DAF CF65, CF75, CF85 Series . Manual — part 505
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CF65/75/85 series ≥0E621376
Removal and installation
REPAIRING WIRING
2-15
2.4 FITTING A SCAT SEAL
SCATs are used in places where wires are
exposed to heavy conditions (environment or
application of the vehicle), with the risk of water
entering the connector.
The SCAT seal, which is made of silicone,
prevents corrosion inside the connector and
keeps the seal properties intact in the event of
temperature changes.
The SCAT seal is pressed around the wire with
the relief part of the contact.
The SCATs are available in various colours and
sizes.
1. Select the right SCAT for the wire, contact
and connector.
2. Slide the SCAT onto an unstripped wire (A).
3. Slide the SCAT far enough onto the wire
and strip the wire to the proper length (B).
4. Slide the SCAT back to the tip of the
stripped wire so that the copper just sticks
out of the SCAT (C).
5. Place the contact in the proper manner (D)
around the SCAT (2) and the stripped
wire (1).
6. Now crimp the contact around the SCAT
and the wire using the proper crimping tool.
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REPAIRING WIRING
Removal and installation
CF65/75/85 series ≥0E621376
2-16
2.5 FITTING AN ELECTRICAL BUFFER CONNECTION
A buffer connection is made when at least two
wire ends must be connected to one another.
This may be required because of a wire repair or
if a wire is to be added to a connection.
Note:
When adding a new wire to an existing wire,
both wires must be of the same thickness.
If part of the existing wire is to be removed, try
to make sure that the wire number can still
easily be found on the wire.
The contact crimping part (1) is the electrical
connection to the stripped wire part. The central
stop (2) is a limiter, preventing the wire to be
connected from being inserted too far. The
insulation is a crimp insulating sleeve with glue
layer (3), which, after heating by a blow drier, will
offer protection against unwanted electrical
contact and corrosion.
There are three different buffer connectors
available: red, blue and yellow. Depending on
the wire thicknesses to be connected (and
possibly the number of wires to be connected) a
specific colour must be used.
-
red
diameter 0.25 - 0.75 mm
2
-
blue
diameter 1.0 - 2.5 mm
2
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yellow
diameter 4.0 - 6.0 mm
2
Connecting more than two wires to
one another is not recommended.
The glue layer of the crimping
insulation is not sufficient to seal all
resulting gaps. So this is certainly
not permitted outside the cab.
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CF65/75/85 series ≥0E621376
Removal and installation
REPAIRING WIRING
2-17
It is very important to carry out contact crimping
in the correct way to prevent electrical faults. For
cold fusion a contact crimping tool is required.
This tool creates a cold fusion between wire and
buffer connector.
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Fitting the contact crimp connector
1. Select the right buffer connector for the
wires to be connected.
Note:
If three wires of the same diameter have to be
connected after all, choose a buffer connector
that is the same diameter as two of the wires.
The single wire on the other side must be
stripped to double length and folded double.
The same applies when a wire is used on one
side that is twice the diameter of the other.
2. Strip the wire to a length of 4 to 5 mm.
Note:
The stripped wire end may not be twisted.
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3. Choose the proper contact crimping tool on
the basis of the buffer connector and wire
diameter, and check the holes to be used.
4. Place the buffer connector in the hole of the
tool and clamp it gently so the buffer
connector will remain in the hole.
5. Slide the stripped wire ends into the side of
the buffer connector that is engaged by the
contact crimping tool.
Note:
The wire insulation may not be slid into the
contact part of the buffer connector.
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Removal and installation
CF65/75/85 series ≥0E621376
2-18
6. Compress the contact crimping tool: Do not
interrupt the contact crimping before the tool
is completely compressed to the end
position. Only then is full contact crimping
completed and the tool can be opened.
7. Repeat this for the other ends of the buffer
connector.
8. Check the contact crimping for damage and
pull the wires to ensure they are properly
fixed.
Note:
Improper contact crimping means a bad
connection, which may cause failures.
Avoid breathing in the vapours
produced when heating the
crimping insulation.
9. Heat the crimping insulation to fix it properly
to the wire insulation. Ensure that the
insulation does not get burnt. If the
insulation gets burnt it will become brittle
and easily break or crack.
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