Instruction Sheet 408-9404 Insertion/Extraction Tool 91285-1 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 1. INTRODUCTION illustrations are for reference only and are not drawn to 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 Read these instructions thoroughly before using the connector contacts. Each tip is color coded according tool. to specific type and wire size. The plug is inserted into 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 NOTE the tool handle. iNOTE All dimensions on this document are in metric units [with 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 B

408-9404 Insertion/Extraction Tip Wire Slot (Ref) Insertion/Extraction Handle Plug Setscrew (Ref) Bottom of Tool (Ref) Figure 2 3. TOOL ASSEMBLY (Figure 2) 3. Using the hex wrench, tighten the setscrew to 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: 1. Insert plug into the widest end of the insertion/ 4.1. Inserting A Wire Crimped Contact (Figure 3) extraction tip. 1. Position tool handle between thumb and 2. Slide the insertion/extraction tip into the end of fingertips, then place wire over the wire slot of the the tool handle with the orientation latch positioned tip. Hold wire in this position with your thumb. 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

408-9404 2. Slide thumb over the wire toward the end of the 3. Place tip over the contact post or crimp barrel and tip. slide the tip straight into the contact cavity until the tip bottoms against the contact shoulder. iNOTENOTE The wire must be positioned inside the wire slot of the 4. Holding the wire tight against the tool handle, pull tip. back on the tool handle to extract the contact. If you experience difficulty in extracting the contact, repeat 3. Slide tip over contact wire barrel until the tip butts Steps 1 through 4. against the contact shoulder. 4. Align contact with the BACK of the contact cavity. 4.3. Inserting A Posted Contact (Figure 5) Push contact straight into the contact cavity until the 1. Place the contact in the contact cavity. Do NOT contact bottoms. push on the contact post. 5. Remove the insertion tool; then pull back on the 2. Position the tip over the contact post. Move the wire to ensure that the contact is locked into the tool along the post until the tip butts against the contact cavity. contact stabilizer. Align the tip on the stabilizer as shown in Figure 5. 4.2. Extracting A Wire Crimped Contact (Figure 4) 3. Hold the tool handle, and push the contact post to 1. Position tool handle between thumb and make certain that the contact is locked in the cavity. fingertips, and align contact wire with the wire slot on the tip. Hold wire in this position with your thumb. iNOTENOTE Contacts with tail lengths longer than 10.85 mm [.427 2. Slide your thumb over the wire toward the end of in.] must use yellow color coded insertion tips. the insertion tip. NOTE iNOTE The wire must be positioned inside the wire slot of the tip. Back of Receptacle Connector 205439-1 (Ref) Wire Wire Slide Extraction Tip Over Slot Contact Post or Crimp Barrel Extraction Handle Figure 4 Rev D 3 of 6

408-9404 Back of Connector (Ref) Contact Contact Post Cavity Insertion Tip Butt Tool Tip Against Contact Stabilizer Figure 5 4.4. Extracting A Posted Contact (Figure 6) 5. TOOL INSPECTION/REPLACEMENT (Figure 7) 1. Place the extraction tip over the contact post. Insertion/Extraction Tool is inspected before shipment. Move the tool along the post until the tip enters the TE recommends that the tool be inspected contact cavity. immediately upon its arrival to ensure that the tool has not been damaged during shipment, and that the tool 2. Align the groove of the extraction tip with the conforms to the dimensions provided in contact stabilizer as shown in Figure 6. Figure 7.Customer-replaceable parts are provided in 3. Push the tip past the stabilizer and straight into Figure 7. If the tool becomes broken or damaged, the cavity until it bottoms. replacement and/or spare parts can be purchased by contacting: 4. For a receptacle style connector, insert a 1.02 mm [.040 in.] diameter pin straight into the FRONT CUSTOMER SERVICE (038-035) of the contact cavity. For a plug style connector, TYCO ELECTRONICS CORPORATION push on mating tip of contact with a suitable device. PO BOX 3608 5. Apply pressure to remove the contact and tool HARRISBURG PA 17105-3608 from the contact cavity. For tool repair service, please contact an TE Representative at 1-800-526-5136. 6. REVISION SUMMARY Since the previous release, the last line of Figure 1 was corrected to indicate contact HD-22. Rev D 4 of 6

408-9404 1.02 [.040] Pin Dia. Back of Connector Contact Post Extraction Tip Groove of Extraction Tip Aligned with Contact Stabilizer Figure 6 Rev D 5 of 6

408-9404 REPLACEMENT PARTS† ITEM COLOR CODE PART NUMBER DESCRIPTION 1 Yellow 543382-5 TIP, Insertion 2 Blue 543382-6 TIP, Extraction 3 Black 543382-7 TIP, Insertion 4 Green 543382-8 TIP, Insertion/Extraction 5 Red 1-543382-0 TIP, Extraction 6 Brown 1-543382-1 TIP, Extraction 7 ----- 2-21006-0 SCREW, Set No. 4-40 X .180 Lg. 8 ----- 2-26538-5 CAP † Available in packs of 25 only (one plug included in each packet). Figure 7 Rev D 6 of 6

Mouser Electronics Authorized Distributor Click to View Pricing, Inventory, Delivery & Lifecycle Information: T E Connectivity: 543382-5 543382-6 543382-7 543382-8 1-543382-0 1-543382-1