Usage:
6V4810 Tool Group permits the in-service repair of VE series electrical connectors used in electrical harnesses where high temperatures, larger numbers of contacts or higher current capacity contacts are needed. 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 6V4810 VE Connector Tool Group
6V4815 Release Tool (1), for 4-6 gauge contacts.
6V4814 Release Tool (2), for 8-10 gauge contacts.
6V4813 Release Tool (3), for 12-14 gauge contacts.
6V4812 Release Tool (4), for 16-18 gauge contacts.
6V4831 Connector Chain (5).
The release tools fit together to make a small group for easy storage and to prevent damage to the tools.
Procedure For Removal Of Contacts From VE Connectors (16 - 18 Gauge)
1 Loosen harness clamp (1) on the VE connector (2).
2 Use 6V6 Connector Pliers (3) to remove the back shell of connector (2).
3 Cut the braid back on a harness approximately 100 to 125 (3.9" to 4.9") so that the back shell can be moved away from the connector.
4 Move back shell (4) away from the connector to permit removal and installation of a contact.
5 Make a selection of the correct release tool for the wire size to be removed. Put the tip of 6V4812 Release Tool (5) in a lubricant (alcohol) before installation in the connector. Put the tip of release tool (5) over the wire to be removed and start it into the insulator inside the connector.
NOTE: After application of the lubricant, the surface must be clean when dry.
6 Start release tool (5) over the back edge of contact (6). This must be done by feel and when the tool goes over the edge, slide the tool completely in to release the spring grip fingers of retaining clip (7).
| NOTICE |
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Do not turn the release tool during release of the retaining clip; this can either destroy the retaining clip or break the tool. |
7 With release tool (5) in position as shown, remove the tool and contact (6) from the insulator.
8 Cut the old contact from the wire with 6V3001 Crimping and Stripping Tool (8). Remove the insulation from the wire, to the correct length shown below, with tool (8).
9 Install the new contact on the wire. The stripped wires should be in the small "U" opening of the contact and the insulation in the large "U" opening of the contact. Put the small "U" opening of the contact in the small crimping jaws of tool (8). Make sure the stripped end of the wire is completely in the "U" opening.
10 Completely close the jaws of tool (8). Put the large "U" opening of the contact in the large jaws of the tool and completely close the jaws of tool (8).
11 To be sure of good electrical and physical characteristics, use solder on the contact and stripped end of the wire. A correct installation of the contact on the wire is shown.
| NOTICE |
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Use only rosin core solder on any electrical connection. |
Installation Of Contacts In VE Connectors (16 - 18 Gauge)
1 Put 6V4812 Release Tool (1) over contact (2) for support during installation. Put the contact in a lubricant (alcohol) and then install it into the insulator with release tool (1).
2 Push contact (2) into the insulator until the tip of tool (1) is beyond the seal rings, as shown, and the wire can be easily slid back and forth in the tool. Hold the wire and push it through the tool until a positive click (sound) is felt and heard. The retaining clips have engaged the contact.
3 Remove release tool (1). Fasten back shell (3) to the back of the connector.
4 Tighten clamp (4) and put tape over the harness from the braid to the back shell for protection.
Procedure For Removal Of Contacts From VE Connectors (4 - 14 Gauge)
1 Remove the back shell on the connector, see Steps 1-4, Page 2.
2 Make a selection of the correct release tool for the wire size to be removed. Put the tip of 6V4815 Release Tool (1) in a lubricant (alcohol) before installation in connector (2); see Note, Page 3. Put the tip of release tool (1) over the wire and start it into the insulator in the connector. Start release tool (1) over the back edge of the contact with up and down and side to side movement. This must be done with feel and when the tool goes over the edge of the contact, slide the tool completely in to release the spring grip fingers of the retaining clip. See the illustrations and Caution on pages 3 and 4.
3 Remove release tool (1) and contact (3) from connector (2). Cut the old contact from the wire with 6V3001 Crimping and Stripping Tool (4).
4 Remove the insulation from the wire with tool (4) or use a knife to remove the insulation from large gauge wires. For correct length of insulation removal, see the chart on page 4. Install new contact (5) onto the end of the wire. Heat the contact with soldering gun (6) or a torch and put the solder to the back edge of the contact, as shown, until it melts (becomes fluid) and flows into the contact. Solder will show in a hole, in the side of the contact, when the contact is full.
| NOTICE |
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Do not damage the wire with the knife. Use only rosin core solder on any electrical connection. If a torch is used, do not damage the insulation or burn off the tin coating (cover) on the contact. |
Installation Of Contacts In VE Connectors (4 - 14 Gauge)
1 Put the 6V4815 Release Tool over the contact for support, if needed. For larger size wire, as shown, the release tool is not needed. Put contact (1) in a lubricant (alcohol) and then install it in the insulator of connector (2). Push the contact into the insulator until a positive click (sound) is felt and heard. The retaining clips have engaged the contact.
NOTE: If the release tool is used, see Steps 1-3, Page 6 for correct installation of the contact.
2 Assemble the connector; see Steps 3 and 4, Pages 6 and 7.
Change In Position Of Contact
1 If a contact has been moved to a different location in the connector, the opening from which the contact was removed must be sealed. Put a Grommet Sealing Plug (1) in position. See the chart on page 10 for the correct plug.
2 Push plug (1) into connector (2).
3 Plug (1) is shown in position in the connector.
Parts For VE Connectors
