Usage:
6V3000 Sure Seal Repair Kit permits the in-service repair of sure seal connectors used to connect electrical components and harnesses together. A new insertion tool has improved the repair procedure for the kit. Identification of parts in the tool group and the procedure for repair of the connectors are shown in the instructions that follow.
Identification Of Parts In 6V3000 Repair Kit
6V3007 Box Assembly (1).
6V3001 Crimping and Stripping Tool (2).
6V3008 Contact Insertion Tool (3).
NOTE: The 7N7780 Pins and the 7N7779 Sockets will accept No. 14 Gauge and No. 18 Gauge Wire.
Spare Parts:
7N7780 Pin Contact (4)
7N7779 Socket Contact (5)
9G3695 Sealing Plug (6)
Spare Connector Housings. Shown are 3-pin 7N7782 Plug Housing (7) and 7N7781 Receptacle Housing (8). A complete list of 1-pin through 10-pin housings is given below.
Procedure For Repair Of Sure Seal Contacts
(1) To remove a contact (pin or socket), that has a defect, from connector housing (1), pull on wire (2) that is fastened to the contact.
(2) If the wire is not fastened to the pin contact, remove pin contact (3) from the connector housing with needle-nose pliers (4).
(3) If the wire is not fastened to the socket contact, push the socket contact out of the connector housing with a blunt (not sharp) 3.0Ø (0.12"Ø) rod (5).
(4) Remove the old pin or socket contact from the wire. Cut the end of wire (2) evenly and then strip (remove) 4-5 (0.15"-0.18") of insulation from the end of the wire with 6V3001 Tool.
(5) Put the smaller "U" opening of new socket contact (6) in the smaller jaws of 6V3001 Tool (7) as shown, with the open side of the "U" toward the double-arc edge of the jaws.
(6) Put the stripped end of wire (2) in position in the smaller "U" opening of socket contact (6). Be sure the stripped end of the wire is completely in the "U" opening.
(7) Completely close the jaws of tool (7). Open the jaws and remove socket contact (6).
NOTE: The jaws must be completely closed to be sure of a correct crimp on the wire and contact as shown.
(8) Put the larger "U" opening of the contact in position in the larger jaws of tool (7), with the opening of the "U" toward the double-arc edge of the jaws. Completely close the jaws of the tool. Open the jaws and remove the contact. The correct installation of socket contact (6) on a wire is shown. The end of the stripped wire should extend beyond the small crimp so it can be seen at (A). The larger crimp (B) should firmly hold the insulation.
NOTE: The repair of a pin contact is the same as the socket contact. All pins and sockets should be soldered using a resin core solder.
Installation Of Contact Assemblies In Connector Housings
NOTE: The installation of contacts in a connector housing is the same for all connector housings. Installation of a contact into a four contact connector housing is shown as a typical example.
(1) To install a socket contact assembly in a connector housing, put the end of 6V3008 Contact Insertion Tool (1) into a lubricant (such as alcohol), as shown. Put tool (1) in position so that the tube end of the tool can be installed through the front end of the connector body. Be sure plunger (2) is extended past the end of the tube.
(2) Install tool (1) into the connector body until it is completely through the body as shown.
(3) With the end of the tube of tool (1) even with the back end of the connector body, pull plunger (2) back so that it is retracted into the tube of the tool. Start new contact (3) into the tube of tool (1).
(4) Push the wire with the new contact into the tube of tool (1) until it stops against the retracted plunger. With the contact against the retracted plunger, hold the wire and the body of the connector with one hand to keep the wire in position; with the other hand, twist tool (1) out of the connector.
(5) After removal of the tool, contact (3) may extend beyond the surface of the rubber in the connector body. To put the contact in position, hold the wire behind the connector body and pull on the wire until the contact is even with the edge of the connector.
(6) Any holes not used for contact assemblies in the housing should be filled with a 9G3695 Sealing Plug (4) to give complete protection to the connector. The sure seal connector is shown with sealing plugs (4) and two contact assemblies correctly installed.
(7) The installation of receptacle housing (5) makes the repair of the connector complete. This section view of a sure seal connector shows the pin and socket contact assemblies in position.