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HOW TO INSTALL CONNECTORS ONTO TRANSFORMER WIRES
A connector will be placed in the primary wires of the transformer. This will allow you to remove the top panel
from the trainer. Follow the procedures below.
1. Cut a six inch length off of each black primary wire.
2. Strip the insulation off of each end of the six inch wires to expose 1/4” of bare wire.
3. Place one wire onto the female pin and crimp the outer crimp tabs with pliers over the insulation as shown
in Figure 1A.
4. Crimp the inner tabs with pliers onto the bare wire as shown in Figure 1B and then solder the wire to the pin.
5. Connect the other female pin to the other wire using the same procedures above.
A
B
Locking Tab
Female Pin
Solder
Outer
Crimp Tab
Inner
Crimp Tab
Female Housing
Figure 1
Figure 2
6. Insert the two pin/wire assemblies into the female housing as shown in Figure 2. Pull on the wire to check
that the pin is inserted all the way in. It should not pull out of the housing. The locking tabs should be bent
outward to hold the pin in the housing.
TRANSFORMER WIRES
1. Strip the insulation off of each of the black primary wires to expose 1/4” of bare wire.
2. Place the wire onto the male pin and crimp the outer crimp tabs with pliers over the insulation as shown in
Figure 3A.
3. Crimp the inner tabs with pliers onto the bare wire and then solder the wire to the pin as shown in Figure 3B.
4. Connect the other male pin to the other primary wire using the same procedures above.
5. Insert the two pin/wire assemblies into the male housing as shown in Figure 4. Pull on the wire to check that
the pin is inserted all the way in. It should not pull out of the housing.
6. Connect the male and female housing as shown in Figure 5. Note that the connector only fits together one way.
7. To detach the connector, push down on the end of the lock arm and pull the two apart.
Figure 3
Figure 4
A
B
Locking Tab
Male Pin
Solder
Outer
Crimp Tab
Inner
Crimp Tab
Male Housing
Lock Arm
Figure 5
