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1.1 Strip cable .276 inches (9/32”) - (7mm) and be careful NOT to nick conductors.
Amphenol specified strip tool can be used in this step. Adjust the striper stopper and put the
cable in corresponding notch to strip the length of 7mm. See below figures.
.276 inches (9/32”) - (7mm)
Cable
1. Assembly Instruction for the male side and female side connector
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1.2 Insert striped cable into contact barrel and insure all conductor strands are
captured in the contact barrel and the conductors are visible in the contact barrel
observation hole. See below figures.
1. Assembly Instructions for the male side connector and female side.
Barrel observation hole
Conductor should be visible
Barrel observation hole
Conductor should be visible
Pin contact
Socket contact
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1.3 Crimp contact barrel by using the hex crimping die. See below figures.
Amphenol specified crimping tool can be used in this step. Put the contact barrel with
striped cable in the corresponding crimping notch and crimp the contact. See below figures.
1. Assembly Instructions for the male side connector and female side.
Crimped pin contact Crimped socket contact
Amphenol crimp tool
Cable size
Cable pull –out force requirement
2.5 mm²
Min. 310 N (70 Lbs)
4.0 mm²
Min. 400 N (90 Lbs)
6.0 mm²
Min. 450 N (100 Lbs)
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1.4 Insert contact cable assembly into back of male and female connector. A “click” should
be heard or felt when the contact cable assembly is seated correctly. See below figures.
1. Assembly Instructions for the male side connector and female side.
PV-090508-F –Female side Connector
PV-090508-M –Male side Connector
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1.5 Wrest the cap by using the torque to 18 -20 inch pounds. (2.0 –2.3 NM).
Amphenol specified wrench tool can be used in this step. Here 2 wrench tools are used,
one is by hand for holding the connector by hand, another is also by hand to wrest the cap
down until the tool starts to snap over.
See below figures.
1. Assembly Instructions for the male side connector and female side.
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2.1 After wrest the cap tightly, align the 2 half connectors and mate them together by hand
until a “click” is heard or felt.
2.2 When the separation of connector is necessary, use the Amphenol specified tool (Ring tool
or wrench tool) to separate. And while using the ring tool or wrench tool, please make sure the
wedge side of the fingers faces the female connector and push the tool down. Then separate
the connector by hand. See below figures.
2. Mate and separate Helios H4 connector
Separated by Ring tool Separated by Wrench tool
