GECKO ASSEMBLY TOOL Z125-902 Insertion/Extraction Tool Holder Insertion tip 26/28 AWG (for insulation up to Ø0.85mm) Removal tip Female contact Insertion tip 30/32 AWG (for insulation up to Ø0.65mm) Removal tip Male contact INSERTION PROCEDURE 1. Strip the wire and crimp the contact on to the wire, ensuring that the correct part is used (see Instruction Sheet IS-37, Hand Crimp Tool Z125-900). 2. Ensure all parts (moulding and crimp sockets) are clean and ready for final assembly. 3. Select the appropriate insertion tool for the wire size in use and attach to the handle. The different tools can be found by unscrewing the cap at the end of the handle (see above for tool identification). 4. Place the crimped contact partially into the moulding. The correct position is reached when approximately 0.4-1.0mm of contact protrudes (see Figures 2 and 3). 5. Place the insertion tool over the wire, with the wire sitting in the groove and the tool resting on the back of the crimped socket (see Figure 1). 6. To complete the assembly, push firmly on the rear of the contact while ensuring the tool remains perpendicular to the mould face. There will be an audible click when the contact is correctly seated within the moulding. 7. Repeat steps 4 to 6 until the moulding is populated as required. Care should be taken not to damage any contacts. It is recommended that the moulding be supported by a small fixture (like an unpopulated mating moulding in a vice) or a hard flat surface. Do not support the mould on any latches fitted, or pressure exerted on inserting the contacts will bend the latches. Harwin North America T: +1 603 893 5376 F: +1 603 893 5396 E: [email protected] W: www.harwin.com IS-38 Issue: 2 Date: 07.05.13 C/Note: 12060 Harwin Europe T: +44 (0) 23 9231 4545 F: +44 (0) 23 9231 4590 E: [email protected] W: www.harwin.com Harwin Asia T: +65 6 779 4909 F: +65 6 779 3868 E: [email protected] W: www.harwin.com.sg Page 1 of 3 Cable Groove Insertion Tool Moulding (back face) Cable Partially Inserted Contact Figure 1 Incorrect contact position Incorrect contact position Correct contact position Correct contact position Moulding Moulding Figure 2 (Female contact position prior to final ‘click-in’) IS-38 Issue: 2 Date: 07.05.13 C/Note: 12060 Figure 3 (Male contact position prior to final ‘click-in’) Page 2 of 3 EXTRACTION PROCEDURE To remove a contact from the moulding, select the appropriate Extraction Tool from the handle and attach as before. Place this tool over the mating end of the contact and push firmly. Care should be taken to keep the tool perpendicular to the mould face, or mould damage may occur. Male Extraction Tool Female Extraction Tool Female Moulding Male Moulding Female Contact Male Contact Figure 4 Notes: 1) Different Tool Tip for Female and Male 2) Following the extraction of Female contacts from their moulding, re-use of that moulding is not advised. It is recommended that a new moulding be used to ensure the integrity of the contact retention in the moulding. IS-38 Issue: 2 Date: 07.05.13 C/Note: 12060 Page 3 of 3