Connectors 2017-06-21T03:44:45+00:00

Wiring Harnesses Australia use only the highest quality connectors from leading manufactures, sourced from around the globe.

The most common connector we use at Wiring Harnesses Australia is Deutsch, as they are proven to be one of the best environmentally sealed electrical connectors in the world. These connectors can withstand the very toughest conditions, which is why Deutsch is our preferred connector for all new wiring solutions.

Deutsch connectors have:

  • Common contact system
  • Air tight crimp terminations
  • Exact contact process control
  • Exact metal process control
  • Silicon wire seals
  • Fail safe connector assembly
  • Are made from Hi performance moulded shells and materials
  • Require no additional sealing

Connector Guide

Below we have put together some useful how to guides for the correct use of some of our connectors and crimping tools.

Deutsch Catalog 2011.indb
Step 1:

  • Choose the correct AWG for the contact being used.
  • Measure from the end of the wire the recommended strip length according to the contact size.
  • Place the wire into a stripping tool at the recommended strip length. Strip the wire according to stripping tool instructions.

Wire Stripping Step 2
Step 2:

  • After stripping, a small piece of the insulation should come off.
  • Check for any broken strands or for a dent in the wire. If either exist, the wire is damaged and should be cut and stripped again.

Wire Stripping Step 3
Step 3:

Measure the exposed strands to be sure the crimp length is correct.

Deutsch Catalog 2011.indb
Leaving the stripped portion of the insulation on the wire until prior to crimping will avoid flayed wire strands.

Crimping tools provide lower total installation and maintenance costs. However, controls are required to ensure that the proper crimp tools designed for the type and size contact are used, the pin or socket is properly inserted into the tool, the wire insulation is stripped properly, and the wire fully inserts into the contact.

When a crimp is completed, correct termination can be visually inspected. The inspector should check for:

  • The removed insulation should expose a conductor length that will pass beyond the inspection hole in the contact and still reveal .100″ (2.54) max. of conductor between the contact and the insulation on the wire.
  • Wire strands intact.
  • All wire strands enter the contact barrel.
  • Wire inserted to the proper depth in the contact.

When the correct crimp tool and process are used, a good termination is assured.

Mechanically crimping contacts is the dominant wire termination method, for some very good reasons:

  • With smaller wire, the crimp is as strong as the wire itself.
  • The joint can be visually inspected. Viewing the wire through an inspection hole in the contact makes inspection quick and easy, both by the operator and by the inspector.
  • Plating thickness is not restricted, as in solder joints, so better corrosion resistance and contact reliability are achieved.
  • Crimping can be done anywhere, without special preparation. Terminations are replaced or modifi ed in the field exactly the same as in the shop, using the same tools and the same techniques, and with the same ease of operation and certainty of results.
  • Total installed and maintenance costs are lower.

Deutsch Catalog 2011.indb

Stamped & formed contacts use a folded type of crimp (Fig. 1) while solid contacts use a 1, 2, or 4 indent crimp (Fig. 2). In both styles of crimps, the wire strands and the contact material are formed together in a solid mass creating a reduction of the wire strands area. The reduced wire strand area creates a minimum of voids allowing for excellent conductivity. Crimping may be accomplished with hand tools or power tools.

stamped_formed_style

Figure 1 – Stamped & Formed Style

solid_style

Figure 2 – Solid Style

Deutsch Catalog 2011.indb
Step 1:

Grasp crimped contact approximately one inch behind the contact barrel.

Deutsch Catalog 2011.indb
Step 2:

Hold connector with rear grommet facing you.

Deutsch Catalog 2011.indb
Step 3:

Push contact straight into connector grommet until a click is felt. A slight tug will confirm that it is properly locked in place.

Deutsch Catalog 2011.indb

Step 4:

Once all contacts are inplace, insert green wedge. The green wedge will snap into place.

Deutsch Catalog 2011.indb
Step 1:

Remove green wedge using needlenose pliers to pull wedge straight out.

Deutsch Catalog 2011.indb
Step 2:

To remove the contacts, gently pull wire backwards, while at the same time releasing the locking finger by moving it away from the contact with a screwdriver.

Deutsch Catalog 2011.indb
Step 3:

Hold the rear seal in place, as removing the contact will displace the seal.

The Industrial Micro Connect and Quick Connect Series use special contacts and tools. The contacts are smaller and designed for high pin density. Removal tools along with multiple crimp tools are available and are designed to work with the smaller contacts and tighter pin arrangements. The common contact system and tools are not compatible with the IMC or QC Series.

Tools and Solid Contacts
Part NumberAdjustable Hand Crimp Tools
MH860QC/IMC #22 crimp tool, adjustable AWG ranges, requires 86-5
AF8-TH163QC/IMC #20 and #16 crimp tool, adjustable AWG ranges
Single Gauge Hand Crimp Tools
AMSC22/1QC/IMC #22 crimp tool, low cost, only crimps 22 AWG wire
AMSC20/1QC/IMC #20 crimp tool, low cost, only crimps 20 AWG wire
AMSC16/A/1QC/IMC #16 crimp tool, low cost, only crimps 16 AWG wire
Insert/Removal Tools
6757-201-2201Insert/Removal Tool #22
6757-201-2001Insert/Removal Tool #20
6757-201-1601Insert/Removal Tool #16

Deutsch Catalog 2011.indb
Note:

Tool must be adjusted for each type/size of contact.

Deutsch Catalog 2011.indb
Step 1:

  • Strip insulation from wire.
  • Raise selector knob and rotate until arrow is aligned with wire size to be crimped.
  • Loosen locknut, turn adjusting screw in until it stops.

Deutsch Catalog 2011.indb
Step 2:

Insert contact with barrel up. Turn adjusting screw counter clockwise until contact is flush with indentor cover. Tighten locknut.

Deutsch Catalog 2011.indb
Step 3:

  • Insert wire into contact. Contact must be centered between indentors. Close handles until crimp cycle is completed.
  • Release handles and remove crimped contact.

Deutsch Catalog 2011.indb

Deutsch Catalog 2011.indb
Step 1:

Cycle the hand tool to the open position. Place the contact into the correct die nest.

Deutsch Catalog 2011.indb
Step 2:

Partially close the tool until the contact is held in place.

Deutsch Catalog 2011.indb
Step 3:

Insert the prestripped wire into the crimp area of the contact.

Deutsch Catalog 2011.indb
Step 4:

Close the tool until the ratchet releases. The ratchet is released when a loud click is heard and crimp is complete.

Deutsch Catalog 2011.indb

Wire TypeInsulation Selector
10 TXL.150-.170
10 GXL.160-.180
10 SXL.170-.205
5.0 mm2.160-.180
6.0 mm2.170-.205

Deutsch Catalog 2011.indb
Step 1:

Cycle handles to release ratchet and fully open crimp jaws. Pull out insulation selector and push into proper diameter using the chart below.

Deutsch Catalog 2011.indb

Deutsch Catalog 2011.indb

Step 2:

  • Insert contact into locator. Adjust alignment and width of crimp wings if necessary to ensure capture by crimp jaws.
  • Insert stripped wire into the contact. Close crimp tool until full-cycle ratchet control releases.

Deutsch Catalog 2011.indb

Deutsch Catalog 2011.indb

Step 1 :

Cycle the tool to release ratchet and open tool. Lift the locator gate, and place the contact into the correct die nest. Adjust alignment of crimp wings to ensure capture by crimp jaws.

Deutsch Catalog 2011.indb
Step 2:

Partially close the tool until the contact is held in place.

Deutsch Catalog 2011.indb
Step 3:

Insert the prestripped wire into the crimp area of the contact.

Deutsch Catalog 2011.indb
Step 4:

Close the tool until the ratchet releases. The ratchet is released when a loud click is heard and crimp is complete.

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