POWER CONNECTOR ASSEMBLY TOOL ZK3610-00 Insertion/Extraction Tool Holder Insertion Tool Extraction Tool (Female contacts) Extraction Tool (Male contacts) INSERTION PROCEDURE 1. Strip the wire and crimp or solder the socket onto the wire, ensuring that the correct part is used (see Instruction Sheet IS-01, Hand Crimp Tool M22520/01). 2. Ensure all parts (moulding and contacts) 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 socket partially into the moulding. The correct position is reached when approximately 1.5-2mm of socket 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 socket 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 or a hard flat surface. Harwin North America Harwin Europe T: +1 603 893 5376 F: +1 603 893 5396 E: [email protected] W: www.harwin.com T: +44 (0) 23 9231 4545 F: +44 (0) 23 9231 4590 E: [email protected] W: www.harwin.com IS-22 Issue: 2 Date: 03.10.07 C/Note: 9874 Harwin Asia T: +65 6 779 4909 F: +65 6 779 3868 E: [email protected] W: www.harwin.com.sg Page 1 of 2 EXTRACTION PROCEDURE To remove a contact from the moulding, select the correct Extraction Tool from the handle and attach as before. Place this tool in the mating end of the socket and push firmly. Care should be taken to keep the tool perpendicular to the mould face, or mould damage may occur. Insertion Tool Cable Groove Cable Partially Inserted Contact Moulding (back face) Figure 1 Contact Contact Moulding Moulding Figure 2 (Correct contact position prior to final ‘click-in’) IS-22 Issue: 2 Date: 03.10.07 C/Note: 9874 Figure 3 (Incorrect contact position prior to final ‘click-in’) Page 2 of 2