4. Removal and installation

1. Removing and installing contacts from connectors

Contact kit A (DAF no. 0694960)

If additions are made to the wiring, a contact may have to be removed from the connector.

For this purpose special ejectors have been developed, which are included in the contact kit.

To facilitate the selection of the contact, crimping tool and ejector, a sticker has been affixed to the inside of the box.

The information given on this sticker is to be interpreted as follows:

At the top is the DAF no. of the contact shown.

Roman numerals I and II. shown under the illustrations, refer to the crimping tool to be used.

The numeral or letter added to Roman numeral I or II indicates the hole in the tool in which the contact is to be placed.

Roman numerals III to VII refer to the type of ejector to be used for removing the contact from the connector.

The information at the bottom refers to the wire core cross sectional area suitable for the contact.

Contact kit B (DAF no. 1240065)

Additional crimping and ejector tools are required for SCAT contacts and for micro-timer contacts.

To facilitate the selection of the contact, crimping tool and ejector, a sticker has been affixed to the inside of the box.

2. Installing contact units on electrical wires

The increasing application of electronics in vehicles has made it necessary to use new types of connectors and contacts. This has resulted in the use of relatively small contacts. More attention must therefore be paid to the connections as a whole.

In addition, the number of connections has considerably increased, so that the wiring harnesses have become thicker. To keep the wiring harnesses manageable, a new type of wiring is now being used:

• Wires with a coresection of 1 to 2.5 mm² and reduced insulation thickness, retaining the mechanical properties, resistant to temperatures up to 70"C (in accordance with DAF standard 9502). These wires are not suitable for engine and gearbox wiring.

• Wires with a core section of 1 to 120 mm² and normal insulation thickness, resistant to temperatures up to 105°C (in accordance with DAF standard 9504).

Note:

In view of the mechanical strength required, the minimum permissible core section is 1 mm².

To ensure the reliability of systems and connections, the following points should be observed when repairs or additions are made to the wiring:

1. Always choose the following:

the correct type of contact the correct wire diameter for the contact used

the correct insulation diameter for the cable used

the correct type of contact material (tin-plated or silver-plated)

2. Use the right tool for the job. Wire ends are always clamped to a contact. For this purpose special tools have been developed.

Only if these special tools are used and if the contact is placed in the right hole, can reliable connections be made.

3. Strip the correct length of wire. Always use stripping pliers. Rule of thumb: stripped length = length of shrinking sleeve + 1 mm. Make sure that the core is not damaged during stripping or problems may occur after some time.

What is a good connection?

A good connection will only be obtained if points

• 2 and 3 are complied with. This implies that both the copper core and the insulation are firmly clamped in place.

Figure 1 shows the correct method of stripping and clamping.

The end of the core should still be visible at A The end of the insulation should still be visible at B.

3. REMOVAL AND INSTALLATION OF CONTACT UNITS OF 39-PIN FLOOR CONNECTOR

Removal and installation of contacts units

of floor part

Removal of contacts units from floor part

• Unscrew union nut G.

• Slide thrust washer H and seal K slightly back on the wiring.

• Now push the contacts out of the connector housing F. using the special ejector tool from contact kit A or B.

Installation of contacts units in floor part

1. Slip union nut (G) and thrust washer up the wiring.

2. Feed the wires without contacts through seal K.

3. Fit new contacts to the wires, using the right tool.

4. Push the contacts home in the connector F.

5. Push seal K against connector housing F.

6. Position thrust washer H so that the two cams on the sides of connector housing F snap into the thrust washer recesses.

7. Finger-tighten union nut G.

Note:

Thrust washer H bears the contact numbers (for correct location of contacts). Make sure that these contact numbers occupy the same position as the contact numbers on the connector housing.

A wrongly positioned wire provokes a leaky seal after removal. If no new wire is inserted in this position, be sure to fit a sealing plug.

Removal of contacts units from counter

floor part

1. Undo end union nut A and adapter union nut B. and slide them back over the insulation hose as far as they go.

2. Slide thrust washer H and seal K back over the wiring harness as far as they go.

3. Slide union nut E back over the wiring harness.

4. Remove the sealing ring (2) carefully.

5. Release the locking rings (3) in connector housing F carefully.

6. Take out centring sleeve D from connector housing C.

7. Now push the contacts out of the connector housing C. using the special ejector tool from contact kit A or B.

Installation of contacts units in counterfloor part

1. Slide end union nut A and adapter union nut B. back over the insulation hose as far as they go.

2. Position centring sleeve D in connector housing C so that all openings are arranged opposite one another.

3. Check that all circlips (3) are located in the relevant recesses (1).

4. Feed the wires without contacts through thrust washer and seal K.

5. Fit new contacts to the wires, using the right tool.

6. Feed the wiring harness through adapter union nut B.

7. Push seal K against connector housing C.

8. Position thrust washer H so that the two cams on the sides of connector housing C snap into the thrust washer recesses.

9. Push the connector pins into connector housing C. observing their correct position.

10. Place sealing ring (2) around centring sleeve D and push it against the stop of connector housing C.

Note:

In performing the work described in the last two steps, avoid twisting the wiring harness. Otherwise serious damage could develop (risk of wire breakage).

Hand-tighten the relevant union nuts. Do not use any tools (pliers) for this job.

11. Screw adapter union nut B on connector housing C.

12. Screw end union nut A (with insulation hose) on adapter union nut B.