How to build SAE J1772 cable assembly

This guide provides the assembly procedure for SAE J1772 cable from parts available from at OpenEVSE.

This guide uses 40A EVJT cable available from OpenEVSE.

Remove 3.25 inches of the outer jacket.

Strip and retain insulation from RED, BLACK and GREEN wire 1/2 inch (0.50").

Strip and retain insulation from Purple wire 3/8 inch (0.375")

Cut orange wire flush with outer jacket.

Slide gland onto the cable. The notched end should face toward the stripped conductors.

Assemble the pin guide/seal.

Insert conductors into the guide/seal, abbreviations are molded into the plastic part. PE = GREEN, CP = PURPLE, N - RED, L - BLACK

Cut 6" each of BLACK and WHITE 18AWG stranded wire.

Strip and retain 0.50" of insulation off both ends of the BLACK and WHITE wires.

Insert the 18AWG BLACK wire in the PE position in addition to the GREEN wire.

Insert a 18AWG WHITE wire in the hole labeled PP.

Insert the ground pin on the 10AWG GREEN wire and the 18AWG BLACK Proximity wire.

Crimp Ground pin with Pico Corporation 400B pneumatic crimping tool at 80PSI.

Insert the power pin on the BLACK wire(s) and crimp.

Insert the power pin in the RED wire(s) and crimp.

Crimp Power pins with Pico Corporation 400B pneumatic crimping tool at 80PSI.

Insert the signal pin on the PURPLE wire and crimp.

Insert the signal pin on the WHITE wire and crimp.

Crimp Ground pin with Pico Corporation 400B pneumatic crimping tool at 80PSI.

Slide up the pin guide onto the pins.

Insert pins into the connector housing.

Screw pin guide to the connector housing using 16 mm screw.

Slide orange seal and black plastic retainer down.

Screw retainer in with three 20 mm retainer screws.

Strip 0.50" off both the BLACK and WHITE wires from the push button switch assembly.

Remove the insulation off all BLACK and WHITE wires.

Twist WHITE wires together from bottom to top and crimp.

Twist BLACK wires together from bottom to top and crimp.

Position switch under the power and ground conductors as shown in the photo.

Fold WHITE and BLACK 18AWG wires in half.

Loosely tighten a tie wrap to keep the wires closely bunched.

Insert nose in bottom shell.

Insert cable gland in bottom shell, adjust position if necessary.

Insert switch in position in the bottom shell.

Secure cable in the strain relief.

Tension button spring and install button/spring/pin. Slid pin into the molded bushing.

Insert and tighten 16 mm screws in holes marked in RED.

Insert and tighten 12 mm screws in positions marked in BLUE.

Remove insulation and crimp ring terminal on BLACK wires.

Remove insulation and crimp ring terminals on RED wires.

Remove insulation and Crimp Sleeve ferrule on GREEN wire.