Pico Insertion/Extraction Tool

1. Introduction

This manual provides comprehensive instructions for the proper use and maintenance of the Pico Insertion/Extraction Tool, model M81969/01-02. This specialized tool is designed for the efficient and safe installation and removal of pin and socket contacts in various electrical connectors, ensuring reliable connections.

2. Safety Information

Adherence to safety guidelines is crucial when working with electrical components and tools. Please read and understand the following safety precautions before using the tool:

• Always wear appropriate eye protection to shield against potential debris or accidental contact.
• Ensure that power is disconnected from any electrical system or circuit before attempting to work with contacts.
• Handle contacts and the tool carefully to prevent damage to components or personal injury.
• Do not use the tool for purposes other than its intended function of inserting and extracting electrical contacts.

3. Product Overview

The Pico Insertion/Extraction Tool, model M81969/01-02, is a precision hand tool engineered for reliability and ease of use. It is specifically designed for working with electrical contacts that meet Mil Spec standards.

• Compatibility: This tool is compatible with contact sizes 20DM and 20DF.
• Wire Gauge: It is suitable for use with wires ranging from AWG 20 to AWG 26.
• Standards: The tool meets Mil Spec requirements, ensuring high performance and durability.

Image of the Pico Insertion/Extraction Tool, showing its ergonomic design and dual-ended functionality for both insertion and extraction.

4. Setup

The Pico Insertion/Extraction Tool is designed for immediate use and requires no assembly. Follow these steps before initial operation:

1. Remove the tool from its packaging.
2. Inspect the tool thoroughly for any visible signs of damage, such as bent tips or cracks, before its first use.
3. Ensure the tool is clean and free of debris.

5. Operating Instructions: Contact Insertion

Follow these steps to correctly insert a pin or socket contact into a connector:

1. Prepare the Contact: Ensure the pin or socket contact is correctly crimped onto the wire according to manufacturer specifications. The crimp should be secure and free of stray strands.
2. Position the Tool: Select the appropriate end of the tool for insertion (typically one end for pins, the other for sockets). Gently slide the wire through the tool's insertion tip until the contact rests against the tip.
3. Insert the Contact: Align the contact and tool with the correct cavity in the connector. Apply steady, gentle pressure to push the contact into the cavity until it seats securely. A slight click may be felt or heard, indicating proper seating of the locking tangs.
4. Verify Seating: Lightly tug on the wire to ensure the contact is fully seated and locked into place. It should not pull out easily. If it does, re-insert the contact.

6. Operating Instructions: Contact Extraction

Follow these steps to correctly extract a pin or socket contact from a connector:

1. Identify the Contact: Locate the specific contact to be removed within the connector.
2. Position the Tool: Select the appropriate end of the tool for extraction. Slide the extraction tip over the wire and into the connector cavity, surrounding the contact.
3. Release the Locking Mechanism: Push the tool firmly into the cavity. This action depresses the contact's locking tangs, allowing it to be released from its seated position.
4. Remove the Contact: While maintaining pressure with the tool, gently pull the wire and contact straight out of the connector. Avoid twisting or applying excessive force, which can damage the contact or connector.
5. Inspect: After removal, inspect both the contact and the connector cavity for any signs of damage.

7. Maintenance

Proper maintenance ensures the longevity and optimal performance of your Pico Insertion/Extraction Tool:

• Cleaning: Clean the tool regularly with a soft, dry cloth to remove any dirt, debris, or residue that may accumulate during use.
• Storage: Store the tool in a clean, dry environment, away from extreme temperatures and corrosive substances, to prevent corrosion or damage.
• Avoid Solvents: Do not use abrasive cleaners, harsh chemicals, or solvents, as these may damage the tool's plastic material or finish.
• Inspection: Periodically inspect the tool's tips for any signs of wear, bending, or damage. A damaged tool can lead to improper contact insertion/extraction and potentially harm contacts or connectors. Replace the tool if significant wear or damage is observed.

8. Troubleshooting

Refer to the following common issues and their solutions:

• Contact will not insert:
  • Ensure the correct tool end (pin or socket) is being used.
  • Verify that the contact is properly crimped and not bent or deformed.
  • Check the connector cavity for any obstructions or damage.
• Contact will not extract:
  • Ensure the tool is fully inserted into the cavity and is properly depressing the contact's locking tangs.
  • Avoid pulling the wire at an angle; pull straight out.
  • The contact or connector cavity may be damaged, requiring careful inspection.
• Tool feels loose or damaged:
  • Discontinue use immediately. A damaged tool can cause harm to contacts or connectors.
  • Replace the tool with a new one to ensure proper functionality and prevent further issues.

9. Specifications

10. Warranty and Support

For detailed warranty information, technical assistance, or to inquire about replacement parts, please refer to the official Pico Corporation website or contact your authorized Pico distributor. It is recommended to retain your purchase receipt as proof of purchase for any warranty claims.