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.
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.
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.
Step 3:
Measure the exposed strands to be sure the crimp length is correct.
Leaving the stripped portion of the insulation on the wire until prior to crimping will avoid flayed wire strands.
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.
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.
Figure 1 – Stamped & Formed Style
Figure 2 – Solid Style
Step 1:
Grasp crimped contact approximately one inch behind the contact barrel.
Step 2:
Hold connector with rear grommet facing you.
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.
Step 4:
Once all contacts are inplace, insert green wedge. The green wedge will snap into place.
Step 1:
Remove green wedge using needlenose pliers to pull wedge straight out.
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.
Step 3:
Hold the rear seal in place, as removing the contact will displace the seal.
| Tools and Solid Contacts | |
|---|---|
| Part Number | Adjustable Hand Crimp Tools |
| MH860 | QC/IMC #22 crimp tool, adjustable AWG ranges, requires 86-5 |
| AF8-TH163 | QC/IMC #20 and #16 crimp tool, adjustable AWG ranges |
| Single Gauge Hand Crimp Tools | |
| AMSC22/1 | QC/IMC #22 crimp tool, low cost, only crimps 22 AWG wire |
| AMSC20/1 | QC/IMC #20 crimp tool, low cost, only crimps 20 AWG wire |
| AMSC16/A/1 | QC/IMC #16 crimp tool, low cost, only crimps 16 AWG wire |
| Insert/Removal Tools | |
| 6757-201-2201 | Insert/Removal Tool #22 |
| 6757-201-2001 | Insert/Removal Tool #20 |
| 6757-201-1601 | Insert/Removal Tool #16 |
Note:
Tool must be adjusted for each type/size of contact.
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.
Step 2:
Insert contact with barrel up. Turn adjusting screw counter clockwise until contact is flush with indentor cover. Tighten locknut.
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.
Step 1:
Cycle the hand tool to the open position. Place the contact into the correct die nest.
Step 2:
Partially close the tool until the contact is held in place.
Step 3:
Insert the prestripped wire into the crimp area of the contact.
Step 4:
Close the tool until the ratchet releases. The ratchet is released when a loud click is heard and crimp is complete.
| Wire Type | Insulation Selector |
|---|---|
| 10 TXL | .150-.170 |
| 10 GXL | .160-.180 |
| 10 SXL | .170-.205 |
| 5.0 mm2 | .160-.180 |
| 6.0 mm2 | .170-.205 |
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.
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.
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.
Step 2:
Partially close the tool until the contact is held in place.
Step 3:
Insert the prestripped wire into the crimp area of the contact.
Step 4:
Close the tool until the ratchet releases. The ratchet is released when a loud click is heard and crimp is complete.
