Copyright 1991, 2005 Caterpillar Inc. All Rights Reserved.

Pgina 1 de 10

4AR00001 793C TRUCK Instruccin Especial

Nmero de publicacin SMHS7531-01 Fecha de publicacin 1982/03/01 Fecha de actualizacin 2000/08/21

Use Of 6V3000 Sure Seal Repair Kit

0613
1400
ALL WIRING HARNESSES THAT USE SURE SEAL ELECTRICAL CONNECTORS
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).

file://c:\SIS\TMP\sis12D1prt.html

18/02/2005

Copyright 1991, 2005 Caterpillar Inc. All Rights Reserved.

Pgina 2 de 10

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)

file://c:\SIS\TMP\sis12D1prt.html

18/02/2005

Copyright 1991, 2005 Caterpillar Inc. All Rights Reserved.

Pgina 3 de 10

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

file://c:\SIS\TMP\sis12D1prt.html

18/02/2005

Copyright 1991, 2005 Caterpillar Inc. All Rights Reserved.

Pgina 4 de 10

(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) 3.0 (0.12") 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.

file://c:\SIS\TMP\sis12D1prt.html

18/02/2005

Copyright 1991, 2005 Caterpillar Inc. All Rights Reserved.

Pgina 5 de 10

(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.

file://c:\SIS\TMP\sis12D1prt.html

18/02/2005

Copyright 1991, 2005 Caterpillar Inc. All Rights Reserved.

Pgina 6 de 10

(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.

file://c:\SIS\TMP\sis12D1prt.html

18/02/2005

Copyright 1991, 2005 Caterpillar Inc. All Rights Reserved.

Pgina 7 de 10

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.

file://c:\SIS\TMP\sis12D1prt.html

18/02/2005

Copyright 1991, 2005 Caterpillar Inc. All Rights Reserved.

Pgina 8 de 10

(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.

file://c:\SIS\TMP\sis12D1prt.html

18/02/2005

Copyright 1991, 2005 Caterpillar Inc. All Rights Reserved.

Pgina 9 de 10

(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.

file://c:\SIS\TMP\sis12D1prt.html

18/02/2005

Copyright 1991, 2005 Caterpillar Inc. All Rights Reserved.

Pgina 10 de 10

(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.
Copyright 1991, 2005 Caterpillar Inc.
All Rights Reserved.

file://c:\SIS\TMP\sis12D1prt.html

18/02/2005