Instruction Sheet 1.2-mm Multiple Contact (MCON) 6-Position Sealed Plug Assemblies 408-32106 2272975- 11 MAR 15 Rev B Plug Assembly Receptacle Contacts (Wire Size) Optional Wire Covers 2272976- 1534594- (0.35 mm) Connector Position 1670144- (0.50-0.75 mm) Assurance (CPA) Wire Exit (Left/Right Shown) Polarization Feature Wire Independent Barrel Secondary Lock (ISL) Outer Housing Housing Contact Cavities Base Mating Face Figure 1 The optional wire cover is available in straight, left/right 1. INTRODUCTION (shown in Figure 1), and 90-degree angle wire exits. 1.2-mm MCON 6-position sealed plug assemblies 2272975- accept the 1.2-mm MCON receptacle 3. ASSEMBLY PROCEDURE contacts given in Figure 1. For applications subjected to severe vibration or high-pressure water spray, the 3.1. Contact Insertion optional wire cover, shown in Figure 1, is recommended. 1. Crimp the contacts using the tooling and This instruction sheet provides assembly (contact inspection requirements given in application insertion, optional wire cover installation, and plug specification 114-18464. The mat seal of these plug assembly mating) and disassembly (plug assembly assemblies will only accept wire with an outside unmating, optional wire cover removal, and contact diameter from 1.2 to 1.9 mm. extraction) procedures for the plug assembly. CAUTION NOTE NOTE Ensure that the wire strands do not extend above the Dimensions in this instruction sheet are in metric units. i wire barrel crimp otherwise, the wire strands could Figures are not drawn to scale. cause damage to the mat seal when the contact is Reasons for reissue of this instruction sheet are inserted into the contact cavity. provided in Section 6, REVISION SUMMARY. 2. Make sure that the connector ISL is in the open (as shipped) position as shown in Figure 2, Detail A. If it is 2. DESCRIPTION (See Figure 1) only partially open or in the closed position as shown Each plug assembly consists of a housing with circuit in Figure 2, Detail B. Refer to Step 1 of Paragraph 4.3. cavities, outer housing, mat seal for the contacts, 3. Insert each terminated contact into the plug peripheral seal, ISL, and CPA. The plug assembly is assembly as follows: available with molded-in seal plugs that provides a specific pattern of open and closed circuit cavities. a. Grasp the wire of the contact, and align the contact with the selected circuit cavity so that the Each circuit cavity is polarized to prevent the contact contact polarizing feature faces in the top of the from being inserted upside-down. After all contacts are circuit cavity (notch indicates top). See Figure 3, inserted, the ISL is used to detect that all contacts are Detail A. fully seated and to provide a secondary contact retention. If a contact is not fully seated or improperly b. Insert the contact straight into the circuit cavity orientated in the circuit cavity, the ISL will not close until it bottoms. If there is significant resistance properly. during insertion, remove the contact, and verify orientation. There should be an audible or tactile The peripheral seal prevents moisture from entering the click when the contact is fully seated. See plug assembly interface. The CPA lock is used to Figure 3, Detail B. provide a visual indication that the plug assembly is fully mated. If the plug assembly is not fully mated, the c. Gently pull the wire to ensure that the contact is CPA lock will not engage. locked in place. See Figure 3, Detail B. 2015 TE Connectivity family of companies TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change. 1 of 4 All Rights Reserved PRODUCT INFORMATION 1-800-522-6752 For latest revision and Regional Customer Service, *Trademark visit our website at www.te.com. TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and/or company names may be trademarks of their respective owners. 408-32106 4. After all contacts have been inserted, orient the ISL in Open Position Detail A plug assembly so that the CPA is facing up, then place Both Sides Raised (Unlatched) the tip of a small screwdriver (ensure that there are no sharp edges) over the top of the ISL. See Figure 4. 5. Holding the screwdriver in a straight position, press it straight down to move the ISL to the closed position. Do not rotate the screwdriver against the CPA.Take care not to damage the peripheral seal. Ensure that both sides of the ISL are seated. Refer to Figure 2 for visual inspection or use a gage designed to simulate the mating device interface to Detail B check that the ISL is in the closed position. ISL Partially Open ISL in Closed Position NOTE NOTE One Side Raised (Unlatched) Both Sides Seated (Latched) i The gage can be built into fixtures used in the harness building process. For additional information, contact PRODUCT INFORMATION at the number at the bottom of page 1. If the ISL does not move to the closed position or is partially open, ensure that all contacts are fully inserted then try again to move the ISL to the closed position. CAUTION To prevent damage to the ISL, do not force the ISL to the closed position. The ISL is designed to close only if all Figure 2 contacts are properly oriented and fully seated. Detail A Tip of Screwdriver on Top of ISL CPA (Ref) Notch (Indicates Top of Circuit Cavity) Contact Polarizing Press Feature Straight Down Mating Face of Tip of Screwdriver Top of ISL Plug Assembly For Reference, Detail B Plug Assembly Shown Here Without Outer Housing Circuit Cavity Retention Latch Against Contact Polarizing Feature Contact Fully Inserted in Circuit Cavity Figure 4 3.2. Optional Wire Cover Installation 1. Hold the plug assembly, grasp the wire bundle, and form (bend) the wire bundle in the desired direction. See Figure 5, Detail A. 2. Align the open end of the base of the wire cover Gently Pull Wire to Ensure with the lip at the wire end of the plug assembly, making Retention of Contact sure that the wire exit will accommodate the desired direction of the wire bundle. See Figure 5, Detail B. Figure 3 Rev B 2 of 4