DAF LF45, LF55 Series. Manual — part 344
5
LF45/55 series
Removal and installation
WIRING REPAIR
2-7
Removing 39-pin connector contacts
1. Loosen union G.
2. Push pressure ring H and seal K back
slightly over the wiring.
3. Then eject the contacts from connector
housing F using a special ejector tool from
contact kit A or B.
Fitting 39-pin connector contacts
1. Fit union G, pressure ring H over the wiring.
2. Fit new contacts to the wires using the
correct tool.
3. Insert the wires and contacts through
seal K.
4. Press the contacts to their definitive
positions in connector housing F.
5. Press seal K against connector housing F.
6. Position pressure ring H so that the two
ridges on the side of connector housing F
fall into the pressure ring recesses.
7. Tighten union G by hand.
Note:
-
Pressure ring H has contact numbers (their
purpose is to enable the contacts to be
positioned correctly). These contact
numbers must be in the same position as
the contact numbers on the connector
housing.
-
When an incorrectly positioned wire is
removed the seal will leak. If a new wire is
not inserted a sealing plug should be fitted.
E500477
G
H
K
F
3
200440
5
WIRING REPAIR
Removal and installation
LF45/55 series
2-8
Removing contacts from 39-pin connector
counterpart
1. Loosen end union nut A and tapered
coupling nut B and push these as far as
possible back over the insulation pipe.
2. Push pressure ring H and seal K as far as
possible back over the wiring harness.
3. Push union E back over the wiring harness.
4. Carefully remove the sealing ring (2).
5. Carefully loosen the locking lugs (3) in
connector housing F.
6. Remove centring sleeve D from connector
housing C.
7. Then eject the contacts from connector
housing C using a special ejector tool from
contact kit A or B.
Fitting contacts in 39-pin connector
counterpart
1. Push end union nut A and tapered coupling
nut B as far as possible back over the
insulation pipe.
2. Fit the centring sleeve (D) in connector
housing C so that all openings are
positioned opposite one another.
3. Check that all locking lugs (3) are
positioned in the lock openings (1).
4. Insert the wires without contacts through
pressure ring H and seal K.
5. Fit new contacts to the wires using the
correct tool.
6. Feed the cable harness through tapered
coupling nut B.
7. Press seal K against connector housing C.
8. Position pressure ring H so that the two
ridges on the side of connector housing C
fall into the pressure ring recesses.
9. Press the connector pins into their correct
positions in connector housing C.
10. Fit sealing ring (2) around centring sleeve D
and press it until the stop of connector
housing C.
2
D
C
E
K
H
B
A
3
1
E500478
3
200440
5
LF45/55 series
Removal and installation
WIRING REPAIR
2-9
Note:
-
When carrying out the last two steps it is
important not to twist the cable harness as
this can lead to serious damage (wire
breakage).
-
Tighten the respective union nuts by hand.
Do not use tools (pliers) to do this.
11. Screw tapered coupling nut B onto
connector housing C.
12. Screw end union nut A (with insulation pipe)
onto tapered coupling nut B.
2.3 FITTING CONTACTS TO ELECTRICAL WIRES
The increasing application of electronics in
vehicles means a much broader range of
connectors, contacts and wiring is being used.
The result of this is that more attention has to be
paid to making and repairing connections.
The following criteria should be taken into
account:
1. Wires with a reduced insulation thickness,
with retention of the mechanical properties,
for use with core sections from 0.5 to
2.5 mm
2
.
2. Wires with a normal insulation thickness, for
use with core sections from 4 to 120 mm
2
.
3. Wires for various temperature ranges:
T1: from --40_C to +70_C (in cab and
chassis) and
T2: from --40_C to +100_C (in engine
compartment and gearbox)
Note:
In view of the mechanical strength required, the
minimum permissible core section is 1 mm
2
,
with the exception of cab wiring. At certain
points this may be 0.5 mm
2
.
To ensure the reliability of systems and
connections, the following points should be
observed when repairs or extensions are made
to the wiring:
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200440
5
WIRING REPAIR
Removal and installation
LF45/55 series
2-10
A. Always choose the following:
-
the correct type of contact
-
the correct wire diameter for the
contact used
-
the correct type of contact material
(tin-plated, silver-plated or gold-plated)
B. Use the right tool for the job. Wire ends are
always clamped to a contact. Special
crimping tools have been developed for this
purpose.
Note:
Connections will only be reliable if these
crimping tools are used and the contact is fitted
in the correct hole.
C. Strip the correct length of wire. Always use
stripping pliers.
The rule of thumb is:
strip length = crimp-sleeve length + 1 mm.
Make sure that the core is not damaged
during stripping or problems may occur after
some time.
Note:
A good connection will only be obtained if points
A, B and C are complied with. This implies that
both the copper core and the insulation are
firmly clamped in place.
Crimping wire to a contact
Choose the right crimping tool and place the
contact in the correct hole.
Note:
The proper crimping tool for each contact can be
found through “Parts Rapido”.
The contact may never be in a twisted, slanting
or slid position (X) in the press clamp opening.
E501500
3
200440
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