This SOP is on how to assemble our industrial plug, MZO 25 L20.
To enable operator training to be consistent and apply the process in a consistent way.
1Insert wire to crimping machine.
2Push the wire until it reaches the stop. The machine crimps automatically.
3Check ferrule has no copper showing.
4Repeat for the opposite end of the cable.
1Ensures the ferrule is crimped to the correct length.
2Ensures a complete and consistent crimp every time.
3Confirms the conductor is fully enclosed, preventing poor electrical connections.
4Ensures both cable terminations meet the required quality standard.
1Insert the crimped loop wire between terminals 15 and 16.
2Fully press down the orange clamps.
3Ensure all conductors are fully inserted.
1Completes the required electrical circuit for this connector configuration.
2Secures the conductors to prevent them working loose during service.
3Prevents intermittent electrical faults caused by loose or partially inserted wires.
1Put each numbered ferruled wire into the corresponding numbered connector.
21 goes to 1, 2 goes to 2, etc.
3Check each wire is fully home. No copper showing.
1Ensures the electrical connections are correct for proper operation.
2Prevents wiring errors that could cause the unit to malfunction.
3Ensures a secure electrical connection and prevents exposed conductors.
1Verify each wire is connected to the correct numbered terminal (1 to 1, 2 to 2, etc.).
2Check each wire is fully inserted with no exposed copper.
3Tug each wire to confirm it is securely retained.
4Refer to the assembly video if clarification is required.
1Prevents wiring errors that could cause the unit to malfunction.
2Ensures a safe and reliable electrical connection.
3Reinforces the correct assembly method and reduces the risk of errors.
4Confirms each wire is securely locked into the connector to prevent field failures.
1Initial plug with Sharpie to indicate all checks on plug are complete
1Provides traceability and confirms the assembly has been completed and verified by the operator.
1Pull the cable fully to the internal stop.
2Hand tighten the cable gland.
1Ensures the cable is positioned correctly to maintain the required internal length and prevent strain on the conductors.
2Prevents the cable moving before the final torque is applied.
1Push wires to the left while inserting the connector.
2Install with Pin 1 bottom left and the cable gland to the left.
1Prevents wires becoming trapped or pinched during assembly.
2Ensures the connector is installed in the correct orientation.
1Place insert into the hood and tighten opposite corners first.
2Tighten the remaining screws.
3 Use Bosch PH1 screwdriver as shown.
1Ensures the insert seats evenly and prevents distortion or misalignment.
2Secures the insert firmly in position to prevent movement during use.
3Prevents damage to the screw heads and allows the correct tightening torque.
1Use the 3D printed wrench to tighten until there's a 1mm gap.
2Check gap with the steel ruler. It should not go in the gap.
1Ensures the cable gland provides the correct clamping force without over-tightening.
2Confirms the cable gland has been tightened to the required specification.
This stage of the process is complete.
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