EV High-voltageShieldedPush-pull handle lockKeys A · B · C · D
GYHF Series Connector
A shielded high-voltage connector for electric vehicles, using a handle-locked straight push-pull structure - reliable to mate, simple to operate. This interactive guide walks through the parts, cable assembly, mating, and the full reference data.
Current ratings
130 / 200 / 250 A
Key positions
A B C D
Mating cycles
500
Cable sizes
25-70 mm²
Contacts
Silver-plated
Storage life
5 years
Before you start - safety
Never energize the connector before it is locked, and never hot-plug it - no live mating or unmating. Handle silver-plated contacts with care and keep the mating faces clean.
The connector ships as a loose kit. Select a part below - or a numbered marker on the diagram - to see what it is and what it does. The plug assembles left-to-right, from the housing out to the tail cover.
Fig 1 · Plug connector kit - exploded view
03
Assembling the cable
All models share four keys (A-D); the procedure below uses key A as the representative. Work through the eight steps - use the arrows or the number rail, or your keyboard's ← → keys.
Prep · humidity-condition the tail cover
Condition the tail cover before assembly: a constant-temperature water bath at 80 °C for 1 h, or a humidity chamber at 50 °C / 95% RH for 6 h (2-3% balanced moisture, distilled / impurity-free water). Install within 3 days of conditioning - re-condition if longer.
04
Mating & unmating
The plug and socket connect with a handle-locked straight push-pull action. Only a plug and socket of the same key position will mate.
Fig 9 · Mating facePlug handle, locking slider, plug-insert latch ear and handle ring groove.
Keying - A · B · C · DSame key only. The signal-wire pins are a lead-termination feature and must never be connected to a power source.
Fig 10 · Mate & unmate sequence (key A)
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Reference data
Matched contacts, matched cables and mounting torques. Filter by model or part number to find your variant fast.
§ 3.3 · Matched contacts
Connector model
Matched contact P/N
§ 3.4 · Matched cables
Connector model
Size
Jacket OD
Type
§ 4.2 · Mounting & busbar torque
M4 clearance hole
0.9-2.9 N·m
Unthreaded / light-hole mounting
M5 clearance hole
1.8-5.9 N·m
Unthreaded / light-hole mounting
M6 clearance hole
3.2-10.1 N·m
Unthreaded / light-hole mounting
M8 clearance hole
7.7-24.7 N·m
Unthreaded / light-hole mounting
M5 threaded hole
3.5-4.5 N·m
Die-cast aluminium threaded seats (…G009 / G005)
M6 busbar · 130/200 A
6-8 N·m
M6 screw + flat & spring washer, copper
M8 busbar · 250 A
8-12 N·m
M8 screw + flat & spring washer
Torque note
For screws / nuts of copper, aluminium or plastic - and threads in die-cast or plastic parts - use the lower torque limit to avoid stripping. Within the ranges above the connector will not be damaged; set the customer-side value to the actual joint. Use a soft copper busbar at the socket tail to avoid contact tilt, seal failure and accelerated wear.
06
Installation & handling
Refit any seal ring dislodged in transit, route and fix the harness to survive vehicle vibration, and observe the general cautions.
Seal rings dislodged in transit
If a socket seal ring or gasket has come off during transport, refit it to the positions shown before installing.
130 A socketGYHF-2-130Z-A · seal-ring seat
250 A socketGYHF-2-250Z-A · seal-ring seat
Harness routing & fixing
Fixing rule
The cable must exit straight from the connector tail. Set the first fixing point within 130 mm (± 10 mm) with no wobble relative to the equipment-side connector, then fix at intervals of ≤ 300 mm. Fix cable bends separately. Do not pull the harness tight - slack prevents strain on the joints when the vehicle is jolted.
Busbar extension adapters
When adapting a customer busbar with GYHF extension adapters (…G014 / …G003 / …G008), fix to the specified bolt torque so the busbar cannot skew.
Fig 14 · Busbar terminalsFix the socket busbar screws to the torque in the reference table; use soft copper busbar to avoid contact tilt.
General cautions
Never mate or unmate live
Do not energize before the connector is locked; strictly no hot-plugging.
500 mating cycles
Keep the mating face clean and oil-free through its service life; handle gently and avoid knocks.
Tools required
Utility knife, calipers, wire strippers and an adjustable crimping machine.
Nickel plating appearance is normal
Nickel-plated die-cast aluminium shells may look whitish, glossy or dull - normal, and salt-spray performance is unaffected.
Do not paint the shield contact area
Never powder-coat or paint where the mounting panel meets the connector - non-conductive coatings break the shield continuity.
07
Silver-plated part care
Both the signal short-circuit pins and the power contacts are silver-plated. Sulphur and light are the enemies.
Fig 15 · Silver-plated componentsSignal short-circuit pins and power contacts are both silver-plated.
StorageKeep away from light - use a black plastic bag, sealed. Ambient air must be sulphur-free.
AssemblyKeep silver parts out of sunlight and prolonged air exposure. If a build runs long (over ~1 week), isolate parts from air between steps. Clear sulphur-bearing items (leather, hard rubber, bench pads, seals, totes) from the area - verify them sulphur-free.
UseNever touch silver-plated areas with bare hands at any stage. Slight pin discoloration does not affect performance. For onward shipment, seal in a black, sulphur-free bag first.
08
Storage & maintenance
Temperature
-5 … 35 °C
Humidity
≤ 80 % RH
Shelf life
5 years
Atmosphere
Sulphur-free
Store plugs and sockets in a warehouse free of acid, alkali and other corrosive gases. When a plug and socket are separated and not yet mated, protect each mating face from contamination. If passing the connector to a downstream user, hand over these instructions too, and fold them into the equipment process spec.
09
Documents & downloads
Datasheets and CAD models for this connector, served live from the Fellten shop. Links open in a new tab.
The full plug datasheet and connector & harness application specification are available on request - or once published on the shop product page they will appear here automatically.
