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Selecting Weather Pack Electrical Connector Parts

Selecting Weather Pack Electrical Connector Parts

Each Weather Pack connection set requires the following parts:

  • One Tower Body (Part No. 4185-001 through -005)
  • One Shroud Body (Part No. 4185-011 through -015)
  • Male Terminals (Part No. 4185-030 through -032), one for each pin in the Shroud Body
  • Female Terminals (Part No. 4185-040 through -042), one for each pin in the Tower Body
  • Terminal Seals (Part No. 4185-070 through -074), one for each Terminal used

First determine how many terminals are needed. Weather Pack connector bodies are available with 1, 2, 3, 4, or 6 terminals. For 5 terminals, use 6 terminal bodies with one Terminal Cavity Plug (Part No. 4185-090).

Next, determine the wire gauge you will use. The modular design of Weather-Pack connectors allows you to mix different wire sizes in one connector when necessary.

Now select Male and Female Terminals based on the wire gauge. Female Terminals are generally used in Tower Bodies and Male Terminals are generally used in Shroud Bodies.

Terminal Selection 20-18 Gauge 16-14 Gauge 12-10 Gauge
Male Terminal 4185-030 4185-031 4185-032
Female Terminal 4185-040 4185-041 4185-042

Finally, select the Terminal Seals based on the diameter of the wire insulation.

Wire Gauge and Type
(Pegasus Part No.)
Diameter
(Inches)
Diameter
(mm)
Seal
Color
Seal
Part No.
22 Gauge GPT/GXL
20 Gauge TXL
22-20 Gauge ETFE (5006 & 5007)
0.051-0.067 1.29-1.70 Red 4185-070
18-16 Gauge ETFE (5008 & 5009) 0.062-0.085 1.60-2.15 Purple 4185-071
20-18 Gauge SXL (4000 through 4006)
20-16 Gauge GPT/GXL
18-14 Gauge TXL
14 Gauge ETFE (5003-14)
0.080-0.112 2.03-2.80 Green 4185-072
16 Gauge SXL (4007)
14 Gauge GPT/GXL
12 Gauge TXL
12-10 Gauge ETFE (5003-12 & 5003-10)
0.111-0.137 2.81-3.49 Gray 4185-073
14-12 Gauge SXL (4008 & 4009)
12 Gauge GPT/GXL
10 Gauge TXL
0.136-0.169 3.45-4.30 Blue 4185-074
Weather Pack Sealed Electrical Connectors
Assembly Instructions for Weather Pack Connector Terminals

This article was first published on 3/23/2009.

It was most recently modified on 3/26/2015.