AB Connectors Limited
Specification No. 528
ABCIRP Connector Series
Assembly and wiring Instructions
AB Connectors Limited Issue 9: July 2010
Page 16 of 41
5.4 Contact insertion – Method 2
5.4.1
This alternative method involves assembling the grommet onto the connector before
inserting the contacts through the grommet and into the insert. The advantage of this
method is that the contacts can be crimped onto the wires before the connector and
accessories are touched, however:
5.4.2
This method is not preferred since it requires that the contact and insertion tools
penetrate the webs in the grommet. There is potential for the retaining clips on the
contacts to damage the grommet sealing holes and effect the performance of the
connector.
5.4.3
Extra care must therefore be taken when using this method and the grommet must be
inspected for damage after the contacts have been fitted.
5.4.4
Prepare the parts as follows:
•
Strip and crimp the contacts as per sections 5.2 and 5.3
•
Slide the accessories over the wires in the correct order.
5.4.5
Assemble the grommet onto the rear of the insulator, ensuring that the recess on the
grommet aligns with the corresponding raised section on the insert.
5.4.6
Tuck the grommet in between the connector shell and the insert until the shoulder on
the grommet is pushed almost level with the top of the serrations on the shell. A
simple tool is available to help when tucking the grommet into position.
Hint: If you push forward on the back face of the grommet it should not buckle. If it does then
the grommet has not been tucked into position correctly. This can cause the grommet to tare
when the backshell is assembled and could affect sealing.
5.4.7
Locate the required wire and feed it partially through the grommet. Note: It is best
practice to work from one side only, inserting from left to right or top to bottom in an
orderly fashion. Some arrangements have a radial pattern where working from the
centre and working outwards is best. Randomly inserting contacts is more likely to
result in wiring errors and difficulty inserting contacts.
5.4.8
Open the “Tweezers-type” insertion tool and close it around the crimp bucket of the
selected contact, ensuring that the wire does not pinch the wire as the tool closes.
Holding the tool as it close to the bucket as possible, apply a firm and even pressure,
