Amphenol HELIOS H4 Assembly Instructions Manual Download Page 4

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H4 ASSEMBLY INSTRUCTIONS ENGLISH REV3 –OCTOBER 2014 

 

Cable preparation and stripping process 

Strip cable 0.276 inches (7.0 mm) and be careful NOT to nick conductors.  
Amphenol specified strip tool (H4TS0000) 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 pictures. 
 
 

 

 

 

 

       Cable against stopper   

 

 

          Stripped cable 

 

Crimp process solid contacts 

When you insert striped cable into contact barrel, always insure all conductor strands are captured in the contact barrel and the 
conductors are visible in the inspection hole. See below pictures. 

 

 

 

 

 

 

Pin solid contact                Inspection hole 

 

Socket solid contact 

 

 

Insert the contact into the corresponding crimping notch or locator (male or female) taking into account the cable size used. 
Press the pliers gently together until the crimp lugs are properly located within the crimping die. Insert the stripped cable end 
until the insulation comes up against the crimp insert. Completely close the crimping pliers. 
 See below pictures. 
Amphenol specified crimp tool (H4TC0001) should be used in this step. 
 
 
 
 
 
 
 
 
 

 

 

Positioner 

 

 

 

           Crimper with die 

 

See below pictures for crimp result solid contacts. 

 

 

 

Crimped solid pin  

 

 

  

Crimped Solid socket 

 

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Summary of Contents for HELIOS H4

Page 1: ...aranteed For protection against electric shock PV connectors must be isolated from the power supply while being assembled or disassembled The end product must provide protection from electric shock Un...

Page 2: ...7422941 Fax 86 755 2991 8310 2 H4 ASSEMBLY INSTRUCTIONS ENGLISH REV3 OCTOBER 2014 Tools required Crimping tool with built in positioner and crimping insert for stamped and formed contacts H4TC0002 or...

Page 3: ...ormed contacts Male stamped and formed contacts 1 5 2 5mm AWG14 H4CFC2D S H4CMC2D S 4 0 6 0mm AWG10 12 H4CFC4D S H4CMC4D S Female solid contacts Male solid contacts 2 5mm AWG14 H4CFC2D H4CMC2D 4 0mm A...

Page 4: ...ch to strip the length of 7mm See below pictures Cable against stopper Stripped cable Crimp process solid contacts When you insert striped cable into contact barrel always insure all conductor strands...

Page 5: ...esponding crimping notch or locator male or female taking into account the cable size used Open barrel socket S F contact Open barrel pin S F contact Press the pliers gently together until the crimp l...

Page 6: ...ble assembly into back of male and female connector A click should be heard or felt when the contact cable assembly is seated in correct position Contacts cannot be removed once seated See below pictu...

Page 7: ...2941 Fax 86 755 2991 8310 7 H4 ASSEMBLY INSTRUCTIONS ENGLISH REV3 OCTOBER 2014 Connector mating and un mating For mating align the 2 half connectors and mate them together by hand until a click is hea...

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