Repair Wiring Harness By Crimping - Ar00.19-D-0100-03A

MODEL ALL 

Fig 1: Crimping Set Overview (220 589 04 99 01)

Fig 2: New Passenger Car Wiring Harness Repair Kit (220 589 04 99 00)

Fig 3: Crimp Pliers (220 589 01 99 10)

Fig 4: Crimp Set Overview (000 589 13 99 01)

Fig 5: JPT Crimping Set (220 589 01 99 05)

Fig 6: Wire Stripper (220 589 01 99 40)

Fig 7: Wiring Harness Repair Kit, Basic (000 589 13 99 00)

1. Select crimp contact (1) in the EPC.
2. Strip line (2) using wire stripper.

   Do not damage wire strands.

   Damaged wire strands can lead to changes in the line cross-section and insufficient crimping strength.

   For line cross sections of up to 1.5 mm² the stripping length (a) is 4 mm, for line cross sections from 1.5 mm² to 4 mm² the stripping length (a) is 5 mm.

3. Select crimping set (4) for manual crimper (5).

   Select crimping set (4) according to crimping set overview in the basic wiring harness repair kit or the crimping set overview in the supplementary wiring harness repair kit for passenger cars.

4. Mount crimping set (4) into manual crimper (5).
5. Fit positioner (6) onto manual crimper (5).
6. Insert crimp contact (1) up to end stop in the positioner (6) and the die set (4).
7. Close manual crimper (5) until the crimp contact (1) is fixed in place in the die set (4).

   The crimp contact (1) may not be distorted here.

   Otherwise, the line cannot be inserted correctly into the crimp contact (1).

8. Insert line (2) into crimp contact (1) (arrow).

   Make sure that all wire strands for the line (2) are fitted properly into the crimp contact (1).

9. Squeeze manual crimper (5) up to limit pressure point and remove finished crimp connection.
10. Check crimp connection for correct shaping and filling.

    Correct crimp connection (A):  The strands of the line are uniformly enclosed. The crimp tab is evenly shaped.

    Wrong crimp connection (B):  The crimp tab has the wrong cross section and it is not completely filled.

    Wrong crimp connection (C):  The individual strands are partly outside the crimp tab. The crimp tab is too full.

    Wrong crimp connection (D):  The crimp claws touch the base of the crimp, crimp tab is wrongly shaped and damaged.