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SECTION 4
Cable Preparation & Crimping
NOTE: Follow crimp tool instructions from tool manufacturer.
1. Prepare cables, cutting to length as needed.
2. Strip outer jacket to length per Table 2.
3. Strip individual conductors to length per Table 1.
4. If desired, label wires according to the location # on the insert.
5. Place stripped end of conductor into contact socket, verify
that between 1 mm and 3 mm of bare copper is exposed
between end of contact and insulation.
6. Place contact with wire into crimping tool and fully squeeze
tool until the contact is crimped and released.
7. Repeat Steps 5-8 for each wire and contact required.
SECTION 5
Contact Insertion Instructions
WARNING: Even if a location is not being used, a blank pin/socket
must be inserted to maintain environmental integrity.
Contact cavities are clearly numbered on the front and rear insert
face to facilitate identification during assembly.
1. Locate contact location 1 on back of insert.
2. Take correct numbered contact and insert into position 1,
pushing by hand until feeling resistance. Complete installation
by pressing contact until hearing and feeling the contact click
into place.
3. Repeat Steps 1 & 2 for each location number on the insert.
When all contacts are assembled into the insert, each contact
shoulder is securely positioned into the front rigid insulator body
providing a stabilized and positive alignment of contacts.
SECTION 6
Maximum Allowable Current Values
WARNING: Maximum total
Formula
amperage per shell is limited by
the temperature threshold of the
D: W1 + W2 + W3 + ...Wn
internal components. Maximum
W + I^2 x R x N
amperages in Table A may
D ≤ Watt Values (Table B)
change when multiple contacts
are used in one shell. If using
multiple conductors, the dissipated heat [watts] should not
exceed the levels in Table B. The formula below can be utilized
to calculate dissipated heat.
NOTE: Maximum heat dissipation levels calculated at max
ambient temperature rating of 40˚C.
D
: Total heat dissipation per shell (watts)
W
: Total heat dissipation per set of contacts of the same
size/gauge (watts) and same current (amps)
I
: Expected current per contact not to exceed the max
current outlined in Table A (amps)
R
: Contact resistance (ohms)
N
: Number of conductors
Table A - Maximum Current Values
PIN SIZE
MAX CURRENT
(A)
18 AWG
8
16 AWG
13
12 AWG
23
10 AWG
33
8 AWG
46
Table B - Maximum Heat Dissipation Per Connector
SHELL SIZE
MAX WATTAGE
MAX WATTAGE
40C AMBIENT
40C AMBIENT
90C RATED
110C RATED
WIRE
12
12.8
16
20.7
20
23.6
24 & 28
35.6
FOR CANADA ONLY
For warranty information and/or product returns, residents of Canada should contact Leviton in writing at Leviton Manufacturing of Canada Ltd to the attention of the Quality Assurance Department,
165 Hymus Blvd, Pointe-Claire (Quebec), Canada H9R 1E9 or by telephone at 1 800 405-5320.
Leviton warrants to the original consumer purchaser and not for the benefit of anyone else that this product at the time of its sale by Leviton is free of defects in materials and workmanship under normal and proper
use for one year from the purchase date. Leviton's only obligation is to correct such defects by repair or replacement, at its option. For details visit www.leviton.com or call 1-800-824-3005. This warranty
excludes and there is disclaimed liability for labor for removal of this product or reinstallation. This warranty is void if this product is installed improperly or in an improper environment, overloaded, misused,
opened, abused, or altered in any manner, or is not used under normal operating conditions or not in accordance with any labels or instructions. There are no other or implied warranties of any kind, including
merchantability and fitness for a particular purpose, but if any implied warranty is required by the applicable jurisdiction, the duration of any such implied warranty, including merchantability and fitness for a
particular purpose, is limited to one year. Leviton is not liable for incidental, indirect, special, or consequential damages, including without limitation, damage to, or loss of use of, any equipment,
lost sales or profits or delay or failure to perform this warranty obligation. The remedies provided herein are the exclusive remedies under this warranty, whether based on contract, tort or otherwise.
© 2015 Leviton Mfg. Co., Inc.
SECTION 7
Table References
Table 1 - Conductor Strip Lengths
Table 2 - Outer Jacket Strip Lengths
SHELL NUMBER
Table 3 - Torque Values for Shell Component Assemblies
SECTION 8
Maintenance
Electrical and mechanical inspection of all components must be performed on a regularly scheduled basis, determined by the
environment and frequency of use. It is recommended that inspection be performed a minimum of once a year.
• Inspect contact crimp locations for security.
RESISTANCE
(OHMS)
• Clean exterior surfaces making sure nameplates remain legible.
• Before using, check tightness of all shell parts.
0.00643
• Check contacts for signs of excessive burning or arcing; replace if necessary.
0.00528
• Check shell parts for damage to threads; replace if necessary.
0.00210
0.00130
0.00086
MAX WATTAGE
40C AMBIENT
125C RATED
WIRE
WIRE
13.2
13.2
27.4
28.9
31.1
33.1
46.8
49.7
LIMITED 1 YEAR WARRANTY AND EXCLUSIONS
For Technical Assistance Call: 1-800-824-3005 (U.S.A. Only) www.leviton.com
CONTACT SIZE
AWG
(mm^2 eqv)
18
0.75
16
1.5
12
4
10
6
8
10
STANDARD ADAPTER
Inches
12 Shell
2.0
16 Shell
2.0
20 Shell
2.5
24 Shell
3.13
28 Shell
3.63
SHELL SIZE
THREAD
LH Thread
12
Coupling Nut
Gland Nut
LH Thread
16
Coupling Nut
Gland Nut
LH Thread
20
Coupling Nut
Gland Nut
LH Thread
24
Coupling Nut
Gland Nut
LH Thread
28
Coupling Nut
Gland Nut
Mechanical
Clamp Bolts
Clamp
CONDUCTOR STRIP LENGTH
Inches
0.453
0.586
0.585
0.688
0.839
JACKET STRIP LENGTH
(MULTI-CONDUCTOR CABLE)
mm
Inches
50.8
3.5
50.8
3.75
63.5
4.25
79.4
4.75
92.2
5.0
METRIC (N-m)
34
20.3
47.5
40.5
27.1
47.6
47.5
33.9
80.0
54.0
40.7
95.0
67.8
47.5
108.5
3.4
mm
11.5
12.88
12.85
14.96
19.30
LONG ADAPTER
mm
89.0
95.25
108.0
120.5
127.0
US (ft-lb)
25
15
35
30
20
35
35
25
59
40
30
70
50
35
80
2.5
PK-A3071-10-00-0A-X3
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