APP SPEC Pak User manual

SPEC Pak® High Power Plug
Assembly Instructions For 2, 3 & 6 Position
Step 1 Slide PG Gland assembly onto wires
• Pull approximately 14 inches (355 mm) of wire through the gland to allow working space.
Step 2 Cable and/or Wire Preparation
• Jacketed cable: Strip outer jacket. Strip insulation from discrete wires (See Table 1
& Figure 2)
• Discrete wires: Strip insulation from discrete wires (See Table 1 & Figure 2)
Caution: Do not damage copper conductors when stripping wires
Table 1
Step 3 Secure body of PG Gland to Receptacle Shell
• Apply a generous bead of Permabond 941 or Loktite 411 to the center of the gland
thread and rotate the gland body to insure full coverage. Work quickly. The adhesive
sets quickly.
• Hand tighten body of PG Gland to the Plug Shell until snug, tighten 1/8 - 1/4
turn with spanner or crescent wrench
Caution: Do NOT over tighten the sealing gland body to the shell. Do NOT tighten
the sealing nut at this time.
Step 4 Contact Termination
• Insert wire into crimp barrel to the full depth
• Visually verify that all strands are inserted into the barrel
• Follow the appropriate crimp instructions which are included with the crimp tools
and/or at www.andersonpower.com
Caution: Keep all Powerpole®contacts parallel to each other while crimping jacketed
cable. Improper crimping my produce high resistance or contact distortion.
Plug Shell Holder Set #8 x 5/8 Screw Gland Assembly
Included Component Included Component Included Component Optional Component
Tool PN Tool Type Contact Series Contact
1309G4 Hand PP75 5900, 5952 or 5915
1368 Die-less Hydraulic PP120 1319, 1319G4, 1319G6, 1323G1, 1323G2
1368 Die-less Hydraulic PP180 1328G1, 1328G2, 1347, 1348, 1382, 1383, 1384
PM1000G1 Hand Auxiliary PM16P12S30, PM16P1416S30, PM16P1620S30,
(PowerMod®) PM16P2024S30, PM16S12S32, PM16S1416S32,
PM16S1620S32 or PM16S2024S32
You will need: - Wire Stripping Tool - APP Crimp Tool, See Section 2 - Phillips Head Screw Driver - 8 Screws, Size #10 or M5
Power Contact
Signal Contacts
SPEC Pak®High Power Shell Kit:
X
PG Gland Sealing Nut
Figure 1
Figure 2
Figure 3
Figure 4
For additional tools see data sheet
or www.andersonpower.com.
Powerpole®Contacts
Outer Jacket – 4” [102 mm]
Contact
Series
PP75 9/16” (14.5 mm)
PP120 15/16” (24.0 mm)
PP180 1-1/8” (28.6 mm)
“X”
PowerMod®Signal Contacts
Outer Jacket – 5.5” [139.7 mm]
Wire Insulation Wire Insulation
Contact OD < Barrel ID OD < Barrel ID
Pins 0.18” (4.5 mm) 0.24” (6.0 mm)
Sockets 0.21” (5.5 mm) 0.28” (7.0mm)

HEADQUARTERS: Anderson Power Products®, 13 Pratts Junction Road, Sterling, MA 01564-2305 USA T:978-422-3600 F:978-422-0128 • EUROPE: Anderson Power Products® Ltd., Unit 3, Europa
Court, Europa Boulevard, Westbrook, Warrington, Cheshire, WA5 7TN United Kingdom T: [phone] F: [phone] • ASIA / PACIFIC: IDEAL Anderson Asia Pacic Ltd., Unit 922-928
Topsail Plaza, 11 On Sum Street, Shatin N.T., Hong Kong T:+(852) 2636 0836 F:+(852) 2635 9036 • CHINA: IDEAL Anderson Technologies (Shenzhen) Ltd., Block A8 Tantou Western Industrial Park,
Songgang Baoan District, Shenzhen, PR. China 518105 T: +(86) 755 2768 2118 F: +(86) 755 2768 2218 • TAIWAN: IDEAL Anderson Asia Pacic Ltd., Taiwan Branch, 4F.-2, No.116, Dadun 20th St., Situn
District, Taichung City 407, Taiwan (R.O.C.) T: +(886) 4 2310 6451 F:+(886) 4 2310 6460 • www.andersonpower.com
SPEC Pak® High Power Plug
Page 2
Step 5 Block Powerpole®housing together
• Orient Powerpole®housings with hoods down (See Figure 4)
• Block Powerpole®housings by interlocking dove tails to create individual rows (See Figure 5)
• If more than one row is required, block rows together by interlocking dove tails
Step 6 Insert Powerpole®block into Powerpole®Holder
• With Hood down, slide Powerpole®block into the holder half marked with on
the left side, aligning the holder posts with the grove in Powerpole® (See Figure 6)
• Orient the remaining holder half with on the left side (See Figure 6)
• Slide remaining half into the assembly, inserting the holder posts into the Powerpole®
grove and aligning the tongues and grooves on the holder halves
Step 7 Install Crimped Signal Contacts into the Connector Housings:
• Orient the insert holder with the to the left
• Snap the crimped signal contacts into the appropriate holes in the back of the holder
halves (See Figure 7). A tactile snap will be felt when contact is latched.
• Repeat until all signal contacts have been installed into the housing
Step 8 Install Crimped Power Contacts into the Connector Housings
• Orient the insert holder with the to the left
• Insert crimped power contacts into the appropriate Powerpole®housing until the
contact lip snaps over the edge of the spring (See Figure 8)
• Repeat until all power contacts have been installed
Step 9 Install insert holder into the plug shell
• Prior to inserting the holder into the plug shell, create 2” (50.8 mm) of slack in
the signal wires, if applicable. Hint: To maintain the proper amount of slack with the
wires, temporarily tape wires together.
• Secure insert holder to the plug by tightening the screws in an alternating manner.
Torque: 13 in-lb (1.4 N-M) (See Figure 9)
Step 10 Secure Sealing Nut on Gland
• Hand tighten until snug.
• Stabilizing sealing gland body (from step 3) with a spanner or crescent wrench
(see Figure 10).
• Tighten additional ½ - ¾ turn using a second spanner or crescent wrench.
Caution: Do NOT over tighten the sealing gland body to the shell.
All Data Subject To Change Without Notice
“SPEC Pak, Powerpole, Anderson Power Products, APP & A, are registered trademarks of Anderson Power Products” 15661 1S6558 REV 02
Figure 4
Figure 5
Figure 6
Figure 7
Figure 10
Correct
Incorrect
PinsSockets
Signal Pin & Socket
Hood Up
Hood Down
Suggest Hood
Orientation for Plug
Grove
Figure 9
Figure 8