www.andersonpower.com
PowerMod
®
Crimp Instructions
WARNING
- Connectors should never be assembled or disassembled
when contacts are live.
SPEC Pak
®
High Power & Mid Power Connectors:
Use Step 1 Only
Step 1 Crimping wire contacts
1. Strip insulation from the end of the wire to be terminated, being careful not
to damage the copper conductors (See Figure 1).
Figure 1
If the wire insulation OD is smaller than the crimp barrel ID, strip to the fol-
lowing dimensions:
For Pin Contacts:
X=.18”, 4.5mm
For Socket Contacts:
X=.21”, 5.5mm
If the wire insulation OD is greater than the crimp barrel ID, strip the wire to
the dimensions:
For Pin Contact
X=.24”, 6mm
For Socket Contact
X=.28”, 7mm
2. Insert the wire into the crimp barrel to the full depth. Visually verify that the
wire is inserted fully by observing the strands through the inspection hole. All
strands must be inserted into the barrel.
3. Follow the appropriate crimp instructions for either the hand tool (Part No.
PM1000G1) or the semi-automatic crimp tool (Part No. PM1001G1). See
website for crimp instructions, www.andersonpower.com.
The maximum dimension across the crimp must not exceed .129”(3.30mm)
or the contact will not latch into the housing. Crimps should be verified for the
specific application due to variations in wire and stranding.
Refer to 1S6494 for greater detail.
Step 2 Insertion of Contacts into Housing
• Crimped contacts are to be inserted fro the rear side of the connector using
insertion tool PM1002G1, if appropriate. A tactile snap will be felt when
contact is latched. Apply a slight tug to confirm latching. The wire and contact
will spin freely when latched in the housing. Contact retention should be 18lb
(80N) minimum.
• Contacts are released from the front side of the connector and removed
from the rear using extraction tool PM1003G1:
1. Slide tool over pin or socket body until the tool bottoms on the housing.
2. Push the button on the top of the tool with thumb.
3. Simultaneously, gently pull on the wire from the back of the connector.
4. Contact should release.
Care should be taken not to damage the contact OD or housing ID. If there
is any doubt with respect to the housing integrity after contact removal,
replace the housing. When replacing contacts in completed assemblies,
great care must be taken to ensure that the replacement contact is latched
(see instructions above).
