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III. Contacts

Fig. 2 describes the various types and sizes of contacts supplied with each connector configuration.
Insert Style No. of Contacts Contact Size Max. Wire Gague Uses silicone wire P/N Cable Dia. Ref. Strip Length Crimp or Solder Crimp Tool P/N Positioner
1001 1 20 16 167-9193 .150 .250 Both M22520/1-01 M22520/1-03
1802 1 20 20 167-9180 .280 .250 Both M22520/1-01 M22520/1-03
1803 1 16 14 167-9180 .280 .250 Both M22520/1-01 M22520/1-03
2204 1 16 16 167-9180 .280 .250 Both M22520/1-01 M22520/1-03
2405 1 12 12 167-9180 .280 .250 Solder    
2406 2 12 12 167-9180 .280 .250 Solder    
1607 3 20 16 167-9193 .150 .250 Both M22520/1-01 M22520/1-03
2408 3 12 12 167-9180 .280 .250 Solder    
1809 4 16 16 167-9193 .150 .250 Both M22520/1-01 M22520/1-03
2810 2 08 08 167-9169 .180 .250 Solder    
2810 2 16 16 167-9634 .100 .250 Solder    
1211 5 20 20 167-9634 .100 .187 Both M22520/1-01 M22520/1-04
2812 5 12 12 167-9180* .280* .250 Solder    
1221 6 20 20 167-9634 .100 .187 Both M22520/1-01 M22520/1-04
2814 6 12 12 167-9180* .280* .250 Solder    
1615 7 20 16 167-9193 .150 .250 Both M22520/1-01 M22520/1-03
4016 4 06 06 167-9193 .150 .375 Solder    
4016 3 12 12 167-9634 .100 .250 Solder    
3218 8 16 16 167-9180* .280* .250 Solder    
4020 20 16 16 167-9634 .100 .187 Solder    
4020 1 12 10 167-9169 .180 .250 Solder    
* Contacts rated for Use cable P/N
25-45 KVDC 167-9180
20 KVDC 167-9169
15-16 KVDC 167-9193
10 KVDC or less 167-9634
IV. Connector Assembly

A. Wire Preparation
  1. First determine which cable and/or wires will go to each position. For information on Reynolds silicone rubber wire, see page 16.
  2. If cable is jacketed, strip jacket back far enough to work with the individual leads but if a cable clamp is used, the jacket should fall within the clamp.
  3. Strip all wire ends. See Figure 2 for strip length.
  4. Crimp or solder wires to contacts. See Figure 2 for appropriate crimp tools and positioners.
  5. If a cable clamp is used, slide it on to the cable. If a rubber bushing is used, also slide it onto the cable. Shell assembly styles 1, 3 and 4 have rear threads that will accept a cable clamp.
  6. Insert configurations 1607, 1211 and 1221 require a compression ring. The compression ring should also be slid onto the cable.
  7. Proceed to step C1 if your connector configuration already has insert assembled into shell.

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