The contacts go in
the housings in only one way. Insert the contacts with their sharp
edge down against the flat spring that is in the housing. They
should slide in and click. If you do not hear a click or they are
not fully seated, fix them. When they are inserted fully you
should notice that the contact and it's wire "floats"
slightly inside it's housing. If it feels tight it may not be
snapped in fully or you have made the contact wider than it
originally was during crimping or soldering.
Tug slightly on
the assembled connector to make sure the contacts are locked in
place. If you have trouble getting the contact to lock in to the
housing you may have crimped the contact wider than its original
size, or deformed it some other way. Look at the side profile of the contacts before and after
crimping, you may have to bend it back straight before inserting
it in to the housing.
When crimping the
contact pins use a crimp that contains the wire completely inside
the pin and doesn't spread the connector apart. A good crimp is
one where the dimensions of the crimped portion are no more than
an uncrimped pin. If the crimp is flattened out you will not be
able to easily push the pin in to the body. If you bend the
contact blade in relation to the crimp area you should straighten
it before putting it in to the body.
A properly crimped
contact should have a minimum hold on the wire of more than 25
pounds. A pair of connectors should snap together with 6 to 8
are soldering the
contact pins instead of crimping them, be careful not to use too much solder. Keep the
solder inside, where the wire goes. If a blob of solder gets on
the outside of the connector body you may have trouble putting the
contact into the housing. If you get solder on the contact surface
area you will not make a good contact.
N O W
------- MAKE SURE you have the polarity correct before plugging in
you equipment. Double check against the pictures here.
WITH THE PWRcrimp or TRIcrimp
This tool is a custom designed crimp tool for
professionally crimping Anderson 15, 30, and 45 ampere Powerpoles®.
It has a contact holder to position the contact correctly, and a
ratcheting mechanism to assure correct force is applied each time.
Because of leverage from the long handles, operation
is easy, even for a 45 Amp terminal on a #10 wire. The results
are professional, providing the
strongest and lowest possible resistance crimp, and are faster than
||Looking at the
PWRcrimp you will see it has three crimping dies, marked 15,
30, and 45, for the respective Anderson Powerpole
contact ampere rating, and the contact holder extends off
the other side of the lower jaw.
You should check out the
crimper by squeezing the handles closed. The ratchet will
click, keeping it closed, until the end of travel and then
allowing the tool to open fully.
PREPARING TO CRIMP
You will need cutters to prepare the wire length,
and wire strippers to strip the wire. Using cutters to strip wire
might possibly nick the wire strands. Strip the wire insulation back
3/8 in., trying not to nick the strands.
PREPARING THE WIRE ASSEMBLY
If you are using paired-wire, orient the wire with
the red/plus wire on your right with the stripped end of the wire
away from you. Place the contact on the wire so that the hooked edge
of the contact tip (flat tab) is down. Do both contacts this way and
when crimped they will fit in to the plastic housing correctly
without twisting the wire.
CRIMPING 15, and 30 AMP
Carefully insert all of the strands of the wire in
to the wire cup on the contact end. Fully open the PWRcrimp jaw;
and, then with the flat tab downward, place the contact and wire
fully into the plastic contact positioner for the respective 15 or
30 amp die.
Make sure that the contact’s split portion of the
wire barrel is facing upwards towards the upper die, and that the
wire is still fully inserted into the contact. Crimp down firmly.
Continue to squeeze through each ratchet index, only until the tool
DO NOT SQUEEZE
PAST THE POINT WHERE THE RATCHET RELEASES,
doing this will make a poor and damaged connection. The ratchet
release point assures that the crimp is fully compressed and makes
the best connection.
CRIMPING 45 AMP CONTACTS
For 45 Amp contacts do not place the wire in to the
contact first. Fully open the PWRcrimp jaw and with the flat tab
downward, place the contact fully into the 45 amp contact positioner
Neatly place all the strands of the wire fully in to
U shaped channel. It is very important that the U shaped contact
tabs are aligned evenly within the channel of the top die on first
click. If it appears to be aligned properly, continue to squeeze
through each ratchet index, only until the tool opens.
Again, DO NOT SQUEEZE
PAST THE POINT WHERE THE RATCHET RELEASES,
doing this will make a poor and damaged connection. Note, that
you can release the tool without clicking further by using the
release lever located at the inside the bottom handle next to the