Owner manual

IS-38 Issue: 2 Date: 07.05.13 C/Note: 12060 Page 1 of 3
GECKO ASSEMBLY TOOL Z125-902
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.
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Insertion/Extraction Tool Holder
Insertion tip 30/32 AWG
(for insulation up to Ø0.65mm)
Insertion tip 26/28 AWG
(for insulation up to Ø0.85mm)
Removal tip
Female contact
Removal tip
Male contact