Amphenol PowerLok PL182X-301-50 User manual

1. 线缆准备：按生产需求选择合适尺寸的线缆; take right-sized cable according to production plan;
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2/3pos PowerLok 直头组装式插头安装规范(屏蔽款)
2/3pos PowerLok 180D Plug Assembly Specification(shielded)
Notice: 请严格按本指引实施装配作业！ please strictly follow this manual to proceed
plug assembly & cable harness operation job!
③SS ring1
不锈钢环1
②Rubber
ring胶圈
①end cap
尾盖
3. 拿取一套产品, 拆包, 拆分零件; take 1set plug
components, disassemble as on the right;
4. 取各1pcs的①尾盖, ②胶圈和③不锈钢环1, 从右边依次穿过线缆; take each 1pcs of ①end cap, ②rubber
ring and ③SS ring1, have cable insert through their holes from right in sequence;
5, 取1pcs的④不锈钢环2自左端穿过线缆, 并与③不锈钢环1按压在一起, 并剪去突出的多余的线头； take a
④SS ring2, load it to the cable end on the left, press together with ③SS ring1, cut off excessive braiding
wire;
⑤R4 holder with anti-rotation
chamfer 带止转切面的R4端子
④SS ring2
不锈钢环2③SS ring1
不锈钢环1
2. 按如下尺寸剥离 线缆绝缘皮和外被;strip off
cable insulation and jacket as following
size on the right;
Doc NO.: AI-PL182&183-301-1

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6, 取1pcs的⑤R4 holder 自左端穿上线缆，并压接在其上(规格参照下表)； take a ⑤R4 holder, load it to the cable end
on the left, then crimp(refer to crimping spec below);
⑤R4holder
端子
7, 组装⑥绝缘筒 到R4 holder脖颈处的沟槽; snap on the ⑥insulation sleeve to the R4 holder neck groove;
8, 插入⑤R4 holder到⑦绝缘罩上, 转动使其触底; 以相同方法装配另一/二条线束的一端; plug the⑤
R4 holder to the ⑦insulation cap, rotate to have it contact the bottom; assemble one end of other pos
cables in the same way as step 1~8.
⑦insulation
cap 绝缘罩
make sure R4 end visible &
reach the insulation cap edge
open.
Plug the R4 holder to the insulation cap,
rotate to have it contact the bottom.
⑤R4 holder
⑥Insulation
sleeve绝缘筒
连接器
Connector
线缆尺寸
Cable size
线缆外径 Accepted
cable OD (mm)
压接高度Crimping
height (mm)
参考抗拉拔力
Retention Force
300系列
Series
35mm² 14.5±0.50 9.6+0/-0.2 2200N
50mm² 17.0±0.50 12.0+0/-0.2 2700N
70mm² 19.5±0.50 13.2+0/-0.2 3300N
线缆压接规格&拉拔力要求 Crimping spec & retention force requirement
Screw the end cap tight, torque
10~12N·M. 拧紧力矩10～12牛米.
9,插入⑥绝缘罩到⑧合金外壳, 转动, 使其触底; 以10~12N∙M拧紧①尾盖,完成此端线束的组装; plug the
⑥insulation cap into ⑧alloy shell, rotate to have it reach the bottom, screw ①end cap tight with torque
10~12N·M, one end assembly done;
⑥Insulation
cap 绝缘罩
⑧alloy shell
合金外壳
2/3pos PowerLok 直头组装式插头安装规范(屏蔽款)
2/3pos PowerLok 180D Plug Assembly Specification(shielded)
crimp cable here
此处压接线束

(3), 以布线状态拉动线束靠近合金外壳, 转动R4 holder, 使其止转切面与合金外壳的2/3pos中心连线相
垂直; 并保持R4 holder与线缆相对位置; drag the cable end close to alloy shell in service
state, rotate R4 holder, have its anti-rotation chamfer surface vertical to link line of the 2/3pos
center in alloy shell; hold relative position of R4 holder & cable;
(4), 拉直线缆, 记录此时R4 holder 止转切面与步骤9已组装完成端插头的相对角度, 并记录; stretch
the cable, record angle between R4 holder anti-rotation chamfer surface and plug end assembled
done in step9;(5), 拔下合金外壳; remove the alloy shell from receptacle;
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11,组装线束另一端. assemble plug on the other end of cable.
10, 将步骤9组装好的插头插接到 对应的PDU/负
载插座上. plug the connector end done in
step9to corresponding PDU or load
receptacle panel.
(1), 再取一套零件, 按步骤1～4操作, 套上端子, 暂不压接端子; take another set plug components,
assemble as step 1~4, then load a R4 holder to the end, pending crimping;
(6), 保持步骤(3)R4 holder与线缆的相对位置, 按照步骤5～9,压接线束, 完成线束另一端组装; hold
relative position of R4 holder & cable as in step(3), follow step5~9, crimp cable, complete
connector assemble of this end;
(7), 将步骤(4)记录的角度/位置写入作业指引, 后续即按该旋转角度操作, 进行批量压接/组装. record
the R4 rotation angle/position in step(4), form an operation instruction for mass assembly.
PDU or
load负载
front view
正视图
Left view
左视图
(2), 取1pcs合金外壳, 将其开口对准并插入(PDU或负载的)插座, 放置待用; take an alloy shell, align its
open with receptacle(on PDU or load panel), plug in, put it aside;
anti-rotation chamfers face ceiling & ground.
alloy shell
合金外壳
Receptacle 插座
注意: 如线束待组装的另一端 未采用止转R4端子, 请忽略以下步骤; 否则, 请严格按以下步骤实施线束另一端的组
装！If the other end to be assembled doesn’t adopt R4 holder with anti-rotation chamfer, then
ignore following steps, or please strictly follow following steps to assemble the other end!
R4 holder
receptacle fixed on
load or PDU插座
Plug in to
engage the
two 插入
HVIL align 高
压互锁位对齐
anti-rotation
chamfer
止转切面
vertical yellow line is
the pos link line. 黄竖
线为两/三芯中心连线.
2/3pos PowerLok 直头组装式插头安装规范(屏蔽款)
2/3pos PowerLok 180D Plug Assembly Specification(shielded)
③SS ring1
②Rubber ring
①end cap
⑤R4 holder with anti-rotation
chamfer 带止转切面的R4端子.
④SS ring1