2M803 datasheet(31/31 Pages) ETC2

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ASSEMBLY INSTRUCTIONS

STEP 1: Remove hardware from plug or

receptacle and slip over wire bundle in proper

order for reassembly.

STEP 2: Using proper plastic or metal insertion

tool for corresponding contact, position wire

in tip of the tool so that the tool tip presses

against the contact shoulder.

STEP 3: Press tool against contact shoulder

and, with firm and even pressure, insert wired

contact and tool tip into center contact cavity.

WIRE STRIPPING

CONTACT CRIMPING

CONTACT EXTRACTION

STEP 5: Remove tool and pull back lightly on wire

to make sure contact is properly seated. Repeat

operation with remainder of contacts to be inserted,

beginning with the center cavity and working outward

in alternating rows.

STEP 6: After all contacts are inserted, fill

any empty cavities with wire sealing plugs.

Reassemble plug or receptacle hardware.

STEP 1: Remove hardware from plug or

receptacle and slide hardware back along

wire bundle.

STEP 2: Using plastic or metal extraction

tool with proper color code corresponding to

contact size, place wire in tool.

STEP 4: Hold wire firmly in tool and extract

wired contact and tool. Repeat operation for all

contacts to be extracted.

STEP 3: Insert tool into contact cavity until

tool tip bottoms against the contact shoulder,

expanding clip retaining tines.

Strip insulation from the end of wire to be crimped. (See

table for proper stripping dimensions.) Do not cut or dam-

age wire strands.

CONTACT SIZE

23, 20HD

.150 (3.18)

.188 (4.77)

CONTACT INSERTION

STEP 5: Fill any empty cavities with wire sealing

plugs. Reassemble plug or receptacle hardware.

STEP 4: When contact bottoms, a slight “click” can

be heard as tines of metal retaining clip snap into place

behind contact shoulder.

STEP 1: Insert wire into rear of contact. Wire

insulation must press against rear of contact. Wire

must be visible through inspection hole.

STEP 2: M22520 series crimp tool and locator is

recommended. See Contact and Tool Table on pages

182 and 183 for choice of turret head and selection

setting according to contact size, part number and wire

gauge size.

STEP 3: Insert contact and wire into tool jaws. To

crimp, squeeze handles together fully until ratchet

releases and allows handles to expand; otherwise,

contact cannot be extracted from tool jaws. Maintain

slight insertion pressure on wire while crimping contact

to wire.

Correct

Incorrect

All dimensions in inches

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