How to build an IEC - Type 2 Mennekes Cable

This guide provides the assembly procedure for IEC Type 2 "Mennekes" 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")

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

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

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.

Remove insulation from the GREEN and BLACK wire.

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.

Required Die Pico 414DA-8N

Require locator - OpenEVSE IEC Power/Ground

Remove the insulation on all the RED and BLACK power wires.

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.

Required Die Pico 414DA-8N

Require locator - OpenEVSE IEC Power/Ground

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.

Required Die Pico 414DA-16N

Require locator - OpenEVSE J1772 Signal

Slide up the pin guide onto the pins.

Add power pins to the empty to positions marked L2 and L3

Slide O ring on each power pin.

Insert pins into the connector housing.

Screw pin guide to the connector housing using 4 - 12 mm screws.

Remove the insulation off all BLACK and WHITE wires.

Twist lead from resistor on both black and white wire from bottom to top and crimp.

Secure cable in the strain relief leaving at least 1/4" exposed.

Insert nose in bottom shell.

Position dust cover end in notch.

Insert dust cap end in shell halves.

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

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

Tighten Cable Gland

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.