions are shown in inches (millimeters).
Dimensions subject to change.
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