JRC 2kW Radar Cable Connector Installation

Cable Preparation -

Cut the JRC 2 kW cable to the required length for the cable being manufactured.

Verify that the correct gender connector(s) have been selected, 10P or 10S as required.

Disassembly the connector into it’s subcomponents, place the body set screw in a secure location
where it will not be lost.

Place the large adhesive lined heat shrink and connector back shell on the cable.

Place the knurled connector shell barrel on the cable with the threaded side toward the cut wire
end.

Temporarily secure these parts on the cable.

Cut back the cable cover jacket approximately 1 ½ ”. Be careful not to damage the braided
shielding or inner wires

Fold back the exposed braid shield to cover the jacket. Remove any mylar or paper wrappers.

Wrap the braid shield with approximately 2 wraps of ½” wide copper tape.

Trim any excess exposed shield wires .

Place a small ty-rap around the copper tape to hold it in place while performing the rest of the
fabrication.

Use an empty connector back shell to gauge the correct lengths for preparing the wires. The
large power wires should be cut as short as possible. If the wires are too long it will be difficult to
fit them inside the back shell due to the bulk. If using adapter wires keep those lengths in mind as
well. Leave the smaller conductors as long as possible as they can be trimmed just before the are
soldered and terminated.

Cut the large power conductor wires back at least 1/2” shorter than the smaller data wires and
coaxial wires.

Strip and prepare the large wires, install heat shrink and solder according to solder map
recommendation. Due to the tight fit between the connector pins it is best to use a heat gun on
each piece of heat shrink as the connection is made.

Strip and prepare the smaller wires, install heat shrink and solder according to the solder map
recommendation. Again it is best to shrink each connection as it is completed.
 Solder Map – Recommended soldering order

Pin# Description Size

1 – Green, Large, #16

2 – Yellow, Large, #16
10 – White, Large, #16
6 - Drain for pin 7, # 24
7 - Black coax signal # 24
3 - Green, small, # 24
5 - Drain for pin 4 # 24
4 - Clear coax # 24
9 - Yellow, small # 24
8 - White, small # 24

Inspect and then assemble the connector back shell, set screw and strain relief.

Electrically test connections pin for pin. All pins are wired straight through and no shorts between
pins are allowed with the exception of the grounds.

Pins 5, 6, the overall cable braided shield and connector shell are an electrically common ground.

Refer to the accompanying pictures for additional construction information.

Notice the S-bends in the smaller “necked” down portion of the power wire connections. These
help with “compressing” the length of wire inside the back shell.

It helps to use a small tie wrap around the copper tape during fabrication to hold the tape in place
and keep it neat.

Notice that all the stray braided shield wires have been taped and trimmed so as not to cause
shorts inside the connector back shell
The exposed copper tape is not a problem as it will be covered by the adhesive lined heat shrink.

The picture below is a larger 6kW connector but the techniques used are simular.
Before heat shrinking the strain relief area. Check the cable electrically using the specifications
sheet and it’s pin out table as a guide. Notice that the fit is so close that you can see wires just
ahead of the strain relief clamp.