2., 5 Mm2, 4 Mm2 Or 6 Mm2 Aluminum Wires With Separate Butt Connectors, Repairing: Procedure

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-- Install the corresponding crimp insert, crimp stamp and contact positioner for the wire cross-section with the contact cross bar as follows on the crimping tool.

-- Open the crimping tool from the : VAS631 001 .

-- Remove the locking pin -1- all the way in the direction of -arrow A-.

-- Open the mount -2- in the direction of -arrow B-.

-- Insert the crimp insert -1- in the crimping tool so that the crimp insert -1- is flush with the front of the clamps.

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-- Tighten the crimp insert with the pins -2- in direction of -arrow A- and the knurled screw hand tight.

-- Insert the crimp stamp -3- that fits the crimp insert in the mount.

-- Secure the crimp stamp with the pin -4- in direction of -arrow B- and the knurled screw hand-tight.

-- Close the adapter -1- in the direction of -arrow A-.

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-- Push the locking pin -2- in the direction of -arrow- all the way.

-- Insert the contact cross bar -1- in the contact positioner -2-.

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-- Position the contact positioner with the contact cross bar on the crimping tool -5- at the same time push the holes in the contact positioner -2- over the knurled screw -4-.

-- Install the knurled bolt -3- and tighten hand-tight.

-- Free up the wire to be repaired approximately 20 cm on both sides of the repair point.

CAUTION:

Risk of damaging the electrical wires.

Expose wrapped wiring harnesses carefully.

-- If necessary, removing the wiring harness wrapping.

-- Cut the damaged section of the wire with wire stripper from the : VAS631 001 .

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NOTE:

When both ends of the vehicle-specific single wire are too short after cutting out the damaged wire section for a repair with a separate butt connector, insert a corresponding long piece of yellow copper repair wire with two butt connectors.

-- Insert the wire end from the front all the way in to the wire cross-section corresponding mount in the jaws of the pliers.

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-- Push the pliers completely together.

-- Open pliers again and remove the stripped wire end.

The insulation must be cut cleanly and remove from the wires.
No insulation can remain on bare wires.
The single wires must not be damaged.

-- For the repair remove the corresponding butt connection with a heat-shrinkable tube from the : VAS631 001 .

-- Push the heat-shrinkable tube on one of the wires.

-- Place the butt connection -1- in the contact positioner -2-.

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The butt connection -1- must be flush with the contact positioner -2- -arrow A-.

-- Push the contact cross bar -3- all the way in the direction of the -arrow B- and secure it with the butt clamp -1-.

The tab -4- on the butt connection -1- must engage in the groove -5- on the contact cross bar -3-.

-- Insert the wire -2- with the bare wire end all the way in the butt connection -1- -arrow-.

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All single wires must be pushed into the butt connection.
The insulation end can at a maximum be flush with the front edge of the insulation crimps.

-- Close the crimping tool completely until it reopens by itself.

-- Push the contact cross bar -2- all the way in the direction of -arrow-.

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-- Remove the butt connection -1- from the contact positioner -3-.

-- Turn the crimping tool for the second crimping.

-- Repeat the wire crimping on the other side as described.

-- Remove the securing pin -1- in the direction of -arrow A- until it stops.

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-- Open the mount -2- in the direction of -arrow B-.

-- Remove the crimped butt connectors.