DAF CF65, CF75, CF85 Series . Manual — part 504
5
CF65/75/85 series ≥0E621376
Removal and installation
REPAIRING WIRING
2-11
Copper connection
1A.
Wire diameter too large
1B.
Wire diameter too small
2A.
Crimp height too great (hole in crimping
tool too large)
2B.
Crimp height too small (hole in crimping
tool too small)
3A.
Asymmetric crimping
3B.
Asymmetric crimping
4.
Proper contact crimping
S
=
material thickness
x
=
cracking
1A.
There is a risk that copper
conductors could stick out, which
would adversely affect the fixed
position of the other copper
conductors.
This may result in a short circuit and
loose contact.
1B.
The contact may crack and the
copper conductors may not be
sufficiently fixed in the contact.
2A.
Copper conductors are not
sufficiently fixed in the contact. The
wire will come loose of the contact.
2B.
The contact will be damaged. The
contact may crack after some time
and the wire will then come loose
from the contact.
3A and B The contact will be damaged and the
copper conductors are not fully fixed
in the contact. The wire may come
loose. The height of any bulge on the
contact may not exceed the material
thickness of the contact. The width of
this bulge may not exceed half the
material thickness.
E501494
1
A
B
2
3
4
Bmax=1/2S
X
Hmax=S
3
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5
REPAIRING WIRING
Removal and installation
CF65/75/85 series ≥0E621376
2-12
Insulation connection
Different types of crimping are allowed:
1.
Normal crimping; the two sides of the relief
part fully engage the insulation.
2. Double crimping; two wires are clamped in
one contact.
3.
Overlap crimping; the two sides of the relief
part engage one another slightly.
4. Double overlap crimping; two wires are
clamped in one contact, the two sides of the
relief part engaging one another slightly.
A. If the insulation connection is correct, the
wire is clamped in the relief part with the
correct pressure and the insulation is not
broken.
B. If the contact pressure is too high the
insulation could break, possibly causing a
short circuit.
This may for instance be caused by:
-
using the wrong crimping tool
-
using an improper hole in the crimping
tool (too small)
-
a defect in the crimping tool delaying
the interruption of the contact pressing.
C. If the contact pressure is not sufficient the
insulation may not be clamped and the wire
may come loose. This will interrupt the
electrical connection but may also result in
a short circuit.
This may for instance be caused by:
-
using the wrong crimping tool
-
using an improper hole in the crimping
tool (too big)
-
interrupting the contact pressing
prematurely.
3
200404
5
CF65/75/85 series ≥0E621376
Removal and installation
REPAIRING WIRING
2-13
E501511
B
A
C
1
2
3
4
1.
Normal crimping
A.
Good insulation connection
2.
Double crimping
B.
The insulation is broken
3.
Overlap crimping
C.
The insulation is not secured
4.
Double overlap crimping
With double crimping the thinnest wire is always
at the bottom.
A connection can be checked by gently pulling
the wire after the contact is placed in the
connector. The lock of the locking bolt in the
connector should then be felt.
E501501
3
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5
REPAIRING WIRING
Removal and installation
CF65/75/85 series ≥0E621376
2-14
Examples of wire-contact connections
A. Wire not sufficiently slid forwards.
The wire is not sufficiently slid forwards to
ensure a proper current transfer and pull
relief.
B. Stripped part of the wire too short.
The stripped part of the wire is too short to
ensure a proper current transfer whereas a
part of the insulation is clamped underneath
the contact press part.
C. Wire too far backwards.
If the stripped part of the wire is too long
and the wire is placed correctly relative to
the contact press part, the pull relief will
cover too little of the wire.
D. Wire too far forwards.
If the stripped part of the wire is too long
and the wire is placed correctly relative to
the pull relief, the copper conductors at the
front will stick out too far past the contact
press part.
E. Copper conductors not clamped.
Copper conductors not clamped may cause
a short circuit to other wires nearby.
F. This is a correct connection.
E501499
A
B
C
D
E
F
1
2
3
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