Usage:
Introduction
These tools allow the in-service repair of CE or VE series electrical connectors. Identification of parts and the procedure for repair of the connectors are described in this instruction.
Do not perform any procedure, outlined in this publication, or order any parts until you read and understand the information contained within.
Contact Extraction Tools
(1) 4C-4071 Extraction Tool (gray) for 4-6 gauge contacts. (2) 4C-4072 Extraction Tool (green) for 8-10 gauge contacts. (3) 4C-4073 Extraction Tool (yellow) for 12-14 gauge contacts. (4) 4C-4074 Extraction Tool (black) for 16-18 gauge contacts.
Removal of Contacts from Connectors (CE Series Shown)
1. Cut tie wrap (1) from the cable and the connector.
2. Cut the braid back on the harness approximately 100 to 125 mm (4 to 5 in) so that back shell (2) can be moved away from the connector.
3. Use 6V-0006 Connector Pliers (3) to remove back shell (2) from connector (4).
4. Move back shell (2) away from connector (4) to permit removal and installation of a contact.
(5) Extraction Tool
View from rear of connector.
5. Select the correct extraction tool (5) for the wire size to be removed.
Place the tool under the wire to be removed and lay the wire in the opening along the length of the tool. Move the tool along the wire (away from the contact) drawing the wire into the tip of the extraction tool.
NOTE: Forcing the wire directly into the tip of the extraction tool could damage or shorten the life of the tool. With the tool on the wire, start it into the insulator of the connector.
Tool inserted to unlock contact.
6. Start extraction tool (5) over the back edge of contact (6). This must be done by feel. Slide the tool completely in to release locking fingers (7).
NOTE: DO NOT turn the extraction tool during release of the locking fingers; this can either destroy the locking fingers or break the tool.
Tool and contact removed.
View from rear of connector.
7. With release tool (5) in position as shown in Step 6, remove the tool and contact (6) from the insulator.
8. Cut the old contact from the wire.
9. Remove the insulation from the wire, to the correct length shown in the following chart.
Crimping Procedure for 12-18 Gauge
1U-5804 Hand Crimp Tool
NOTE: To Assure proper electrical performance, contacts must be crimped using the correct crimping tools. DO NOT solder. (Refer to last page for correct contact to use with each wire gauge.)
(1) Lock clip. (2) Wire gauge selector knob.
(2) Wire gauge selector knob (3) Centerline of indentors. (4) Adjustment screw. (5) Locknut in lock position. (6) Locknut in release position. (7) Contact in position.
1. Remove the lock clip (1).
2. Raise the wire gauge selector knob (2) and rotate it until the arrow is aligned with the wire size to be crimped.
3. Lower the wire gauge selector knob (2) and insert the lock clip (1).
4. Loosen locknut (5) and turn adjusting screw (4) in until it stops.
5. Insert the contact and turn adjusting screw (4) counterclockwise until the contact is flush with the indentor cover. Tighten locknut (5).
6. Insert the wire into the contact (the contact must be centered between indicators or indentors).
7. To crimp the wire in the contact, squeeze the handles of the crimp tool together until the handles hit the stop.
8. Release the handles and remove the crimped contact.
9. Inspect the contact to ensure that all wire strands are in the crimped barrel.
NOTE: Tool must be readjusted for each type/size of contact.
Crimping Procedure for 4-10 Gauge
(Refer to last page for correct contact to use with each wire gauge.)
4C-4075 Hand Crimp Tool Assembly
(1) 4C-4076 Retainer Assembly for 4-6 gauge contact.
(2) 4C-4077 Retainer Assembly for 8-10 gauge contact.
(3) 4C-4078 Jaw Assembly.
* The 4C-4075 Hand Crimp Tool Assembly includes all the above items.
1. Bolt the correct retainer assembly on the jaw assembly (3).
2. Insert contact into retainer assembly. Close jaws far enough to hold contact.
NOTE: Make sure retainers engage contact in crimp area. Do not crimp on contact shoulder.
3. Insert appropriate size wire into contact.
4. Continue the crimping process by compressing the handles until a positive stop is felt. This will complete the crimp cycle.
5. Release the handles and remove the crimped contact. Inspect the contact to ensure all wire strands are in the crimped barrel.
Installation of Contacts in Connectors
1. Grasp the contact approximately 25.4 mm (1.0 in) behind the contacts crimped barrel.
Contact being inserted.
2. Hold the connector with the rear insert facing you.
Contact locked in position.
3. Push the contact straight into connector grommet until a positive stop is felt. A slight tug will confirm that it is properly locked in placed.
4. Thread the back shell onto the back of the connector.
5. Wrap tape around the area where the braid had been removed, to keep the braid from fraying and to protect the wire.
6. Install a tie wrap to the connector and cable.
- * The 9X-6772 Tie Wrap is recommended for all endbells.
- * The 4C-5877 Tie Wrap Application Tool is recommended for installing the tie wraps.
7. If the number of wires is such that, when placing the tie wrap around the endbell it will not hold the wires tight to the endbell, it may be necessary to insert the tie wrap into the center hole of the back shell, as shown in the above illustrations.
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. Place a grommet sealing plug (1) in position. See the chart that follows for the correct plug part number.
2. Push plug (1) into connector (2).
Plug (1) is shown in position in the connector.
