How To Wire the DF63W | Harness Assembly 

Hello and welcome to the DF 63 W Harness Assembly Guide.

Today we'll take you through the step by step process to ensure a successful assembly.

STEP 1:

Begin by inspecting the crimped wire. Make sure it meets the crimped conditions specified on the applicator website. Ensure your crypt wire meets the standards for optimal performance. Scan the QR code for quick access.

STEP 2:

Let's move on to assembling the plug housing and PIN contact. Pay attention to the correct orientation before inserting the contact. As shown on page two of the assembly instruction, the lock on the housing should face up and the Lance holder on the contact should face down. Insert the contact straight, ensuring it's not at a diagonal. Feel for a tactile click, and then give it a slight tug to ensure it's secure.

STEP 3:

Now let's move on to assembling the socket housing and socket contact. Pay attention to the correct orientation before inserting the contact again. As illustrated on page two of the assembly instruction, the lock on the housing should face up and the Lance holder on the contact faces down. Insert the contact straight, making sure it's not at a diagonal. Feel for a tactile click and give it a slight tug to ensure it's securely in place.

STEP 4:

Bending the harness. If you need to bend the hardness, allow for sufficient cable length for slack.

Follow the instructions on page five of the assembly instructions. Avoid added stress that can cause contact failure and waterproofing issues.

STEP 5:

Binding the cable. Binding too close can cause stress and loosen the contact. Remember not to bend in the area between the connector and the binding. Now that we've covered the main steps in the harness assembly, let's briefly address some common problems and effective solutions.

Problem 1.

Improper crimping leading to low contact retention and poor mating with the opposite contact. To overcome this, make sure you use approved HIROSI tooling for crimping. This ensures a proper and secure connection.

Problem 2.

Bending the cables too close to the connector can deform the seal, affecting waterproofing and retention force if the terminal isn't seated properly. Avoid added stress that can cause contact failure and waterproofing issues.

Problem 3.

Binding the harness if needed. If you need to bind the harness, be cautious as binding wires can contribute to issues and sure it doesn't add more tension.

Problem 4.

Using high temperature heat guns near connectors may melt the plastic, compromising the integrity of the components. Opt for infrared shrink wrap machines when working near connectors. They provide a safer alternative without the risk of melting. By addressing these common challenges with the recommended solutions, you can ensure the reliability and longevity of your connectors.

And there you have it. You've now successfully assembled your DF 63 W harness. If you have any questions, refer to the assembly instructions for more details or reach out to a HIROSI representative.

Thank you for joining us and happy assembling.