Assembly Instructions for SAF-D-GRID Receptacle
2003G1 Series, Receptacle Contact, #12/16 AWG
2002G_ Receptacle Housing Series
Crimp Tooling
Consult instruction manual for specific operating and maintenance procedures.
Prior to crimping, strip back the wire insulation .34” [8.6mm] ± .01” [0.3mm]. These contacts should not
be crimped to any wire larger than #12 AWG or smaller than #16 AWG. Each of the three wires will use
the same 2003G1 series contact.
Contacts that have been crimped properly should meet the following criteria:
1. Wire must be visible at contact end of wire barrel and should extend beyond the wire barrel,
but not beyond the wire stop.
2. Wire must be visible at the wire entry end of the wire barrel.
3. A bell-mouth should exist at the wire entry end of the wire barrel (Figure1).
4. The contact should be straight and parallel to the wire barrel as indicated. A slight upward
or downward bending (± ½º) of the contact is allowed (Figure1).
5. The recommended crimp heights are given in Table 1. The crimp height is measured with
calipers in the area between the arrows (Figure1).
Actual values may differ from the recommended values given below. These values are only guidelines
for class C stranded tinned copper wire, and should give contact retention forces approximating the
values required by UL486A. Actual measurements of pull-out force versus contact crimp height should
be made to establish correct limits for the type of wire and machine conditions in each individual situa-
tion. As such, process controls should be established based on initial sample evaluations.
Once the contacts have been crimped onto the wires, they should be inserted into the receptacle hous-
ing (Figure 2.). The ground contact should be inverted relative to the power contacts. The positive wire
should be inserted in the position marked with a “+” on the bottom of the housing. The negative wire
should be inserted in the position marked with a “-” on the bottom of the housing. Once the contacts
have been inserted, pull slightly to verify they are fully seated past the internal spring.
Application Tooling
Part
Number
Description
Hand
Tool
Press Air
Feed
Applicator
2003G1 Receptacle
Contact,
Reeled
-
354500 - 1
354578 - 1 1852859 - 3
2003G1-
LPBK
Receptacle Contact, Loose Piece
1309G9
-
-
-
