Instruction Sheet  LGH* Commercial Single-Line 408-10077 Connectors 11 APR 12 Rev B 10 kV DC Connector Kit 20 kV DC Connector Kit 30 kV DC Connector Kit Receptacle Pin Contact Housing Pin Contact Pin Contact Plug Housing Receptacle Housing Cap Plug Cap Housing Cap Socket Plug Contact Housing Receptacle Housing Socket Socket Contact Contact CONNECTOR WIRE CRIMP TOOLING ‡ CONTACT VOLTAGE CONTACT SIZE EXTRACTION INSULATION HAND RATING KIT TYPE † DIE SET TOOL DIAMETER (Max) TOOL mm² AWG 867157-1 203802-6 2.66 [.105] Plug 0.2-0.6 20-24 — 91038-3 10 kV DC 867157-2 203802-6 4.06 [.160] 91544-1 (408-7357) 867156-1 Receptacle 203816-6 0.2-0.6 20-24 4.06 [.160] — 861610-1 66399-1 0.3-0.6 22-20 91523-1 4.7 [.185] — 861610-3 66101-2 0.8-1.4 18-16 91505-1 Plug 861610-4 66399-1 0.3-0.6 22-20 91523-1 7.67 [.302] — 861610-2 66101-2 0.8-1.4 18-16 91505-1 861751-1 20 kV DC (408-9567) 861753-1 66400-1 0.3-0.6 22-20 91523-1 4.7 [.185] — 861753-3 66099-2 0.8-1.4 18-16 91505-1 Receptacle 861753-4 66400-1 0.3-0.6 22-20 91523-1 7.67 [.302] — 861753-2 66099-2 0.8-1.4 18-16 91505-1 863103-1 66741-8 5-6 10 90140-1 863103-2 Plug 66740-8 2-3 14-12 12.7 [.50] 90145-1 863558-1 30 kV DC 863103-3 66740-8 1.4 16 90145-2 69710-1 (NA) 863104-1 66259-1 5-6 10 90140-1 Receptacle 12.7 [.50] 863104-3 66261-1 1.4 16 90145-2 † Bulkhead receptacle connector kits are also available. ‡ 626 Pneumatic Tool System can also be used.  Contact TOOLING ASSISTANCE CENTER at the number at the bottom of this page for details. Figure 1 1. INTRODUCTION Dimensions in this instruction sheet are in metric NOTE units [with U.S. customary units in brackets]. This instruction sheet provides assembly procedure Figures are not drawn to scale.  for LGH commercial single-line connectors. Kit part i numbers, which contain the connector, are listed in Figure 1. © 2012 Tyco Electronics Corporation, a TE Connectivity Ltd. company TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change. 1 of 2 All Rights Reserved PRODUCT INFORMATION 1-800-522-6752 For latest revision and Regional Customer Service, *Trademark visit our website at www.te.com TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or company names may be trademarks of their respective owners. 408-10077 Reasons for reissue of this instruction sheet are 5. Terminate the contact onto the wire using the provided in Section 6, REVISION SUMMARY. tooling listed in Figure 1. Refer to the instruction sheet included with the tooling. 2. DESCRIPTION 6. Insert leads into the housing until the contacts latch in the cavity. The contacts should be located Components of each connector kit are shown in the proper distance from the end of the housing Figure 1. All of the components (excluding contacts) according to the dimension provided in Figure 3. are made from UL-Recognized self-extinguishing plastic material (94V-0 rated). Voltage rating is given in Figure 1. The connectors are designed for commercial Wire (Ref) application in industrial environments and have an operating temperature range of 15 to 85°C [59 to 185°F]. A (See Table) 3. ASSEMBLY PROCEDURE End of Plug Contact 3.1. Inserting Contacts Housing 1. Determine the voltage requirement for the application. 2. Select the connector kit based on the voltage B (See Table) requirement according to wire size and insulation diameter. Refer to Figure 1. End of Receptacle 3. Refer to Figure 2, and strip the wire jacket (if Contact Housing required) and insulation to the proper strip length. Wire Strip Length Jacket (See Table) DIMENSION VOLTAGE RATING A (Plug) B (Receptacle) Insulation (See Table) 10 kV DC 0.00-0.76 [.000-.030] 009.14-9.65 [.360-.380] 20 kV DC 0.76-1.52 [.030-.060] 18.03-18.80 [.710-.740] Conductors (Ref) Note: Not to Scale 30 kV DC 2.03-2.54 [.080-.100] 18.03-18.54 [.710-.730] Figure 3 WIRE STRIP LENGTH VOLTAGE CONNECTOR RATING KIT JACKET INSULATION 3.2. Connector Mating 867157-1 15.49-16.00 — Align the mating face of the connectors, and push them 867157-2 [.610-.630] 10 kV DC together. The housings contain keys and keyways that 4.83-5.08 867156-1 — will align the contacts for positive mating and sealing. [.190-.200] 861610-1 22.86-24.13 3.56-4.32 4. CONTACT REMOVAL 861610-3 [.900-.950] [.140-.170] Use the applicable extraction tool listed in Figure 1 to 861610-2 22.86-25.4 remove the contacts (one at a time) from the connector. — 861610-4 [.900-1.000] Refer to the instruction sheet (referenced in Figure 1) 20 kV DC provided with the extraction tool. 861753-1 861753-2 6.60-7.37 3.56-4.32 861753-3 [.260-.290] [.140-.170] 5. REPLACEMENT AND REPAIR 861753-4 The connectors and contacts are not repairable. Do 863103-1 not use defective or damaged connectors or contacts. 863103-2 Do not re-use the contacts by removing the wire. 20.32-22.86 30 kV DC 863103-3 — [.800-.900] 863104-1 6. REVISION SUMMARY 863104-3 Revisions to this instruction sheet include: Figure 2 • Changed company name and logo • Modified Figure 3 4. Tin lead between the contact and wire insulation to provide mechanical strength required for lead • Added Section 5 insertion. Rev B 2 of 2