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This guide provides the assembly procedure for IEC Type 2 "Mennekes" cable from parts available from at OpenEVSE.
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This guide uses 40A EVJT cable available from OpenEVSE.
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Remove 3.25 inches of the outer jacket.
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Strip and retain insulation from RED, BLACK and GREEN wire 1/2 inch (0.50").
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Strip and retain insulation from Purple wire 3/8 inch (0.375")
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Strip and retain insulation from Purple wire 3/8 inch (0.375")
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Slide gland onto the cable. The notched end should face toward the stripped conductors.
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Insert conductors into the guide/seal, abbreviations are molded into the plastic part. PE = GREEN, CP = PURPLE, N - RED, L - BLACK
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Cut 6" each of BLACK and WHITE 18AWG stranded wire.
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Strip and retain 0.50" of insulation off both ends of the BLACK and WHITE wires.
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Insert the 18AWG BLACK wire in the PE position in addition to the GREEN wire.
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Insert a 18AWG WHITE wire in the hole labeled PP.
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Insert the ground pin on the 10AWG GREEN wire and the 18AWG BLACK Proximity wire.
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Crimp Ground pin with Pico Corporation 400B pneumatic crimping tool at 80PSI.
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Insert the power pin on the BLACK wire(s) and crimp.
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Insert the power pin in the RED wire(s) and crimp.
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Crimp Power pins with Pico Corporation 400B pneumatic crimping tool at 80PSI.
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Insert the signal pin on the PURPLE wire and crimp.
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Insert the signal pin on the WHITE wire and crimp.
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Crimp Ground pin with Pico Corporation 400B pneumatic crimping tool at 80PSI.
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Slide up the pin guide onto the pins.
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Add power pins to the empty to positions marked L2 and L3
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Slide O ring on each power pin.
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Insert pins into the connector housing.
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Screw pin guide to the connector housing using 4 - 12 mm screws.
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Remove the insulation off all BLACK and WHITE wires.
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Twist lead from resistor on both black and white wire from bottom to top and crimp.
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Secure cable in the strain relief leaving at least 1/4" exposed.
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Insert nose in bottom shell.
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Position dust cover end in notch.
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Insert and tighten 16 mm screws in holes marked in RED.
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Insert and tighten 12 mm screws in positions marked in BLUE.
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Tighten Cable Gland
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Remove insulation and crimp ring terminal on BLACK wires.
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Remove insulation and crimp ring terminals on RED wires.
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Remove insulation and Crimp Sleeve ferrule on GREEN wire.
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Almost done!
Finish Line