PYLE-STAR-LINE Electrical Connectors with Mod I Inserts ASSEMBLY and TERMINATING INSTRUCTIONS ‘the following table gives the wire alzes and cord/oable types to be used with the Ster-live plugs, receptactes and cable connectors. ‘The plugs and cable connectors fre intended for conpoction to 3, 4, oF 5 conductor cord/eable depending, on the ‘contact ineert configuration. Amore rating | conductor | type ‘of device | size avo_| cord/cabie_|} The cord sealing grip range of plu fand cord connectors 42 1/8". For 20 naw 5, 50 of gromet 43/40 4t wii seal and grip # cord 20 2,00 8, 0 ia. in the range of 730 dla. wax. to 3625 aia. ain. Inaide aia. of 60 16.46 “ Grommet can ba determined from 200 won “ 2rx- WHICH & ta inaide dia. of gromet in aixteanths of an inch. 200 rome | _¥ wo types of inserts are available in ¥OD 1 conatruction-pressure and solder Cerainationa of contacts, For preasura termination torque terminal scrova aa 20 sp 30 amp 40 amp 60 amp 100 amp 200 ap Wit rontact #10 Contact #0 Contact #4 contact 1/0 contact #4/0 contact kein yn » 25 20 $0 100 we aa ne na 57 13 A. Prepare end of cable by stripping Jacket and inavlation per tables show on page 3. Renove any rigide or grooves by scarting the edges to provide « snccth Surface on the cable to inaure good gromet sealing. Tin conductors to be soldered to vithin 1/16" ef inaulation. Use only reoin flux for al soldering. B. Site the gland nut, cable grip or anti-triction washer, gromet and cable Adapter over the cable in the ofder saned. Ba sire the right eiza gromet has eon selected to obtain « good gromet seal. If 4 dust cover with ring and chain ie ueed, ring must be place on cable barrel bafore cerminating. See Fig. 1. Pace contact-insert complete with contacts tn barrel, ining up Keyway Sn insert and key in barrel. See Fig. 2. Use a thin, blunt vood of plastic object ‘to aenint in senting silicone inaulation. Push entire insert ameembly into Darrel shell until fully seated. When properly seated, back tace of back cap Angulation shoulder should protrude from Deck end of barrel 1/16" maxinun, S00 Pig.3. If the inert assoably becones separated, re-asseable the insulation penbern so vhan correctly asseabled no color coding will be exponed to view, f¢ shown in Pig. 3+ cont EF rien D. elder conductors in contacts, f solder type. ALL CONTACTS MUST NDIAIN 18 PIACE EVEN IP EVERY ORF 18 NOT BEING USEO IN ORDER 70 INSURE RIVIROHENEAL SIALING. ‘Tue B{licone insulation 4a heat reaistant, bot retsonable care mat De exerciaed to prevent unnecemary heating. 1. apport the barrel assembly in a vise having smooth-faced Jove; sheiie vith faneie akizt have flange for holding. shelia vith wale skirt but without flange ‘ould be held with dust cover or female shell as a holding tixture. The fall hee are designed to withstand the assenbly tor 17. Ayply cable adapter or insulation olasp nut by hand, turning counter-clockvise {Heet end thresd) until hand-tighe, APPLY WMENCH TO. CABLE ADAPTER OR EHSULAGION CLAKD AN TIGHTEN UNTIL IT SHOULDERS PULLY ON BARREL. Seo Pig. 3. Slip gromet into cable adapter and engage either cable grip or gland washer fn gland nut. DRAW UP EIGHT WINH WRENCH. Tf aplit clamp rot te ueed, tighten clasp screws PREPARING CABLE FOR TERMINATING Vee suitable tool ail strippers to resove cable sheath and conductor inulation. fare cable end Sa cut square, Rafer to the folloving tables for wire cutting tne sttipping dimensions, Use applicable disensions Cor vhichevar method of ‘termination ie used.STEP 4 = renminarinc conouctors - sentlsan he baal hat ain pete hypotonia Sweet pes wns ‘Stop epncton Roane te ac eeten wes ty tonne nel eran, PRECAUTIONS: erne eennas Wrought tno ‘Soa Comacs svou te nerd ito cra cues wah 8 Coma neon on fe poge ‘Stegoyo ev estetinedton 8 ay seat. Conard be nse nen ete ion aay ‘Std costs we ves tonne tet ae acon: nraeesinonwengcavy eonenaston amp Fete ‘Stain pesto on tsar Rey ps cre! ou wih rene! oe Poe MOO I CONTACT SIZES 8.4.8 VO INSERTIONS {Speed eae rove. fe sua gees tom bas Din ee ew oni et aoa ae SE wee Sten Svar Sac Wat Conse ace. te nadarot Seu acetals Sy Sa ung reo ngh gnednonSeyway whe he oy ease str vert nan si spacer rcs tnt ass nach wt aca rents cara nena Ps ong ey neen eon song heron cor ett oe ce a cota rr oe Soe ‘These of pid to th resent conte se aminant een clr} matinee the longed ore hig ot ad ener ity fire he contact ‘Asi sly the coe ove the utr uae a the sant lamina, mid he lone lation on he ‘ipping the contact tothe seal pear ote contact into ao fats o ate IMPORTANT: MOD I! OF II! IF ALL CONTACTS IN AN INSERT CONFIGURATION ARE NOT BEING USED, PLUG UP ANY OPEN CAVITIES TO ASSURE ENVIRONMENTAL SEALING, STEP 5 — caste aparren a pLuc SHELL ASSEMBLY afl STEP 6 ~ Finat assewotyCABLE AND WIRE CUTTING AND STRIPPING DIMENSIONS Dimension "" ix the correct length of straightened conductors to provide proper folder termination. Dimension "'C" La slightly longer than the depth of the contact tolder veil. ‘the grouéing contacts use prossure wire terainals and should be stripped to the ‘inaneion "E conductors for all oqntacte with pressure vire terminala should be ext and stripped te dinensions "DY & "E". ‘WOWDUAL CONDUCTOR. sTHIPING CEncri/aes wih soe of wong sotto oneronevtring tee ks ‘vie a Sao nt == or MOD. 1 PYLE STAR-LINE CONNECTOR SEQUENCE OF ASSEMBLY (Se «~- OY INI Chicago, it 60651-1697 Form M01 (Re 10)